BONAIRE B009RS User manual

Installation Manual
DUAL CYCLE
REFRIGERATED COOLING COMPONENT
B009RS/DC
B012RS/DC, B015RS/DC
B016RT/DC, B019RT/DC

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 3
Table of Contents
Installation Instructions
General ......................................................................................................................................... 4
Product Selection Matrix ............................................................................................................... 4
UNIT DETAILS.................................................................................................................................5
Outdoor Unit Dimensions .............................................................................................................. 5
Outdoor Unit Access and Clearances ........................................................................................... 6
Indoor Unit Dimensions................................................................................................................. 7
Indoor Coil Clearances.................................................................................................................. 8
UNIT INSTALLATION......................................................................................................................9
Indoor Coil..................................................................................................................................... 9
Coil Location.............................................................................................................................................. 9
Coil - Floor or Platform Mounting ............................................................................................................ 10
Coil - Suspension Mounting .................................................................................................................... 10
Leveling the Coil Box............................................................................................................................... 10
Outdoor Unit................................................................................................................................ 11
Condenser Installation ................................................................................................................ 12
Interconnecting Tubing................................................................................................................ 12
Installation Notes..................................................................................................................................... 13
Unit Interconnecting Tubing Table.......................................................................................................... 13
Recommendation for Interconnection Tubing Installation....................................................................... 14
Pipe Installation........................................................................................................................... 15
Flare Preparation..................................................................................................................................... 15
Pipe Welding Preparation........................................................................................................................ 15
Pipe Welding........................................................................................................................................... 15
Connecting the tubes .............................................................................................................................. 16
Piston Assembly...................................................................................................................................... 16
Evacuation and setting in operation ............................................................................................ 17
Additional Charge........................................................................................................................ 18
Drain Line Installation.................................................................................................................. 18
ELECTRICAL CONNECTIONS......................................................................................................19
Outdoor Unit Connections........................................................................................................... 19
Wiring Diagram - Single Phase Outdoor Unit.............................................................................. 20
Wiring Diagram - 3 Phase Outdoor Unit...................................................................................... 21
COMMISSIONING..........................................................................................................................22
Commissioning Check List.......................................................................................................... 22

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 4
General
Installation Instructions
GENERAL
Bonaire Dual Cycle air conditioners combine ducted gas heating and refrigerative cooling, using an
inline coil box, to create a cooling and heating system. The heater provides the controls and fan
for the heating and cooling system.
The Bonaire Dual Cycle cooling component includes two separate units – indoor coil and outdoor
Unit. The two components are interconnected by two refrigerant tubes and an electric cable.
WARNING
The refrigerative cooling component must be installed by authorized technicians, according to
Climate Technologies specifications and using recommended standard tubing, electric cables and
proper installation tools. Failure to comply with the above may invalidate your warranty!
PRODUCT SELECTION MATRIX
DUAL CYCLE
REFRIGERATIVE UNIT DUCTED GAS HEATER
BONAIRE VULCAN /PYROX
Outdoor Unit Indoor Coil BV3 BV4 BV5
B009RS 8.9kW B009DC – 9.0kW 20 20 21
B012RS 12.0kW B012DC - 12.0kW - 20 XA 21 XA
B015RS 14.7kW B015DC - 14.9kW 30XA 30 XA 30 XA
B016RT 15.8kW B016DC - 15.8kW
30 XA 30 XA 30 XA
35
B019RT 18.5kW B019DC - 18.5kW
30 XA 30 XA 30XA
35

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
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Dimensions & Clearances
Installation Instructions
Unit Details
OUTDOOR UNIT DIMENSIONS
B009RS
B012RS
B015RS
B016RT
B019RT
Unit Weight A B C D E
B009RS 92kg 970 960 365 160 90
B012RS 97kg 970 960 365 160 90
B015RS 103kg 970 1260 395 Connections Inside Unit
B016RT 108kg 970 1260 395 Connections Inside Unit
B019RT 131kg 970 1465 365 160 90

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 6
Dimensions & Clearances
Installation Instructions
OUTDOOR UNIT ACCESS AND CLEARANCES
In selecting a proper location, the following criteria
must be considered:
a) The outdoor unit and the indoor unit must be
installed as close to each other as possible, within
10m. For longer tube specifications see table on
page 13 or consult your technical sales rep.
b) Outdoor unit installation should provide for:
1. Easy service access.
2. Minimum disturbance to the owner and nearby
neighbors.
3. A minimum distance of 100 mm from the wall
4. If installed in a closed place (balcony, attic, etc),
outdoor air vent must be provided to prevent
hot/cold air from recirculation through the
outdoor unit.
5. If several outdoor units are installed in the
same area, make sure that the hot air outlet
from one outdoor unit does not enter another
outdoor unit.
6. Verify that any wall on which the outdoor unit is
installed is capable of carrying the unit’s
weight. Do not install on a light unstable
structure susceptible to vibration.
7. When installing on a balcony above the first
floor, make sure that the outdoor unit location
allows easy access for removal of the top
cover and/or the entire unit, if necessary.
8. If the outdoor unit is installed in a non-
accessible location, long and flexible
refrigerant tubing and electrical cable must be
installed to allow the unit to be moved for
servicing.
9. Do not install the unit in a highly polluted area
in which the air is contaminated by oil mist, salt
or sulfuric gas.
When the top is blocked
The front and the sides must be clear for
these minimum clearances.
When the back & sides are blocked
The back and the side minimum
clearances must be achieved
When all the sides are blocked
If all sides are blocked, this will be an
unacceptable installation
Multiple Units – Lateral and Behind relationships
When the back is close to the Wall
The top and the front need to be open.
This includes protruding window sills.

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 7
Dimensions & Clearances
Installation Instructions
INDOOR UNIT DIMENSIONS
Unit Dimensions
Unit Weight A B C D E F G
B009DC 15Kg 641 501 501 250 483 435 435
B012DC 20Kg 701 561 561 300 660 612 612
B015DC 20Kg 701 561 561 300 660 612 612
B016DC 20Kg 701 561 561 300 660 612 612
B019DC 24.5Kg 841 701 701 350 686 638 638

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 8
Dimensions & Clearances
Installation Instructions
INDOOR COIL CLEARANCES
Clearance Options for Maintenance
Unit A B C
B009HD 500 300 300
B012HD 500 300 300
B015HD 500 300 300
B016HD 500 300 300
B019HD 500 300 300

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 9
Unit Installation
Installation Instructions
Unit insta llation
INDOOR COIL
Coil Location
The indoor coil is designed for installation in
conjunction with a duct gas central heater
within a ceiling/roof space or other
compartment, where there is no influence
from outdoor conditions.
While selecting the location, the following
conditions must be assured:
a) The location should assure free flow of the
return air into the central heater without
interference.
b) The unit should not be installed close to
rooms where noise should be avoided
(bedrooms, children rooms, etc).
c) Consider air distribution from the unit to
the rooms and select a suitable location
for even air flow.
d) Avoid obstacles which may restrict the
return air intake or the discharge supply air
flow.
e) If installing the indoor coil on a platform
ensure that the structure is capable of
supporting the indoor unit and platform.
NOTE: The indoor unit should not be installed
outside.
1. Ducted Gas Heater
2. Ducted Gas Heater Platform
3. Transition duct – air on
4. Suspended hanging option –
indoor fan coil
5. Indoor Coil
6. Platform Option – Indoor fan coil
7. Transition duct – air off
8. Discharge Air Grilles

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 10
Unit Installation
Installation Instructions
Coil - Floor or Platform Mounting
1. Create a platform using bearers and
chipboard. Place the unit platform over load
bearing walls or on strategically located
trusses in the roof space.
2. Place serrated rubber pads or isolating
springs under each corner of the unit to
minimize / eliminate any noise transmission.
Coil - Suspension Mounting
Use the accessory kit – P/n 6601905 Hanging
Bracket Kit. For installation detailed see the
instructions supplied with this accessory kit.
1. Fasten the hanging brackets to the indoor coil.
2. Use field supplied threaded rod to suspend the
unit.
M10 or greater is recommended to brace the unit
mounting.
3. Fix the threaded rod to a structurally sound part of
the roof or concrete pad.
Check with local and national building codes and
or a structural engineer as to the fixing of the unit
or building support structure if applicable.
4. Secure the indoor fan unit to the threaded rods
ensuring all fasteners are secure and tight.
Failure to correctly secure the suspension
brackets and threaded rod to the indoor unit
could cause it to fall and inflict injury or damage.
Leveling the Coil Box
1. Adjust the level of the unit as required. The
drainpipe end of the unit must be lower by at
least 5mm for good drainage.
2. Take care not to damage the drain tubes or
coil when lifting to adjust unit level
3. For suspension mounting units, tighten the
locking nuts once the revised position is
determined.