38GHP AIR-COOLED MULTI SPLIT CONDENSING UNITS

Transcription

1 Concepcion Carrier Air conditioning Company Philippines INSTALLATION MANUAL, START-UP & SERVICE INSTRUCTIONS 38GHP AIR-COOLED MULTI SPLIT CONDENSING UNITS CONTENTS: Physical Data and Dimensions , 7 Introduction Refrigerant Line Sizing Evacuation, Dehydration & Charging Expansion System Service Guides Piping Connection & Compressor Location 7 Electrical Connections and Wiring.... 6, 8, 10 Operation and Start-up Recommended Service Clearances SAFETY CONSIDERATION Installation and servicing of air conditioning equipment can be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should install, repair or service air conditioning equipment. Observe precautions in the literature, tags and labels attached to the unit and other safety codes. Wear safety glasses and gloves. Use quenching cloth and have fire extinguisher available for all brazing operations. RECEIVING 38GHP condensing units are shipped individually and protected with wood skid and plastic shrink wrap. Do not roll, throw or drop the unit. This may damage unit when you do so. Always store the unit in upright position. PROTECTION Protect unit from damage caused by job site debris. Do not allow dust, debris and water get into the unit. These will damage unit s component and unit performance will be affected. INSPECTION Check the shipment against shipping list and remove unit protective covering. If the unit has been damaged, file claim with transportation company and immediately notify Concepcion- Carrier. ELECTRIC SHOCK HAZARD Before installing or servicing system always switch off main power supply. There may be more than one disconnect switch. Electric shock can cause personal injury. 1

2 Table 1-2 COMPRESSOR SERIES MODEL 38ASB ASB ASB ASB1818 DIMENSIONS HEIGHT, mm 722 WIDTH + VALVE, mm DEPTH, mm 337 NOMINAL AIRFLOW, m 3 /min CONDENSER COIL: Copper Tube/Aluminum Fin NO. OF ROWS FINS PER INCH AREA, m FAN MOTOR 0.25 KW; 1.7 FLA, 1 ea. COMPRESSOR NO TYPE Rotary PROTECTIVE DEVICE Current and Thermal Overload ELECTRICAL CHARACTERISTICS V / 1 ph / 60 Hz FULL LOAD COMP AMPS AT COMP V TOTAL LOCKED COMP ROTOR AMPS COMP AT 230 V POWER COMP INPUT COMP AT 230 V TOTAL NET WEIGHT, KG Table 2-3 COMPRESSOR SERIES MODEL 38GHP GHP GHP GHP GHP DIMENSIONS: HEIGHT, mm 1,835 WIDTH, mm 905 DEPTH + VALVE, mm NOMINAL AIRFLOW, m 3 /min CONDENSER COIL: NO. OF ROWS FINS PER INCH AREA, m FAN MOTOR KW, 2.7 FLA, 1 ea kw, 3.8FLA, 1 ea. COMPRESSOR NO TYPE Rotary ELECTRICAL CHARACTERISTICS Volts/1 phase/60 Hertz FULL LOAD COMP AMPS AT COMP V COMP TOTAL LOCKED COMP ROTOR AMPS COMP AT 230 V COMP POWER COMP INPUT COMP AT 230 V COMP TOTAL NET WEIGHT, KG

3 SYSTEM (2&4 COMPRESSOR SERIES) DIMENSIONS: MODEL 38GHP GHP GHP HEIGHT, mm 1835 WIDTH, mm 905 DEPTH + VALVE, mm NOMINAL AIRFLOW, m 3 /min CONDENSER COIL: NO. OF ROWS FINS PER INCH AREA, m FAN MOTOR 0.395kW; 2.7 FLA; 1 ea kW; 3.8 FLA; 1 ea COMPRESSOR NO. 2 4 TYPE Rotary Scroll Rotary ELECTRICAL CHARACTERISTICS Volts/1 phase/60 Hertz Volts/1 phase/60 Hertz FULL LOAD COMP AMPS AT COMP V COMP COMP TOTAL LOCKED COMP ROTOR AMPS COMP AT 230 V COMP COMP POWER COMP INPUT COMP AT 230 V COMP COMP TOTAL NET WEIGHT, KG INTRODUCTION The 38GHP models are designed for use with 2, 3 or 4 indoor fan coil units depending on the number of compressors. Each compressor has its own independent control & power wirings but all the compressors share a common fan drive system. Each compressor also has its own refrigerant lines and each piping circuit has a holding charge of 0.5 kg. Install these condensing units either thru-the-wall, outdoors on a slab or on the roof. When installing units, allow sufficient space for airflow clearance, wiring, refrigerant piping and servicing units. The air-side clearance must be at least 600 mm or more. REFRIGERANT LINE SIZING Follow the recommendation given under UNIT DATA for the selection of tube OD. Wrong sizing would either result in excessive pressure drop or unsatisfactory oil return. The cooling coils should be connected as close as possible. Both liquid and suction line lengths should be less than 15 meters. Condensing units should not be more than 5 meters above or below the evaporator coils. Run refrigerant tubes as directly as possible, avoiding unnecessary turns and pipe bends. Condensing unit may be connected to evaporator sections using fieldsupplied tubing of refrigerant grade, correct size and condition. Suspend refrigerant tubes so they do not transmit vibration to structure. Leave some slack in refrigerant tubes between structure and unit to absorb vibration. Longer interconnecting pipe run will result considerable cooling capacity drop. See Table 4 for approximate percentage of system cooling capacity reduction Table 4 REDUCTION IN CAPACITY VS. INCREASE IN PIPE LENGTH Actual Compressor Capacity PIPING LENGTH (ONE WAY) 5m 10m 15m 09 k 0 % 1.5 % 3.0 % 12 k 0 % 1.7 % 3.2 % 18 k 0 % 1.6 % 3.4 % 24 k 0 % 1.5 % 3.6 % 36 k 0 % 1.5 % 3.7 % 3

4 FIELD PIPING WORKS Do not bury any section of line set underground. If any section is buried, refrigerant may migrate to cooler buried section during extended periods of unit shutdown. This causes refrigerant slugging and possible compressor damage at start-up. If either refrigerant tubing or indoor coil is exposed to atmospheric conditions for longer than 5 minutes, it must be evacuated to 1000 microns to eliminate contamination and moisture in the system. PIPING CONNECTION Run refrigerant tubes as directly as possible and avoid turns and bends. Use refrigerant grade tubing and correct size Allen wrench. Align tubing flare with service valve connection and tighten the nut with the correct torque. Refer to Table 5 for vertical and horizontal piping length. AIR PURGE Air does not function as refrigerant because it can not be condensed in the condenser. Air and moisture remaining in the system have undesirable effects. Therefore, they must be purged out completely. AIR PURGING PROCEDURE Remove the blind caps of the liquid valve. Loosen the valve stem of the liquid valve by 90 0 for 5 seconds with a hexagonal key wrench. Then close the valve stem quickly. Push the valve core of the suction valve. Stop pushing as soon as the hissing stop. Open the liquid valve for about 3 seconds, then close quickly to check for gas leak. After checking for gas leaks, open the liquid and suction valves all the way. Re-install the blind caps. FIG. 1 MAXIMUM ALLOWABLE PIPING LENGTH AND ELEVATION DIFFERENCE Actual Compressor Capacity MAX. DISTANCE L - m (ft) CDU above FCU MAX. LIFT H m (ft) CDU below FCU 09 k 15 (50) 7.5 (25) 5 (16) 12 k 15 (50) 7.5 (25) 5 (16) 18 k 15 (50) 10 (33) 7.5 (25) 24 k 15 (50) 10 (33) 7.5 (25) 36 k 18 (60) 10 (33) 7.5 (25) Table 5 MAX PIPE DISTANCE L & H FIG. 2 PIPING LENGHT 4

5 SIGHT GLASS AND FILTER DRIER Sight glass and filter drier are field supplied and installed applicable for model 38GHP036,048, 060, other models are factory installed. Warranty will be voided if these models were not fitted with external filter drier in the field installation. TUBING CONNECTIONS AND LEAK TEST Both suction and liquid are equipped with flare type connections. Assemble flare joint by aligning tubing with machine surface of fitting. Start run onto threads by turning backwards first then forwards. All lines should be assembled with type L or quarter hard drawn refrigeration grade copper tubing and not with copper water pipe. Use only the following brazing alloys: Copper to Copper % Silver Alloy (no flux) Copper to Steel or Brass % Silver Alloy (no flux) Remove cap and Schrader core from service port to protect seals from heat damage. Wrap service valve with wet rag before applying heat. Flow dry nitrogen into a service port and through the tubing while brazing to prevent pipe oxidation. Pressurize line set and coil through service fittings with dry nitrogen to 150 psig maximum (or refer to Carrier Standard Service Techniques Manual, chapter 1, section 1-6) If a leak is found, recover pressure and repair all leaks. WARNING: DO NOT USE OXYGEN TO PURGE LINES OR PRESSURE SYSTEM FOR LEAK TEST. OXYGEN REACTS VIOLENTLY WITH OIL, WHICH CAN CAUSE AN EXPLOSION RESULTING IN SEVERE PERSONAL INJURY OR DEATH. PIPING INSULATION Insulate both suction and liquid lines as per Figure 8 shown below. EVACUATION AND DEHYDRATION Evacuation is the most important part of the entire service procedure. The life and efficiency of the equipment is dependent upon the thoroughness exercised by the serviceman when evacuating air and moisture from the system. Air in the system causes high condensing temperature and pressure, resulting in increased power consumption and reduced system efficiency. Moisture chemically reacts with the refrigerant and oil thus forming corrosive acids which attacks motor windings and parts, causing early breakdown. After the system has been leak checked and proven leak free, connect now the vacuum pump and evacuate system to 29 Hg vacuum. It is advisable to connect both vacuum pump hose to the high-side and low-side of the system. FINAL LEAK TEST After the unit has been properly evacuated and charged, use a halogen leak detector to check system for leaks. In the absence of this, water-soap solution is acceptable. All piping within the condensing unit, evaporator, and interconnecting tubing should be checked for leaks. If a leak is detected, the refrigerant should be recovered before repairing the leak. REFRIGERANT CHARGING The 38GHP units are all Factory charged with R22 for holding charge purposes only. Refrigerant charge adjustment is required on all systems following super heat charging method explained in details in the preceding discussions below. IMPORTANT For accurate system performance, charge by superheat method as shown in Table 7 and 8. To check and adjust, follow this procedures: 1. Operate unit for a minimum of 30 minutes before checking charge. 2. Measure suction pressure by attaching a gauge to suction valve service port. 3. Measure suction line temperature by attaching a service thermometer to unit suction line near suction valve. Insulate thermometer for accurate readings. 4. Measure outdoor coil air inlet dry-bulb temperature with a second thermometer. 5. Measure indoor coil air inlet wet-bulb temperature with a sling psychrometer. 6. Refer to Table 7. Find air inlet dry-bulb temperature entering outdoor coil and wet-bulb temperature entering indoor coil. At this intersection note down the superheat. 7. Refer to Table 8. Find superheat temperature and suction pressure, note suction line temperature. 8. If unit has higher suction line temperature than charted temperature, add refrigerant until charted temperature is reached. 9. If unit has lower suction temperature than charted temperature, bleed refrigerant until charted temperature is reached. 10. If air temperature entering outdoor coil or pressure at suction line changes, change to new suction line temperature indicated on chart. 11. This procedure is valid independent of indoor air quantity. 5

6 FIG. 3 PIPE INSULATION ASSEMBLY FIG. 4 ACCURATOR ASSEMBLY EXPANSION SYSTEM The 38GHP units are factory equipped with a system for refrigerant gas expansion called piston while model 38ASB series uses capillary tube type. As shown below, this system has a small piece with a fixed, calibrated, easily removable hole inside a nipple to be easily connected to liquid line by a 3/8 size flare nut. The piston application properties include a more accurate refrigerant gas flow into the evaporator compared, for instance, with the capillary system. On some application wherein long pipe length can not be avoided, piston size can be changed to adjust operating conditions of the applications. Consult Carrier Service Department for proper selection of piston size other than specified. ACTUAL COMPR. CAPACITY 09K 12K 24K 36K PISTON SIZE R22 CHARGING METHOD Table 6 PISTON SIZE TABLE Sh Sh Sh Sh Sh Sh= Charge unit according to Carrier super heat Charging method. COMPLETE ELECTRICAL CONNECTIONS Each refrigerant circuit has its own control and power wiring except the fan motor is common to all the refrigerant circuits. The compressor motor is protected by an overload relay. The compressor is further protected by a high pressure switch. For a 2, 3 and 4 compressor system, fan motor starts together with one or more compressors. For all circuits, any interruption to the load will initiate a 3 minute delay and prevent the compressor from being re-energized until the normal delay period has elapsed. The wiring circuits are wired such that the fan motor is de-energized whenever all the compressor happen to cycle off. Since many of the components in each of the 38GHP models are identical, careful wiring is important. POWER - Unit is factory wired for voltage shown on name plate. Provide adequate fused disconnect switch within sight of unit, readily accessible, but out of reach of children. Provision for locking switch open (off) is advisable to prevent power from being turned on while unit is being serviced. Route power wires through opening in the unit side panel knock-out holes and connect into control box. Unit must be grounded. WIRING PROCEDURE This unit is factory wired for voltage shown on the unit nameplate. Remove service cover of the outdoor unit and connect wires firmly to the terminal block individually as shown in wiring diagrams. Secure service cover back once wiring connection is tested and completed. PISTON REPLACEMENT MUST BE ONLY DONE BY QUALIFIED TRAINED SERVICE TECHINCIANS. IF PISTON ARE NOT PROPERLY POSITIONED, THIS WILL RESULT SYSTEM MALFUNCTION. SEE FIG. 4 FOR CORRECT POSITION AND DIRECTION. All switches, fuses and field wiring must carry unit running ampere and must comply with local code requirements. Unit factory wiring diagram is shown on the inside of the service cover. Note: Operation of unit on improper line voltage constitutes abuse and could affect Carrier Warranty. Do not install unit in system where voltage may fluctuate above or below permissible limits of +/- 10% of the rated voltage. 6

7 SERVICE GUIDES CAUTION: Disconnect electric power from main switch before performing any maintenance or service units. GENERAL NOTES When performing any routine service operations or doing specific repairs to the components, motors, fans and other components, all drain passages should be thoroughly cleaned. Inside painted surfaces should be cleaned with mineral spirits to remove grease. Check indoor and outdoor units to see that all controls are functioning correctly and the operation of the units is normal. Be sure that the tubing does not vibrate against the side of the indoor or outdoor unit. Ensure that the indoor unit is leveled in order that condensate drains correctly from it. When disconnecting power or control wiring, it is recommended that identification tags be attached to the wires to facilitate rapid and correct re-assembly. Before disconnecting any capacitor it is necessary that the capacitor be discharged by shorting its terminals with an insulated screwdriver. CLEANING The single most important item affecting your air conditioning effectiveness is its cleanliness. The following items require regular attention (Caution: disconnect electric power from main switch before performing any maintenance item.) Paint any parts that show evidence of rust with a good rust resistant paint. The rubber mounting grommets for the compressor in the outdoor unit should be replaced if they deteriorate. Check all the wiring for deterioration and electrical contacts for tightness and correction. PIPING CONNECTION AND COMPRESSOR LOCATION 38GHP units are multi-split units. Correct coupling of suction and liquid lines to every fan coil is essential. The same is true for the wiring. The following diagrams should be used for field coupling. (All views are from the back of the unit.) Check fans to see they are centered in the fan housings, correctly positioned and tight on shafts. After replacing fans, check clearance of wheel to housing prior to operation. Shield coils with cardboard prior to removing interior components. FIG. 6 PIPING CONNECTION 7

8 3 COMPRESSOR SERIES: COMPRESSOR CAPACITY, Btu/hr 38GHP GHP GHP GHP GHP K 9K 9K 12K 12K 12K 24K FIG 7 COMPRESSOR & VALVE LOCATION 3 COMPRESSOR SERIES COMPRESSOR SERIES: COMPRESSOR CAPACITY, Btu/hr 38GHP COMPRESSOR 4 9K 9K 12K 2 COMPRESSOR SERIES-HIGH TONNAGE: COMPRESSOR CAPACITY, Btu/hr 38GHP GHP K 24K 36K 36K FIG. 8 COMPRESSOR & VALVE LOCATION 4 COMPRESSOR SERIES 1 2 ELECTRICAL CONNECTIONS POWER WIRING WARNING TO AVOID POSSIBLE INJURY OR DEATH DUE TO ELECTRICAL SHOCK, OPEN THE POWER SUPPLY DISCONNECT SWITCH (SWITCH-OFF) AND SECURE IT IN AN OPEN POSITION DURING INSTALLATION. USE LOCK-OUT AND TAG-OUT SECURITY LOCKS! Unit is factory wired for voltage shown on nameplate. Provide adequate fused disconnect switch within sight of unit, readily accessible but out of reach of children. FIG. 9 COMPRESSOR & VALVE LOCATION 4 COMPRESSOR SERIES Provision for locking switch open (off) is advisable to prevent power from being turned on while unit is installed or serviced. Disconnect switch, fuses and field wiring must comply with local codes. Size the wire as per electrical specification shown in CCAC Service Installer Blue Book. Use terminal marked L and N for 230V-1Ph-60Hz power supply. See respective wiring diagram shown on the preceding pages. CAUTION THE CONTROL VOLTAGE FROM THE FAN COIL UNIT MUST BE OF 230V. DO NOT CONNECT THE POWER SUPPLY TO THE SIGNAL 8

9 OPERATION AND START-UP PRELIMINARY CHECKS Before operating the unit be sure the following are in order. 1. All wiring connections are correct and tight. 2. All barriers, covers and panels are in place. 3. Electrical power supply conform to unit s requirement. 4. All joints are leak tested and leak free. 5. All valves are opened. TO START THE UNIT 1. Field disconnect switch is closed. 2. Set room temperature below ambient setting. 3. Compressor will start once time delay has elapsed (normally 3 minutes as factory setting). 4. Operate unit or at least 30 minutes, then check system refrigerant charge using superheat method. Table 7 Superheat Charging Table (English) (Superheat Entering Suction Service Valve) INDOOR COIL ENTERING AIR ( F) WET-BULB OUTDOOR TEMP( F) Symbol dash (-) means: Do not attempt to charge system under these conditions or refrigerant slugging may occur. Superheat Charging Table (Metric) (Superheat Entering Suction Service Valve) INDOOR COIL ENTERING AIR ( C) WET-BULB OUTDOOR TEMP( C) Symbol dash (-) means: Do not attempt to charge system under these conditions or refrigerant slugging may occur. Table 8 Required Suction Tube Temperature (English) (Entering Suction Service Valve) SUPERHEAT SUCTION PRESSURE AT SERVICE PORT (psig) TEMP ( F) Required Suction Tube Temperature (Metric) (Entering Suction Service Valve) 9 SUPERHEAT SUCTION PRESSURE AT SERVICE PORT (KPaG) TEMP ( K)

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11 AIR BLOW FRONT REAR AIR IN FIG. 10 RECOMMENDED SERVICE CLEARANCES Concepcion Carrier Air conditioning Company Philippines Concepcion Carrier Air Conditioning Company Km. 20 East Service Road, South Superhighway, Alabang, Muntinlupa City Tel. No. (63) Fax No. (63) Website: Manufacturer reserve the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations Form 38GHP-1IOM Replaces: NEW 11