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
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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
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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.

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 11
Unit Installation
Installation Instructions
OUTDOOR UNIT

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 12
Unit Installation
Installation Instructions
CONDENSER INSTALLATION
Installation on flat surface (roof, ground, etc)
Install outdoor unit support in a position elevated at
least 100 mm on a concrete pad, concrete block or
wooden beams, in order to allow free water flow
underneath.
1. Outside the building
2. Outdoor Unit
3. Floor
4. Concrete slab or equivalent
5. Wall
6. Anchor bolts
7. Serrated Rubber / Waffle Pad 40x80 mm
INTERCONNECTING TUBING
The tubing between the indoor and outdoor units consist of two copper tubes and an electric cable
routed through a 60-mm wall opening. In addition, a drainage hose is installed between the indoor
unit and the closest drainage point. Connect both sections, taking the shortest, most direct route.
1. Outside wall
2. Gas (Vapor) Line
3. Liquid Line
4. Electric Cable
5. Inside wall
6. Incline Angle

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
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Unit Installation
Installation Instructions
Installation Notes
1. When laying the tubing for the installation, make sure that
the ends are sealed to prevent penetration of dirt, moisture
etc. To prevent dust or moisture from entering the tubes,
seal them with caps or masking tape. It is recommended
to clean the inside space of the tubes with nitrogen before
connecting them to the unit.
2. Whenever possible, avoid passing tubes through hot
zones, such as walls next to ovens, chimneys, etc. In
such cases, additional insulation or other means of
protection should be employed.
3. Tubing route shall be kept in straight lines as much as
possible. When installing, keep the number of tube bends
to a minimum. If bends are necessary, perform them only
by using professional tube benders and not manually.
4. Make sure that tubing is insulated on its entire length,
including tube end and quick connectors, or flare-nuts, to
avoid tube “sweating” and water dripping from it.
5. Tubing shall be of refrigerant grade, without any damage.
Tube inside walls must be kept absolutely clean prior to
and during installation operations.
6. The Gas line shall be individually insulated with a minimum
9mm (3/8”) thick closed cell pipe insulation.
7. For diameters, length of liquid and gas lines, and height
difference, see the table below for each model. If the
liquid or gas tube diameters differs from the corresponding
flare connector diameter (mounted on the unit), use a
suitable reducing union for this purpose.
NOTE: it is not a requirement to insulate the liquid line unless
it is exposed to direct sun or extreme ambient temperatures.
Unit Interconnecting Tubing Table
TUBING LENGTH, UP TO – (IN METRES, ONE WAY)UNIT
MODEL
CONNECTING
LINE
10 15 20 25
MAXIMUM
TUBING
LENGTH
MAXIMUM
HEIGHT
DIFFERENCE
B009RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)”
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 10M
B012RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)”
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B015RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B016RT Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B019RT Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
28.6(1⅛”)
9.53 (⅜”)
28.6(1⅛”)
9.53 (⅜”)
25M 15M

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
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Unit Installation
Installation Instructions
Recommendation for Interconnection Tubing Installation
Three possible versions are schematically illustrated:
1) The outdoor unit installed above the indoor unit – such installation requires an oil trap in the
gas line at the lowest point of the riser. The radius of the oil trap should be as short as
possible. Horizontal runs of liquid line should follow the gas line (except for trap). In case the
insulation must be partially removed for installation purposes, it is imperative that lines be fully
insulated after the installation has been completed.
2) The units are installed at the same level – no
trap is required.
3) The outdoor unit is installed below the indoor
unit – such installation requires an inverted gas
line trap to be installed at the indoor unit. The
top of the trap must be greater than the height of
the indoor unit.
1. Air
2. Outdoor Unit
3. Gas Line
4. Liquid Line
5. Indoor Coil
1. Air
2. Liquid Line
3. Gas Line
4. Oil trap every 3m
5. Indoor Coil
6. Outdoor Unit
1. Air
2. Indoor Coil
3. Liquid Line
4. Gas Line
5. Outdoor Unit

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 15
Unit Installation
Installation Instructions
PIPE INSTALLATION
WARNING
This paragraph describes the necessary steps for setting the unit into operation. Be sure to
follow the instructions, to assure proper functioning of the air conditioner.
The outdoor unit is pre-charged with the correct amount of refrigerant. In extended runs, for
additional refrigerant charge please refer to the outdoor unit name plate. This process shall be
performed only by qualified refrigeration technicians with a professional charging set.
Flare Preparation
a) Cut the tube, using a tube cutter.
Make sure that the cut is perpendicular
to the tube axis. Ensure the pipe is de-
burred and free of metal shavings
b) Slip the flare-nut over the tube, secure
the tube in the flaring tool and perform
the flare on the tube end. The tube
projection length (A) from the flaring
block varies with tube diameter and
shall be set as indicated in the table.
c) Apply few drops of refrigeration oil to
the tube before flaring.
Pipe Welding Preparation
The indoor / outdoor unit final connections are made using flared couplings. Where welded
joints are required the following are the requirements.
1. Keep piping capped at ends when storing, handling and installing.
2. Use locally supplied, sealed, clean, refrigeration grade copper piping only.
3. Using a flat surface, hold down the pipe at one and roll out the requirements.
NOTE: Take care not to dent, flatten or damage the pipe.
4. Use only a rotating wheel pipe cutter to cut the tube.
5. Use only a de-burring tool to de-bur the pipe ends.
Pipe Welding
Take care when using brazing flame torch, ensure that hot pipes or flame do
not cause a fire
1. Use quality brazing rod suitable for copper to copper joins on refrigeration grade tubing.
Flare Depth (A)
A (mm) TUBE OD
1.3 9.58mm (⅜”)
1.9 15.88mm (⅝”)
2.1 19.05mm (¾”)
1. Copper Tube
2. Flaring Tool

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 16
Unit Installation
Installation Instructions
2. Before brazing wrap a wet cloth around pipes next to the indoor unit to prevent hot pipes
from melting foam insulation in the unit. Make sure the flame or heat from the flame does
not contact the unit casing or wiring, or damage will occur
3. Heat the pipe up as per the illustration
4. Use nitrogen gas for flowing though
piping during pipe brazing. If oxygen,
acetylene or fluorocarbon gas is used, it
will cause an explosion or poisonous gas.
5. Use a regulator valve when nitrogen gas
flowing is performed during brazing. The
gas pressure should be maintained within
0.03 to 0.05Mpa. If an excessively high
pressure is used, it will cause an
explosion.
Connecting the tubes
1. Connect and tighten the flare nuts to the
refrigeration valves on the outdoor unit and
to the male connectors of the indoor unit.
2. Coat the flared surfaces lightly with
refrigeration oil to improve sealing.
3. Two spanners of the correct size should be
used. A holding spanner should be used on
the back-up nut and a tightening spanner
(Torque spanner recommended) on the flare
nut.
4. Tighten the flare nut with the tightening
spanner while ensuring the holding spanner
remains securely in place.
Note: First manually tighten the flare nuts,
and then use wrenches. See table for
torque tightening values.
5. Check for leaks. Use leak detect solution
or soap solution for leak testing. An
electronic leak detector is recommended.
IMPORTANT
If the recommended tightening procedure is not followed and the fitting is
subsequently damaged or the thread stripped it will NOT be covered by our
manufacturer’s warranty. Any service calls required to repair this fault may be
deemed chargeable to the Dealer/Installer.
Piston Assembly
Should you need to remove or
check either of the pistons during
installation, please ensure that
they are correctly refitted as per
the following diagrams.
Toque Values
Description Tube (Inches)
Flare Sizes 9.58mm
(⅜”)
15.88mm
(⅝”)
19.05mm
(¾”)
Torque (N.M.) 40-45 70-75 80-85
Outdoor Unit
Piston
Assembly
Indoor Unit
Piston
Assembly

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 17
Unit Installation
Installation Instructions
EVACUATION AND SETTING IN OPERATION
a) Connect two charging hoses from the charging set to the outdoor unit as shown in the diagram
below.
b) Connect the centre hose of the charging set to a vacuum pump.
c) CAUTION - turn on the vacuum pump and make sure that the low pressure gauge reading
moves from 0 kPa to -100 kPa; then evacuate the system for a further 10 minutes.
If gauge needle does not move from 0 kPa to -100 kPa, this indicates a leak. Take the
following measures: tighten all connections; if leaking stops when the tubing connections are
tightened, proceed from step c. If leaking persists even after connections are tightened, detect
the leak and repair it; be sure to proceed only after all leaks have been eliminated.
d) Close the valves of both the gas and liquid sides of the charging set and turn off the vacuum
pump. Make sure that the gauge needle does not move for about 5 minutes.
e) Disconnect the charging hoses from the vacuum pump and from the service ports of both the
three-way valves.
f) Replace the service port and valve caps of both tree-way valves and tighten them with a torque
wrench; see table of torque values listed on the previous page.
CAUTION
When performing the following steps, avoid any exposure to the service valve ports; remember
that the system is under pressure.
g) Remove the valve caps from the service valves. Position both valves to “open” using a 5mm
Hex/Allen key wrench. Open each valve by rotating the centre spindle in an anti-clockwise
direction until fully back seated.
h) Replace valve caps of both service valves. Check for gas leakage with a leak detector or
soapy water.
1. Charging Set
2. Vacuum Pump
3. Outdoor Unit
4. Service Port
5. Valve Cap
6. 3-Way Gas Valve
7. 3-Way Liquid Valve
8. Valve Cap
9. Gas Flare Connection
10. Liquid Flare Connection
11. Indoor Coil

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 18
Unit Installation
Installation Instructions
ADDITIONAL CHARGE
1. Each condenser unit is supplied pre-charged for 10 meters of 9.53 (3/8”) liquid line. For
additional charge add 57 grams per meter for over and above the specified system pre-charged
length. See the unit name plate for this information. DO NOT exceed the maximum equivalent
pipe length on each unit.
2. Service port on the liquid service valve is not supplied on all units.
1. Valve Protection Plug
2. Insert 5mm Hex / Allen key to
open/close the Refrigerant Valve
3. Valve Protection Cap
4. Refrigerant Valve
5. Service Port cap
6. Flare Nut
7. Valve Mounting Bracket
8. Copper Tube
DRAIN LINE INSTALLATION
a. It is recommended to prepare a drainage
point with rigid 20mm plumbing pressure
PVC pipe tube by a qualified technician.
b. The drain run must be installed with a
constant minimum down slope of 2% and
equipped with a trap, at the indoor unit.
c. Install a “P” trap in the drain.
d. Use the 25mm flexible plastic coupling
hose provided to connect from the indoor
unit primary drain point to the “P” trap
and drain pipe. Secure with clamps.
e. To check the system, fill the condense
tray with water and verify its free flow
through the drain line.
Verify that no leaks are present from the
drain line or unit.

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 19
Electrical
Installation Instructions
Electrical Connection s
WARNING
1. Electrical connection shall be made only by authorized electricians and in accordance with
local electrical requirements and codes.
2. The system must be grounded.
3. Single phase models and three phase models are available; for each of them, the
necessary wiring diagram is shown.
4. Connect the unit to the main power supply as per its applicable wiring diagram.
5. Use supply wire sizes as per local electrical codes and regulations.
OUTDOOR UNIT CONNECTIONS
Mains Installation
1. Install a dedicated circuit from the mains switch
board. Circuit breaker requirements as per table
below.
2. Connect the mains cables to the incoming
connection block on the outdoor unit
Use supply wire sizes as per local electrical
codes and regulations.
3. Connect 1.0mm twin active cable between the
ducted gas central heater and the outdoor unit.
This is for 24Volt switched voltage from the gas
central heater to activate the refrigerative system.
See wiring diagrams on the next pages for
outdoor unit connections and the central heater
instructions for the heater control connections.
Model Recommended
Circuit Breaker Full Load Amps Recommended Cable Size
B009RS 32A 16.5 4.0mm
B012RS 32A 21.8 4.0mm
B015RS 40A 32.4 6.0mm
B016RT 3 x 32 A 14.8 4.0mm
B019RT 3 x 32 A 19.5 4.0mm
PLEASE NOTE: Circuit breaker and cable sizes are subject to cable run length – refer
AS 3000 wiring rules

DUAL CYCLE -REFRIGERATED COOLING COMPONENT
Page 20
Electrical
Installation Instructions
WIRING DIAGRAM -SINGLE PHASE OUTDOOR UNIT
Dual Cycle
Connection