BeiJer KIRBY WRC User manual

WRCRemote Condenser
File No. IM-043A
Date 09/03/20
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286 Horsley Road Milperra NSW 2214 Locked Bag 63 Wetherill Park NSW 1851 Ph: 612 9774 7369 Fax: [phone]
7146
WRC Installation Manual

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Introduction
The information contained in this booklet will provide the necessary safety information to
competently transport, lift, install commission and service the World Remote Condenser (WRC)
as per Kirby requirements.
This manual should be kept in a dry place for a period of at least ten years, for possible
future reference. Read carefully and thoroughly all the information contained this
manual. Pay particular attention to the user instruction that appears and the heading
“Warning” or “Caution”. Failure to do so could result in damage to the machine, person
or property.
If you have any concerns regarding the performance and use of this unit, please contact your
local outlet on 13 23 50.

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Contents page Page numbers
A Important safety information and instructions –retain for future use -4-
1 Lifting & Installation for either: VERTICAL / HORIZONTAL AIR FLOW -7-
1.1 Unloading from means of transportation -7-
1.2 Installation: - (Vertical air flow) -7-
1.3 Installation: - (Horizontal air flow) -8-
1.4 Tools Required (Not Supplied) -8-
2Unit Dimensions and Refrigerant Connections -16-
2.1 Horizontal Air Flow -16-
2.2 Vertical Air Flow -17-
2.3Weight Table –WRC Condenser -18-
3Electrical Connections -18-
4Installation and Location Guidance -21-
5 Motor Maintenance -26-
6Start up -26-
7Cleaning -27-
8Piping requirements -28-

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A Important safety information and instructions –retain for future use.
Kirby Safety Precautions
SAFETY PRECAUTIONS FOR ALL WRC Units.
Kirby is very safety conscious when designing and manufacturing these products, but it is
essential that the end user, installer or service personnel also exercise care when working with
or on the unit.
Warning
This indicates contents for which the possibility of human death or severe injury
can be assumed in case of handling under disregard of this indication.
Caution
This indicates contents for which the possibility of human injury or the possibility
of material damage can be assumed in case of handling under disregard of this
indication.
Warning –Lifting & Installation Precautions
Refer “Appendix A” of this booklet.
Warning- Stand unit on flat and level ground
The WRC unit with the skid must be placed on flat and level ground with a suitably hard surface
to bear the weight of the unit.
Refer to Picture 2.
Caution –Cyclone or High Wind Regions
An optional brace for legs may be required. Refer page 13.
The WRC unit:
Moving Machinery
WRC Units have components that may start up automatically. All electrical items must be
isolated before any service or repairs are carried out.
No Smoking
Kirby recommends No Smoking within a distance of 15 metres of the WRC Unit.

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Warning –Weight
The weight of WRC units will vary from model to model. Please check page –8- and –26- for the
correct packaged gross weight.
Warning –Electrical Hazard
A qualified Electrician must carry out all electrical work.
Always isolate the power to the unit before checking, diagnosing, removing and replacing the
fan assemblies. Never work on any electrical item without isolating or disconnecting the power
supply.
Caution –WRC Unit Pressurised
In the manufacturing of this product it is essential to pressurize and test the heat exchanger coil.
This unit is shipped with some pressure within it. Please take care when unsealing the unit to fit
the pipe and line connections.
Caution –Refrigerant Type
The WRC is designed for use with fluorocarbon refrigerants; under no circumstances can
Ammonia based gas, Hydrocarbon based gas, Water* or Glycol* be used in this product.
Refrigerant type: HCFC and HFC
(*For Water and Glycol Kirby offers the WDC dry cooler to special order)
Caution –Sharp Edges
The WRC is manufactured with sheet metal and in this process all care is taken to ensure the
edges are concealed. In some circumstances this cannot occur.
The aluminium fins of the heat exchanger have sharp edges and can cause severe cuts if
contacted carelessly.
Please take care when accessing in or around the WRC.
Warning –Qualified Personnel
WRC’s may only be installed, commissioned and serviced by qualified and trained personnel.
Personal Protective Equipment
Kirby recommends as a secondary safety precaution that all personnel working in and around
the WRC wear appropriate Personal Protective Equipment (PPE).

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Installation Instructions.
This product must be installed and maintained in accordance with the following:
•AS/NZS5149:2016 –Parts 3 & 4 (as applicable)
•AS4041:1998 –Pressure Piping
•Refrigerant Handling Code of Practice, Part 2
Useful information-
•Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (and amendments) and
Regulations 1995
•AIRAH, DA19 –HVAC&R Maintenance
•CIBSE Code M - Commissioning Management
NOTE- There may be other applicable Codes and Standards that must be considered. It is the
responsibility of the Installer and Owner to ensure all requirements are considered and complied
with.
Standard Design Conditions
WRC condensers are designed to operate with a maximum operating pressure of 3450kPag,
with a maximum KTD of 18K, and a minimum of 5K (please refer to the relevant technical data
literature for more specific recommendations). Special circuiting may be needed to achieve
specific conditions outside of these limits- please refer to your Kirby representative.
Motors must NOT be subject to air-over-motor temperatures greater than allowed by the fan
manufacturer(s). Please refer to the relevant technical literature.
APPROVED REFRIGERANTS-
R404A/R507A/R448A/R407F/R407C/R134a/R513A are approved for use in all WRC remote
condensers.
MAXIMUM WORKING PRESSURE-
WRC models have a maximum working pressure of 3450kPag.
Standard condensers cannot use Ammonia (NH3) as refrigerant.
For special design requirements (non-standard conditions and/or refrigerants such as Glycol,
etc.), please inquire with your local representatives and/or Kirby local branches.
MAXIMUM ALLOWABLE PRESSURE (PS/PSS)
UNIT DATA
PS (kPag)
PSS (kPag)
3450
n/a

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1 Lifting & Installation for either: VERTICAL / HORIZONTAL AIR FLOW
1.1 Unloading from means of transportation: -
Due to the size and weight of the WRC it is essential that it is unloaded with suitable material
handling equipment. This may include either a crane or forklift that has a safe working load
greater than the weight of the WRC Unit.
(Horizontal Airflow shipment)
Refer Picture. 1 –Upright shipment (Horizontal Airflow shipment)
Preferred method: - Forklift
•Check load-rating plate to determine maximum safe working load. .
•Look for the cut-outs where the forklift tynes are to be entered into the skid so the WRC
can be lifted safely.
•Position tynes at centre of cut-out of skid, ensuring full engagement across the skid
depth.
Alternative method: - Crane method
•Use suitable lifting equipment that is able to safely load/unload the WRC unit from the
means of transportation.
•Refer picture 1 (horizontal airflow) for the designated WRC lifting points. Do Not lift the
WRC by any lifting points other than those specified (All lifting equipment used must have
a safe working load greater than the weight of the WRC.)
•If spreader bar & chains are used they must be at points ‘A’ & ‘B”. If unavailable, proper
lifting equipment such as long slings must be used at minimal angle to unit.
(Vertical Airflow shipment)
Refer Picture. 3 & 9 –Horizontal shipment (Vertical Airflow shipment) –Crane only
•Use crane that is able to safely load/unload the WRC unit from the means of
transportation. Check load rating plate to determine maximum safe working load. For
WRC Unit weights refer table on page 23.
•Refer picture 3 & picture 9 (vertical airflow) for the designated WRC lifting points. Do Not
lift the WRC by any lifting points other than those specified (All lifting equipment used
must have a safe working load greater than the weight of the WRC.)
•If spreader bar & chains are used they must be at points ‘A’ & ‘B”. If unavailable, proper
lifting equipment such as long slings must be used at minimal angle to unit.
•
1.2 Installation: - (Horizontal Airflow Shipment to Vertical air flow Installation)
Units can be laid down using a crane or a forklift. If using a crane, remove the attached
brackets and shackles for access to lifting points, or take care to ensure chains or slings
do not foul on the brackets.
If using a forklift, use the attached brackets and shackles (on twin coil units only) as
shown in Pic 2. Ensure a suitably rated forklift is used that also allows sufficient height
above the unit to achieve the specified maximum chain angle.

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1. Attach lifting equipment to unit (refer Pic. 1) at point 1
2. Remove pallet screws from all places except at ends 2 (refer Pic. 1)
3. Tilt unit over onto base (refer Pic. 2) by carefully raising unit until balance point is
reached, and then commence lowering to the ground.
4. Remove remaining pallet screws and remove skid (refer Pic 3). Skid must be removed by
suitable equipment to prevent the skid from falling.
5. Attach lifting equipment to lifting brackets 5 (refer Pic 3) using suitable lifting equipment
rated greater than the weight of the WRC.
6. Raise unit and move legs from position ‘A’ to position ‘B’ (refer Pic 4,6 & 7).
7. Attach cross brace to legs (refer Pic 5&6) noting the final position under the legs.
8. Remove transport brackets (refer Pic 5 & 8) after moving unit to final location.
1.3 Installation: -(Horizontal air flow)
1. Attach lifting equipment to WRC unit (refer Pic. 1) at points 1
2. Remove pallet screws from all places (refer Pic. 1)
3. Raise unit to a minium height sufficient to remove from skid.
4. LEAVE ALL LEGS IN POSITION A as supplied. (ref Pic 4.)
5. Sliding Legs can be fitted at point 5 on base of unit for final installation purposes.
6. Galvanised transport brackets may be removed, all black leg braces (point 7 on picture 4)
can be left in place as supplied.`
ENSURE THE LEGS ARE ADEQUATELY SUPPORTED UNDERNEATH, PREFERABLY
ALONG THEIR FULL LENGTH, ESPECIALLY IF EXTENDING THE LEGS TO SUIT A
FRAME MOUNT.
IF FULL LENGTH SUPPORT IS NOT FEASIBLE, A MINIMUM OF THREE SUPPORT
POINTS INCLUDING UNDER THE BOLTING LOCATIONS, ARE NECESSARY.
1.4 Tools Required (Not Supplied):-
•Ratchet spanner with socket (13mm)
•Ring spanner (or combination spanner) 13mm
Recommended additional Tooling (not supplied): -
•10, 11, 12mm socket & ring/combo spanner
•1 x Phillip screw driver (long)
•1 x Straight screw driver (long)
Required fasteners (supplied):
•refer Pic 8

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Picture 1; Recommended lifting points and approx. weights
NOTE : UNITS SHOWN WITHOUT LAYOVER BRACKETS, PLEASE REMOVE THEM IF CRANE IS
USED TO LIFT UNIT OFF THE TRUCK . DO NOT USE LAYOVER BRACKET FOR ANY OPERATION
OTHER THAN LAYOVER (Refer page 9 of this booklet)
1
max weight
(packed)
1. Standard with ‘AL’
fins approx. 530kg
2. Option with ‘CU’ fins
approx. 795kg
‘A’
’A’
‘B’
Fork lift here to
remove from truck
2
2
max weight
(packed)
1. Standard with ‘AL’
fins approx. 980kg
2. Option with ‘CU’
fins approx. 1470kg
‘A’
’A’
‘B’
Fork lift here to
remove from truck
2
2
1
Fork lift here to
remove from truck
‘B’
2
1
‘A’
2
max weight
(packed)
1. Standard with ‘AL’
fins approx. 750kg
2. Option with ‘CU’
fins approx. 1125kg
Fork lift here to
remove from truck
‘B’
2
1
‘A’
2
max weight
(packed)
1. Standard with ‘AL’
fins approx. 1420kg
2. Option with ‘CU’
fins approx. 2130kg
max weight
(packed)
1. Standard with ‘AL’
fins approx. 1020kg
2. Option with ‘CU’
fins approx. 1530kg
‘A’
’A’
‘B’
Fork lift here to
remove from truck
2
2
1
Fork lift here to
remove from truck
‘B’
2
1
‘A’
2
max weight
(packed)
1. Standard with ‘AL’
fins approx. 1890kg
2. Option with ‘CU’
fins approx. 2835kg
max weight
(packed)
1. Standard with ‘AL’
fins approx. 1290kg
2. Option with ‘CU’ fins
approx. 1935kg
‘A’
’A’
‘B’
Fork lift here to
remove from truck
2
2
1
Fork lift here to
remove from truck
‘B’
2
1
‘A’
2
max weight
(packed)
1. Standard with ‘AL’
fins approx. 2380kg
2. Option with ‘CU’
fins approx. 3570kg

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Picture 2; Tilt over to ground position
A)
MAX. g= 120v
LIFT
& TILT
B)
"FORKLIFT"
LOWER
CONNECTED TO
APPROPRIATE
CRANE OR FORK-LIFT
(REFER PAGE 8 OF
INSTRUCTION BOOKLET
FOR WEIGHT OF UNIT)
A
DETAIL A
REMOVE CHANNEL
& SHACKLES AFTER USE
TO BE USED ONLY FOR
THIS OPERATION
(OR REVERSE)
C)
NOTE :
FOR SINGLE COIL UNITS
USE EXISTING HOLES ON LEG
TO TILT OVER. USE SUITABLE
“D” SHACKLE OR EQUIVALENT
TO ALLOW MOVEMENT DURING
LOWERING
D)
Stand only on flat and level ground.
Maximum standing angle from vertical = 5°

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Picture 3; Lifting points after removing skid and lifting off truck for horizontal shipment.
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5

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Picture 4; Leg position A and B
6 Position A
6 Position B
6 Position A
6 Position B
7 Leg Brace
7 Leg Brace

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Picture 5; Final leg position
7
7
7
7
7
7
7
7

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Picture 6; bolt holes and bolts
Picture 7; standard fitment and fitment for cyclone or high wind regions (KIT option: KP445-7) *1
*1 KITquantity: 1 KIT (= 1 pair of braces with fasteners) X number of pairs of legs
(For further information regarding the cyclone kits, please refer to Kirby Technical Bulletin TB_100)
bolts 2x M8x30
1. Standard position:
bolt on a frame
2. Security bolt for cyclone
region as option
3. Security brace for cyclone
region as option: KP445-7
1. option: 770 mm
2. option: 610 mm
or
3. option: 192 mm
above 70% open-
Mesh-ground
(Please see page
25/26 Fig 9/10 as
well!)
bolts 2x M10x120
1.
2.
3.

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Picture 8 –Final Position –(Required fasteners; supplied):
•M10 Bolt, Nut & Washers x 8 off
•Bolt M8 x 30mm, 8 of f
•Nut M8, 8 off
•Washer Flat M8, 8 off
•Washer Spring M8, 8 off
•M10 Bolt, Nut & Washers x 8 off
•Bolt M8 x 30mm, 8 off
•Nut M8, 8 off
•Washer Flat M8, 8 off
•Washer Spring M8, 8 off
•M10 Bolt, Nut & Washers x 16 off
•Bolt M8 x 30mm, 16 off
•Nut M8, 16 off
•Washer Flat M8, 16 off
•Washer Spring M8, 16 off
•M10 Bolt, Nut & Washers x 16 off
•Bolt M8 x 30mm, 16 off
•Nut M8, 16 off
•Washer Flat M8, 16 off
•Washer Spring M8, 16 off
•M10 Bolt, Nut & Washers x 12 off
•Bolt M8 x 30mm, 12 off
•Nut M8, 12 off
•Washer Flat M8, 12 off
•Washer Spring M8, 12 off
•M10 Bolt, Nut & Washers x 12 off
•Bolt M8 x 30mm, 12 off
•Nut M8, 12 off
•Washer Flat M8, 12 off
•Washer Spring M8, 12 off
•M10 Bolt,Nut & Washers x 16 off
•Bolt M8 x 30mm, 16 off
•Nut M8, 16 off
•Washer Flat M8, 16 off
•Washer Spring M8, 16 off
•M10 Bolt, Nut & Washers x 16 off
•Bolt M8 x 30mm, 16 off
•Nut M8, 16 off
•Washer Flat M8, 16 off
•Washer Spring M8, 16 off

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2 Unit Dimensions and Refrigerant Connections
2.1 Horizontal Air Flow

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2.2 Vertical Air Flow (800mm EC)
Note: WRCV model double coils are supplied to site in vertical airflow.

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2.3 Weight Table - WRC Condenser
3 Electrical Connections
For units fitted with EC (electronically commutated) variable speed fans please refer to wiring information
supplied with each unit.
Wiring of EC fans is dependent on control methods and programming requirements.
Please refer to the wiring schematic MS783-61, on Page 19 of this document for wiring.

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KIRBY WRC UNIT –WIRING SCHEMATIC:

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FAN CONTROL AND FAULT WIRING: