Emerson COPELAND H Series User manual

User Manual
H-Series Condensing Unit

2
Table of Contents
Content Page
Introduction 3
Safety Information 4
Nomenclature 6
CDU Models & Data 6
Features & Benefits 7
Physical Layout 8
Dimensional Drawings 9
Electrical Connections 10
Installation & Startup 14
Operational Checklist 20

Introduction
Thank you for purchasing the Emerson™ H-Series Condensing Unit. We hope
that this product meets your intended refrigeration requirement. Please read
through this operation manual to familiarize yourself with the installation, com-
missioning, and operation of this product. Please do read the following informa-
tion in this page before proceeding with the rest of the manual.
The Emerson™ H-Series scroll refrigeration condensing units should only be
installed by suitably qualified and experienced refrigeration technicians.
No responsibility can be accepted for damage caused by inexperienced or inade-
quately trained site technicians or improper system design. All instructions and
procedures described in this manual are based on good refrigeration trade prac-
tices as applicable to this particular product. The installation contractor may
prefer to use variations to these recommendations. However, the methods
described in this manual represent the minimum requirements to avoid any sub-
sequent warranty claims for this equipment and its components. These instruc-
tions do not cover the fundamentals of good electrical or refrigeration practice
and are therefore intended for use only by qualified and/or experienced person-
nel or technicians.
For any additional query, please consult your local sales office, quoting unit
model and serial number as shown on the nameplate. In case of ambiguity, the
wiring diagram supplied with each unit takes precedence over the diagram in this
manual.
Emerson H-Series Condensing Units are fitted with high efficient Copeland Scroll
Compressor and the Dual Temperature Condensing Units are fitted with high
efficient ZFI Copeland Scroll compressors with vapor injection technology.
This document is designed to help the contractor and customer for the installa-
tion, commissioning & operation of Emerson’s H-Series Condensing Unit.
3

1. Safety Information
1.1 Installation and commissioning work on CDU shall be carried out only
by qualified, refrigeration personnel who have been trained and instructed.
1.2 H-Series condensing unit is manufactured according to the latest safety
standards. Emphasis has been placed on the user’s safety. For relevant stan-
dards please refer to the manufacturer’s declaration, available on request.
You are strongly advised to follow these safety instructions.
1.3 Icon explanation
1.4 Safety Statements
a. Only qualified and authorized refrigeration personnel are permitted to
install, commission and maintain this equipment.
b. Electrical connections must be made by qualified electrical personnel.
c. All valid standards for connecting electrical and refrigeration equipment
must be observed.
d. The national legislation and regulations regarding personnel protection
must be observed.
Use personal safety equipment. Safety goggles, gloves, protective clothing,
safety boots and hard hats should be worn where necessary.
4

1.5 General Instructions
1.6 Safety Refrigerants/Lubricant
a. Please use correct refrigerant as designed to work in safe operating envelope.
b. Compressor is supplied with an initial oil charge. The standard oil charge for
use with HFC refrigerant is polyol ester (POE) lubricant Emkarate RL 32 3MAF.
5

2. Nomenclature
Family series
H - series
H M X A - 0 1 5 - T F M - 5 1 1
Nominal HP
015: 1.5HP
Platform Revision no.
Scope of supply
Code
Application range
M Medium temperature
L Low temperature
D Dual temperature R-404A
R-404A
R-404A
Application Refrigerant
Unit voltage code
Code
TFM 400 V ±10 % - 3 - 50Hz
Voltage supply-phase
Bill of material
~
511 Filter drier, Moisture Indicator, Liquid receiver, Suction & Liquid Line Service Valves, HP Cutout, Adjustable LP Cutout.
513 Filter drier, Moisture Indicator, Liquid receiver, Suction & Liquid Line Service Valves, HP Cutout, Adjustable LP Cutout, Oil separator,
Suction accumulator, Coresense / Injection Management Module, Sub cooler, Vapour injection Expansion valve.
3. Models
Mechanical data
85HMXA-020-TFM-511 ZB15KQE-TFD-558 4.6 2922 1029 x 424 x 840 3/4" 1/2"
81
HLXA-020-TFM-511 ZF09KAE-TFD-618 4.6 2922 1029 x 424 x 840 3/4" 1/2" 82
HMXA-015-TFM-511 ZS11KAE-TFD-600 4.6 2922 1029 x 424 x 840
1029 x 424 x 840 3/4" 1/2" 81
Liquid
Size
Net WeightCompressor model Receiver
Capacity (I) Air Flow (m³/s) Suction
Size
Dimensions
Depth/Width/Height
(mm)
3/4" 1/2"
ZF06KAE-TFD-618 4.6 2922
5910
6.7 5910
4.6
4.6
6.7
6.7 5910
85
3/4" 1/2" 91
1029 x 424 x 840
1029 x 424 x 840
1029 x 424 x1242 7/8" 1/2"
3/4" 1/2"
106
7/8" 1/2" 120
7/8" 1/2" 125
1029 x 424 x1242
1029 x 424 x1242
Condensing Unit
ZFI09KQE-TFD-550
ZFI13KQE-TFD-550
ZFI17KQE-TFD-550
ZFI21KQE-TFD-550
ZFI23KQE-TFD-550
HDXA-030-TFM-513
HDXA-040-TFM-513
HDXA-050-TFM-513
HDXA-065-TFM-513
HDXA-075-TFM-513
HLXA-015-TFM-511
2922
2922
6

4. Features and Benefits
Electrical data
LRA MOC RLA
ZFI21KQE-TFD-550
ZFI23KQE-TFD-550
HDXA-065-TFM-513
HDXA-075-TFM-513
HDXA-030-TFM-513 ZFI09KQE-TFD-550
HDXA-040-TFM-513
HDXA-050-TFM-513
Condensing Unit
ZFI13KQE-TFD-550
ZFI17KQE-TFD-550
14.1 74.0
9.8 50.0
Compressor
Unit MOC
HLXA-015-TFM-511 4.2
HMXA-015-TFM-511 ZS11KAE-TFD-600 4.2 27.0 3.3
12.4 10.6 1.7
12.6 64.0 10.9 8.9 1.7
8.1 6.9 1.7
7.5 40.0 6.6 6.4 0.9
Total Fan
Current
Compressor model
6.2 23.5 5.3 4.9 0.9
3.8 0.9
4.9 0.9
4.3 0.9
ZF06KAE-TFD-618 5.1 28.0
5.0 0.9
HLXA-020-TFM-511 ZF09KAE-TFD-618 6.2 41.6 5.3
HMXA-020-TFM-511 ZB15KQE-TFD-558 5.8 26.0 4.9
Features Benefits
High efficiency Copeland™ ZFI Vapor injection compressors for Dual temperature application.
Vapor injection technology improves system capacity by up to 30% and efficiency by up to 20%.
New valving technology adjusts the scroll compression ratio based on operating condition, significantly
improving performance.
Specially designed condenser.
Compressor is provided with Emerson EVI CoreSense™ kits to control superheat of vapor injection and
to maintain safe discharge temperature in dual temperature application.
Fully featured options such as filter drier, sight glass, oil separator and suction accumulator available as
standard scope of supply in dual temperature models.
Compressors are supplied with internal thermal protectors that safeguards against motor overheating
and high current.
Envelope
Unique operating envelope (-40°C to 7°C evaporating temperatures) and up to 49°C ambient, providing
a broad range of selection (dual temp application).
Scroll compressor has an inbuilt check valve that isolates high pressure gas, allowing the compressor to
start unloaded with low inrush currents.
Less vibration.
Inventory Same units for both medium and low temperature requirements for majority of the capacities resulting
in rationalization of unit inventory.
Optimal layout of components for easy serviceability.
Pre-wired electric junction box, liquid receiver, HP safety cartridge switch and adjustable LP control
switch.
Multi-evaporator
One condensing unit could be connected to two evaporators. The lowest load operation should be
more than 35 of the total load.
Smooth Operation
Maintenance
Reliability
Efficiency
7

Condenser
Internally grooved copper tubes with hydrophilic coated aluminum fins.
Fan Motors
Thermally protected, single-phase fans. Option to have fan speed controller.
5. Physical Layout of the Dual Temperature Unit
Condenser Block
Fan Motor
CoreSense /
Injection
Management
Oil Separator
Suction
Accumulator
Moisture
Indicator
Liquid Line
Filter Drier
Scroll
Compressor
Adjustable
Pressure Control
Suction &
Liquid Line
Service Valves
Liquid Receiver
Receiver Out Service Valve
Oil Sight Glass
8

6. Dimensional drawings
840
500
500
300
300
500 352
70
70
23 90 172
424
Power Supply Hole
Suction Service Valve
Liquid Service Valve
388
110
580
2 HOLESØ15MM DIA
2-R7.5MM GROOVE
1029
21
94
1242
172
90
500 300
300
500
352
70 70
1029
23
424
94
Liquid Service Valve
Suction Service Valve
Power Supply Hole
388
110
580
2 HOLESØ15MM DIA
2-R7.5MM GROOVE
500
21
Single Fan Unit
1.5 - 4 HP
Dual Fan Unit
5 - 7.5 HP
7. Scope of supply
511 (HL & HM Units) Filter drier, Moisture Indicator, Liquid receiver, Suction &
Liquid Line Service Valves, HP Cutout, Adjustable LP Cutout.
513 (HD Units) Filter drier, Moisture Indicator, Liquid receiver, Suction & Liquid Line
Service Valves, HP Cutout, Adjustable LP Cutout, Oil separator, Suction accumula-
tor, CoreSense / Injection Management Module, Sub cooler, Vapour injection
Expansion valve.
9

8. Electrical connections
H Series Condensing Unit Compressor L-N L1-L2-L3
TFM
ZFI-TFD
230 ± 10% V/1/50Hz 400 ± 10% V/3/50Hz
052-3452-01
Remarks:
A1 = Coresense Module For M1 A5 = Terminal Box Compressor
C1 = Run Capacitor M21/M22
F1 = High Pressure Control F2 = Low Pressure Control
K1 = Contactor M1 K6 = Relay Unit Alarm (If Fitted) K7 = Voltage Free Relay Contact For
Alarm Device
M1 = Compressor Motor M21 = Fan Motor / Condenser M22 = Fan Motor / Condenser
R2 = Crankcase Heater
TF = Coresense Transformer
FSC = Fan Speed Controller
S = Mid Coil NTC Sensor
Rev 00
U V W PE NN 3 4 5 6 7 8 AL
1
N L L L L K6
EXV
M22
R2
SW-3
GR
L1 L2 L3
T1 T2
T3
BR
A1
A5
TF
Typical Control Circuit
L
K1 R2
4
N
6
N
GY K1
8
K6
BU N
A1
5
N
TF
P
F1
P
1
4
2
Auxiliary
Safeties
1
24
P
7
WH
WH
WH
WH
C1 C1
F1
F2
1~
M1
F2
RD
YE
BU
WH
WH
RD
BK
OG
OG
RD
RD
RD
RD
P
TF7
220 ± 10% V/1/60Hz 380 ± 10% V/3/60Hz
ZFI-TF7
BU BK GY OG
SW-2 SW-1
LED-3
RESET LED-2
LED-1
LED-4
BU
BR
RD = Red
YE = Yellow
BU = Blue BK = Black
GR = Green GY = Grey OG = Orange
WH = White
BN = Brown
G/Y = Green / Yellow
RD
M21
1~
K7
G/Y
K1
1 2
1310 12
23 24
RD
BK
RD
RD
Notes:
1. Dashed Line "---" Is Wired By Installer
2. For FSC Installation; Remove Wire 3 & 4
From Terminal N & 3. Connect These Wires To FSC Terminal 1 & 3. Install Wire Harness 1 & 2 Supplied With Kit As Per Drawing. Connect NTC Sensor (S) To FSC Terminal 23 & 24
3. Set The FSC Trimmer To Complete The
Installation
FSC
S
BK
RD
RD
BK
BK
BK
Colour Legend
12
3
4
FSC Trimmer Setting
060
40
10 301 30
10
050
SET DIFF. MINIMUM
SPEED
CUT
OFF
A1 Dip-Switch Default Factory Setting
SW1
12
BIT1- ON BIT2- ON
SW2
BIT1- OFF BIT2- OFF
SW3
BIT1- OFF BIT2- ON
1212
ELECTRONIC
EXPANSION
VALVE
DLT SENSOR
VAPOR IN SENSOR
VAPOR OUT SENSOR
AL
2
BU
10

H Series Condensing Unit Compressor L-N L1-L2-L3
TFM
ZFI-TFD
230 ± 10% V/1/50Hz 400 ± 10% V/3/50Hz
052-3452-02
Remarks:
A5 = Terminal Box Compressor
C1 = Run Capacitor M21/M22
F1 = High Pressure Control F13 = Discharge Gas Thermostat (If Fitted) F2 = Low Pressure Control K1 = Contactor M1 K6 = Relay Unit Alarm (If Fitted) M1 = Compressor Motor M21 = Fan Motor / Condenser M22 = Fan Motor / Condenser R2 = Crankcase Heater
TF = Coresense Transformer
FSC = Fan Speed Controller
S = Mid Coil NTC Sensor
Rev 00
U V W PE N 3 4 5 6 7 8
N L L L K6
M22
R2
L1 L2 L3
T1 T2
T3
A5
Typical Control Circuit
L
K1 R2
4
6
N
K6
7 8
N
P
F1
P
1
4
2
F13
1
24
P
7
WH
WH
WH
WH
C1 C1
F1 F2
1~
M1
F2
RD / LGY
YE / CGY
BU / BK
BK
OG
OG
P
TF7 220 ± 10% V/1/60Hz 380 ± 10% V/3/60Hz
ZFI-TF7
M21
1~
G/Y
K1
1 2
1310 12
23 24
RD
BK
RD
RD
Notes:
1. Dashed Line "---" Is Wired By Installer
2. For FSC Installation; Remove Wire 3 & 4
From Terminal N & 3. Connect These Wires To FSC Terminal 1 & 3. Install Wire Harness 1 & 2 Supplied With Kit As Per Drawing. Connect NTC Sensor (S) To FSC Terminal 23 & 24
3. Set The FSC Trimmer To Complete The
Installation
FSC
S
BK
RD
RD
BK
BK
BK
Colour Legend
12
3
4
FSC Trimmer Setting
SET DIFF. MINIMUM
SPEED
CUT
OFF
F13
BK
K1
5
060
40
10 301 30
10
050
BU
BN
BU
BN
RD = Red
YE = Yellow
BU = Blue BK = Black
CGY = Charcoal Grey LGY = Light Grey OG = Orange
WH = White
BN = Brown
G/Y = Green / Yellow
11

9. EVI CoreSense™ control kits and LED Indications
EVI CoreSense control kits
The EVI CoreSense control kit of Dual Temperature H-Series unit is intended to
control vapor injection, maintain a safe discharge temperature, and provide
intelligent diagnosis and protection.
The kit includes a printed circuit board (PCB), an electronic expansion valve (EXV),
and three sensors, as well as containing a transformer and an EXV filter.
In vapor injection application, the valve is driven by sensors mounted near the
heat exchanger and attempts to maintain the vapor outlet sensor 5K higher than
the vapor inlet. The system will switch to discharge line temperature control if
vapor injection is insufficient to maintain a safe discharge temperature. If the
discharge temperature becomes dangerously high, the system will stop the
compressor, turn on an LED alarm, and trigger a voltage free alarm relay contact.
The compressor can auto-reset, but not lockout.
Printed circuit board
Wear a ground strap when working with the PCB to avoid the risk of damage from
static discharges.
General PCB layout, input and output ports are shown in the image below, the
ports to EXV, DLT, as well as the vapor in and vapor out sensors are done with
Poka-yoke connector design. Connect sensors, EXV, and system wiring as shown
in wiring diagram.
The PCB is supplied power through a transformer with a power input of 50/60 Hz,
220VAC, and an output of 12VAC to the PCB board.
LED 1
LED 2 LED 3
LED 4
SW1 SW2 SW3
Board power supply input terminals
(from 12 VAC transformer)
Compressor start/stop input signal
(from LP switch/cold room temp sensor)
(220 VAC)
Reserved
Compressor
contactor
Dry contact -
alarm output
terminal
Dip-switch Programming
ports
Communication ports
EXV driver
output ports
DLT sensor
input ports
Vapor in sensor
input ports
Vapor out sensor
input ports
Vapor-out
to compressor
Vapor-out sensor
Liquid-in
Liquid-in
to EXV side
Filter
Vapor-in sensor
EXV liquid
supply
Liquid-out
12

DIP Switch Setting
LED Indications
SW1
Bit 1
Bit 2
DLT Control Point
Default
OFF
OFF
95 deg C
OFF
ON
100 deg C
ON
OFF
105 deg C
ON
ON
110 deg C
CO M P RE S S O R SH U TD OW N S AT 125 D E G C DLT
SW2
Bit 1
Reset Mode
Default
ON

OFF
Auto Reset
Bit2

ON
10 deg K
OFF
5 deg K
SW3
Bit 1

Default
ON
2 minutes
OFF
0
Bit 2

ON

OFF

LED1 (yellow-green)
LED1 will light up during initialization after power on, after that, blinking lights will
indicate the sensor status.
LED Number
Color

Code

LED1 Yellow -
Green
1

2

3
DLT sensor failure
4
-in sensor failure
5
-out sensor failure
LED Number
Color

Code
EXV Status
LED2 Yellow -
Green
1

Constant ON

LED Number
Color

Code
EXV Status
LED3 Yellow -
Green
1
EXV Closing
Constant ON

LED Number
Color

Code

LED4 Red Constant On
DLT 
DLT sensor failure
-in sensor failure
-out sensor failure
13

10. Installation, system processing and commissioning
7. Scope of supply
511 (HL & HM Units) Filter drier, Moisture Indicator, Liquid receiver, Suction &
Liquid Line Service Valves, HP Cutout, Adjustable LP Cutout.
513 (HD Units) Filter drier, Moisture Indicator, Liquid receiver, Suction & Liquid Line
Service Valves, HP Cutout, Adjustable LP Cutout, Oil separator, Suction accumula-
tor, CoreSense / Injection Management Module, Sub cooler, Vapour injection
Expansion valve.
Utmost care must be taken while handling the H-Series condensing unit.
Please go through the contents below to ensure proper handling.
a. Inspection
Inspect the condensing unit and any accessories shipped with them for damages or
shortages before and during unloading. All items on bill of lading should be
accounted for prior to signing the shipping receipt. Note any shortages or damage
on delivery receipt (specify the extent and type of damage found). Unit should be
inspected carefully for concealed damage.
Notify Emerson sales/application personnel of the damage immediately.
Request an immediate joint inspection and do not repair the unit until inspected by
Emerson’s representative.
The system is shipped with a holding charge of dry nitrogen. Check to see that
pressure is still in the unit upon receipt. Report lack of pressure immediately to the
Emerson’s application/sales representative.
b. Location and Fixing
The unit should always be installed in a location that ensures clean air flow.
It is recommended that a clearance of 300 mm from the wall (or the next unit) be
maintained from the unit’s left and rear panels whereas a clearance of 500 mm
must be maintained from the unit’s right, top and front panels (seen facing the
front of the unit).
Both service access and airflow have been considered in making these
recommendations.
Where multiple units are to be installed in the same location, the contractor needs
to consider each individual case carefully.
There can be many variations of unit quantities and available space and it is not the
intention of this manual to go over these. Ideally, the unit should be mounted on a
solid concrete slab with anti-vibration pads between unit feet and concrete.
However, the H-Series condensing unit has also been designed for wall mounting
on suitable brackets. Wall mounting brackets are not included. Another factor to
consider in finding a good installation site is the direction of the prevailing wind.
For example if the air leaving the condenser faces the prevailing wind, the air flow
through the condenser can be impeded, causing high condensing temperatures
ultimately resulting in reducing unit life. A baffle is a remedy for this situation.
14

c. Refrigeration Piping Installation
All interconnecting pipes should be of refrigeration grade, clean, dehydrated and
must remain capped at both ends until installation. Even during installation, if the
system is left for any reasonable period (say two hours), pipes should be re- capped
to prevent moisture and contaminants from entering the system.
Do not assume that the service connection sizes on the unit (at the service valves)
are the correct size to run your interconnecting refrigeration pipes. The service
valve sizes have been selected for convenience of installation and in some cases
(larger units) these may be considered too small. However, for the very short pipe
run within our units, these service connection sizes are adequate.
The pipe should be sized to ensure optimum performance and proper oil return.
The sizing must also consider the full capacity range through which this particular
unit will need to operate.
Pipe runs should be kept as short as possible, using the minimum number of
directional changes. Use large radius bends and avoid trapping of oil and
refrigerant. This is particularly important for the suction line. The suction line
should ideally slope gently towards the unit. Recommendation slope is
1/200~1/250. P traps, double risers and reduced pipe diameters may be required
for suction lines where long vertical risers cannot be avoided. All pipes should be
adequately supported to prevent sagging which can create oil traps.
The recommended pipe clamp support distance is shown in the table.
d. Refrigerant line insulation
- Insulate suction lines from the evaporators to the condensing unit with
minimum 1” thickness closed-cell type insulation on low temperature
circuits.
- Liquid lines of Dual temperature systems to be insulated with minimum of ¾”
insulation.
- Long liquid lines run in areas exposed to high temperatures should be fully
insulated with minimum 1/2” insulation.
- Suction and liquid lines should never be taped or soldered together.
15
Tube Dia
Max distance between 2 clamp support
1/2 inch
1.2 M
5/8 inch
1.5 M
7/8 inch
1.8M
11/8 inch
2.1M
1-5/8
2.3

16
e. Electrical
- All electrical work must be done in accordance with the National Electrical
Code and existing local codes.
- Power supply must be the same as specified on the unit’s name plate.
- Voltage fluctuations in excess of 10 percent must be corrected.
- Before starting the unit, ensure that all protective devices are in place and
that all wiring is secure.
f. Brazing Recommendation
Maintain a flow of oxygen-free nitrogen through the system at a very low pressure
during brazing. Nitrogen displaces the air and prevents the formation of copper
oxides in the system. If copper oxidization is allowed to form, the copper oxide
material can later be swept through the system and block screens such as those
protecting capillary tubes, thermal expansion valves, and accumulator oil return
holes. This minimizes any entry of contaminants and moisture.
- Remove the liquid line connection cap.
- Then remove the suction connection cap.
- Open both valves midway.
- Care should be taken to avoid the holding charge from releasing too quickly.
- Be sure tube fitting inner diameter and tube outer diameter are clean prior to
assembly.
- Since both tubes are extended from the condensing unit housing, we
recommend insulating the housing by using a wet cloth on the copper tubing.
- Recommended brazing materials: a copper / phosphorous or copper /
phosphorous / silver alloy rod should be used for joining copper to copper
whereas to join dissimilar or ferric metals, use a silver alloy rod, either flux
coated or with a separate.
- Use a double tip torch.

g. Start-up & Operation
Initial pressure test (by vacuum and nitrogen) - Step-by-step:
- Use a 4-port gauge manifold with 3/8” hose and connections to the vacuum
pump. The vacuum gauge does not have to be connected for this part of the
process.
- Connect the gauges to service ports provided on receiver valve and suction
tube. In order to remove any non-condensable that may have entered the
system during installation, follow these steps:
- Start the vacuum pump. The evaporator fan should be running and the
compressor crankcase heater is energized at this point. This will involve
powering up the unit so it is important to disconnect the live feed wire to the
compressor contactor (so the compressor cannot run and the crankcase
heater can be energized).
- Open both valves on the manifold and then open the main vacuum valve on
the pump. Run the system until the vacuum level of -0.85 bar (as read on
manifold gauge) is achieved.
- Shut off the main vacuum pump valve. Check for vacuum rise using the
manifold compound gauge. A rise would indicate a large leak.
- If vacuum holds for 10 minutes, break vacuum with Nitrogen. Check the
name plate of the unit / compressor for allowable leak test pressure. Ensure
that pressure regulators are installed on the Nitrogen cylinders. Check for
leaks and repair leakage.
Leak Check
The success of all the subsequent commissioning depends on a leak free system,
free of contaminants, free of oxides, free of non-condensable’ s, that has been evac-
uated to a low vacuum and charged with the prescribed refrigerant.
Leak test is particularly important for field-connected systems. Typically, field
systems lose as much as 20%–30% of their refrigeration charge annually. This is not
only an unnecessary expense but also damages the environment. Compressor oil
can be lost at the same time as refrigerant and eventually lead to compressor
failure. (Time spent on leak test will eventually reduce the time spent on the evacua-
tion process).
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Ensure that all service valves are open during the leak test process. It is important
to recheck all joints within the unit as well as the external joints.
- The unit is shipped with a holding charge of dry nitrogen and should be leak
free.
- Ensure that the test pressure do not exceed the system design pressures.
- Do not expose system pressure control LP to test pressures above the design
pressure. This can damage the pressure controls.
- Using an approved, calibrated electronic gas leak detector, leak test the entire
system paying attention to all joints (you might have to charge small quantity
of refrigerant before charging the Nitrogen to enable this procedure).
- Periodically check functionality of the electronic leak detector during this
process.
- To further check system integrity, spray a soapy water solution over joins then
visually inspect for bubbles.
- Leave the system under pressure for a designated period (24 Hours).
- Check and record the ambient temperatures and the system pressure with
calibrated approved instruments. This process is to be carried out every 8-12
hours during the pressure testing process.
- If the test pressures cannot be maintained, repeat the leak testing process
employing the isolation of sections of the system to determine the source of
leaks. Repair the leak and repeat the leak testing process until system can be
signed off as leak free and approved by authorized personnel.
- Record findings and confirm pressure testing process completion.
Evacuation
- After the system is leak checked, connect approved dual stage vacuum pump
sized to application with preferably fresh oil to evacuate the system.
- Ensure all inline system shut-off valves and solenoid valves are fully open.
- Evacuate the system to 300 microns.
- A triple evacuation is recommended in case of using analog gauges as we
might not know the exact vacuum level being achieved
Charging and commissioning
Reminder:
- The scroll compressor design requires system charging with liquid refrigerant
into the liquid line.
- Do not vapor charge the H-Series Scroll unit. After ensuring all valves are
opened and system is evacuated properly, only then start the refrigerant
charging process. Also ensure that LP cutout is not by-passed during the
charging process.
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Step-by-step:
- Ensure that there is no power supply to the H-Series unit. The Liquid Line
solenoid needs to be kept open for the charging process and this may require
a temporary power feed to it.
- Connect the refrigerant cylinder to main service hose and purge line at the
manifold end.
- Ensure correct orientation of the refrigerant cylinder. Follow cylinder
labeling/instructions so that liquid refrigerant can be charged into the
system. This will be charged through the high-pressure side of the manifold
and H-Series unit liquid service valve. Ensure that at least 70-80% of the
required refrigerant charging is done by this method.
- The compressor can then be started, and the unit continued to be charged
(with the controlled liquid refrigerant through the suction service valve). The
quantity of charge should always be measured. See note.
- The system needs to be operated down to its design evaporating
temperature before you can be sure the charge is correct. It is at this point
that the normal refrigeration operational checks can be carried out - such as
checking the liquid line sight glass for bubbles and the operating pressures.
Refrigerant charging is regarded full/complete when the operating temperature of
the system has been stable for some time and the liquid line sight glass is clear.
h. Maintenance
Condenser Fins
Condenser fins become dirty over time as ambient air is induced to the condenser.
Dirty coil surfaces result in high condensing temperatures and poor unit
performance. Regular cleaning is recommended with frequency depending on the
installation and the surrounding environment. As a general guide, it is advisable to
do this at least once every two months.
Fins should be cleaned with liquid detergent diluted with clean water. Before
washing, a light brush downward (in the direction of the fins) should be done to
remove heavy deposits.
Electrical Connections
Check tightness of electrical connections occasionally.
Routine Leak Test
All joints should be checked for leaks during site visits. All joints should be leak
tested once a year. Condenser Fan(s) and Motor(s), an annual inspection of these
items is recommended. Fastenings may loosen, bearings may wear, and fans may
require cleaning of solid deposits which can cause imbalance.
TURN OFF OR DISCONNECT THE ELECTRICAL POWER SOURCE BEFORE
CLEANING THE CONDENSER COIL OR DOING MAINTENANCE. 19

30
System Start-Up and Operational Check Sheet
Client Details
Facility/Customer Name :
Address :
Contact Details :
Installer :
Installation Date :
Condensing Unit Info
CDU Model :
Serial Number :
CDU Location :
Indoor Unit Make/Model :
System Details
Room/Case ID :
Pipe Length (approx.) :
OAT @ Start-Up/Check :
PSI Leak Test : PSIG
Duration : Hours
System is Leak Tight : Y / N
Triple Evacuation : Y / N
Micron Gauge Reading : microns
Total Evacuation : PSIG @ # of Hrs
Refrigerant :
Total Charge : Kg.
Sight Glass Clear : Y / N
Evap Fans Running : Y / N
Liquid Line Insulation : Y / N
Sound and Vibration
Comments
System Operation
COMP Voltage : V
COMP Current : A
Suction Pressure : PSIG/Bar
Liquid Line Pressure : PSIG/Bar
COMP Suction Temp : °C
COMP Disch Temp : °C
Liquid Line Temp : °C
Compressor SH : K
Subcooling : K
Adjustable LP Setpoint : PSIG
Design/Operating Temp: °C
Actual Room/Case Temp : °C
Condenser Fins :
To TXV
from Evap
COMPRESSOR
SUPERHEAT
(10-20K)
_________
SUCTION LINE
TEMP. T1
________ °c
Compressor Superheat = P1 - T1
Subcooling = P2 - T2
LIQ. LINE PRESSURE
P2 = _____________ PSI
P2 = °C from PT Chart
SUCTION PRESSURE
P1 = _____________ PSI
P1 = °C from PT Chart
COMP DISCHARGE
TEMP. T3
_________ °C
SUBCOOLING
___________
LIQUID LINE
TEMP. T2
_________ °C
Prepared by: _______________________________________ Date: _______________________________________
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