SURREY USA12 Manual

1
INSTALLATION AND SERVICE MANUAL
MANUAL DE LA INSTALACIÓN Y SERVICIO
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INDEX
1. INTRODUCTION ................................................................................................... 03
2. NOMENCLATURE ................................................................................................ 03
3. SAFETY INSTRUCTIONS ..................................................................................... 04
4. UNIT RECEPTION AND INSPECTION ................................................................. 04
5. INSTALLATION ..................................................................................................... 04
5.1. GENERAL RECOMMENDATIONS ........................................................... 04
5.2. BASIC INSTALLATION PROCEDURE ..................................................... 05
5.3. EVAPORATING UNIT INSTALLATION ..................................................... 06
5.3.1. General recommendations.......................................................... 06
5.3.2. Positioning ................................................................................... 06
5.3.3. Condensate drain ........................................................................ 08
6. INTERCONNECTION PIPINGS ............................................................................ 09
6.1. INTERCONNECTION PIPING HANGING AND ATTACHMENT............... 09
6.2. INTERCONNECTION PIPING EVACUATION .......................................... 09
7. ELECTRIC INTERCONNECTIONS ...................................................................... 10
7.1. USA A COMMAND 220 V ELECTRIC CHART ......................................... 10
7.2. USA A COMMAND 24 V ELECTRIC CHART ........................................... 11
8. FIRST START-UP................................................................................................. 12
9. COOLING SYSTEM ............................................................................................. 12
9.1. EXPANSION SYSTEM ............................................................................. 12
10.MAINTENANCE ................................................................................................... 13
10.1. GENERAL TOPICS ................................................................................. 13
10.2. PREVENTIVE MAINTENANCE .............................................................. 13
10.3. CORRECTIVE MAINTENANCE ............................................................. 13
10.4. LEAK DETECTION ................................................................................. 13
10.4.1. Detection Methods .................................................................... 13
10.4.2. Leak Repair ............................................................................... 14
10.5. VACUUM AND REFRIGERANT CHARGE PROCEDURE ..................... 14
10.5.1. Dehydration ............................................................................... 14
10.5.2. Refrigerant Charge .................................................................... 14
10.6. SYSTEM INTERNAL CLEANING ........................................................... 15
10.7. REFRIGERANT COLLECTING .............................................................. 15
10.8. GENERAL CARE .................................................................................... 15
11. TROUBLESHOOTING GUIDE ............................................................................ 16
12. PREVENTIVE MAINTENANCE CHART ............................................................. 18
13. GENERAL TECHNICAL FEATURES ................................................................. 19
14. GENERAL INSTALLATION TIPS ...................................................................... 19
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1. INTRODUCTION
This manual is addressed to properly trained installers with the purpose of helping in installation
and maintenance procedures.
It is important to stress that any repairs or services can be dangerous if accomplished by not
properly trained personnel. Only properly trained staff should install, start up and give any
maintenance to the equipment mentioned on this manual.
If after the reading, you still need additional information just get in contact with us!
2. NOMENCLATURE
_- WIRED REMOTE CONTROL 24 V
O - WIRED REMOTE CONTROL - 220V
D- WIRELESS REMOTE CONTROL - 24V
M - WIRED REMOTE CONTROL &
SWEEP MOTOR - 24V
N - WIRELESS REMOTE CONTROL
WITHOUT SWEEP MOTOR - 24V
NOMINAL FREQUENCY 5- 50 Hz
6 - 60 Hz
C- COOLING
H- COOLING AND HEATING
US A A 12 C 5 O
EVAPORATING UNIT
AMBIENT
IDENTIFICATION IN
THE PROJECT CHANGES (VERSION)
12 = 12.000 BTU/h 18 = 18.000 BTU/h
24 = 24.000 BTU/h 30 = 30.000 BTU/h
36 = 36.000 BTU/h 42 = 42.000 BTU/h
48 = 48.000 BTU/h 60 = 60.000 BTU/h
LIST OF SYMBOLS
- Ground
- Caution
- Risk of electric discharge
- Fuse
- Read the manual before using
V - Volt
A - Amps
Hz - Hertz
W - Watt
Kg - Kilogram
Oz - Ounce
in - in
IPXX - IP number
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*
FIGURE 1 - HANDLING OF US A UNITS.
3. SAFETY INSTRUCTIONS
The new indoor units US A were projected to offer
you a safe and reliable service when operated within the
specifications foreseen in project.
However, due to this same conception, aspects
regarding installation, start up and maintenance should be
strictly observed.
WARNING
* Verify the weights and dimensions of the units (see
item 13) to guarantee an appropriate and safe handling.
* Learn how to handle the oxyacetylene equipment
safely. Leave the equipment in the vertical position
inside the vehicle and also in the working place.
* Use dry nitrogen to pressurize and to check the system
for leaks. Use a good regulator. Be careful not to
exceed 200 psig of test pressure in the rotary
compressors.
* Before working in any one of the units always turn off
the power supply unplugging the indoor unit from the
wall outlet.
* Never introduce the hands or any other object inside
the units while the fan is working.
4. RECEPTION AND INSPECTION
OF THE UNITS
* To avoid damages during handling or transport, don’t
remove the unit’s packing until arrive to the defined
place of installation.
* Prevent strings, chains or other devices from touching
the units.
Never lift or carry the evaporator unit by the
plastic side parts. Hold it on the metal parts, as
shown on figure 1.
WARNING
* Observe the limit of suitable piling up indicated in the
units’packing.
* Don’tshake the outdoorunit during transportationnor
incline more than 15oin the vertical.
* Avoid exposing the machine labor accidents, seeing
to it that it is immediately carried to the installation
site or a safe place.
* When removing the units from the package and
removingthe expanded polystyreneprotectionsdon’t
discardthem immediately because theymaybeuseful
eventuallyas protection against dust,orother noxious
agentsuntil the building and/orinstallationis comple-
te and system ready to operate.
5. INSTALLATION
5.1 GENERAL RECOMMENDATIONS
First, consult the norms or codes applicable to the
installationof the equipmentinthe selected place,to make
sure the system is in accordance to them.
Make also a careful planning of the unit location to
avoid interference with any type of existing (or planned)
facilities,suchaselectricalinstallation,waterpiping,sewer,
etc.
Install the units so that they are free from any type of
obstruction from the taking of return air or airflow.
Choose places with enough clearance for repairs or
services of any kind and also to make the piping
easier(copper tubes that interconnect the units, electrical
wiring and drain).
Remember that the units should be leveled after their
installation.
Verify if the external place is free of dust or other
particles that might obstruct the condenser coil.
* Always maintain the fire extinguisher close to the
working place. Check the extinguisher periodically
to certify it is completely loaded and working
perfectly.
* When working in the equipment always observe the
safety warnings in the labels attached to the units.
* Always follow all the applicable norms of safety
and use clothes and equipment of personal
protection. Wear gloves and protection glasses
when handling the units or the system refrigerant.
WARNING
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It is indispensable that the indoor unit possesses
hydrauliclinefor drainage of the condenser.Thishydraulic
line should not have a diameter less then 1/2" and should
have, right after the exit, a siphon to guarantee a perfect
fall and isolation of air. At the start up, this siphon should
befilled in with watertoavoid taking air fromthedrainage
line.The drainage intheoutdoor unit is indispensableonly
when installed in the high and causing leak risk.
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*INTERCONNECTION
CONNECTION TO
INTERCONNECTION PIPING
ELECTRICAL CONNECTIONS
FINAL DETAILS
5.2 BASIC PROCEDURES FOR
INSTALLATION
* INDOOR UNIT US A
CHOICE OF LOCATION
CHOICE OF POSITION FOR INSTALLATION
HOLE IN THE WALL (Ø10cm)
POSITION OF
INTERCONNECTION PIPING
INSTALLATION OF HYDRAULIC
PIPING FOR THE DRAIN
ASSEMBLY
*OUTDOOR UNIT
CHOICE OF LOCATION
INSTALLATION OF HYDRAULIC
PIPING FOR THE DRAIN
ASSEMBLY
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FIGURE 3 - SIZES FOR EVAPORATING UNIT INSTALLATION
5.3 EVAPORATING UNIT INSTALLATION
5.3.1 - GENERAL RECOMMENDATIONS
Before installing, read this instructions carefully
to get familiar with the unit’s features. Sizes and weights
can be found on item 14 on this manual. The following
rulesapply to allinstallations.
a) Plan the units’ placement carefully to avoid
occasional interference with any existing (or planned)
installations, such as electrical installation, water
piping, drain, etc.
b) Install the unit so that it is free from any type of
obstruction on the air flow, both on the air outflow
and air intake.
c) Choose an installation place with enough clearance
for maintenance and general repair.
d) The place should allow for the passage of piping
(system pipes, electric wires and drain).
e) The unit should be leveled after installation.
a) The unit should only be installed horizontally
Underceiling, vertically on the floor (console mode)
or on the wall (see fig. 4 and 5)
b) The unit comes with two (2) brackets for
Underceiling or on the wall installation. There is also
a brace for assembly of the remote control.
c) Figure 6 indicates the positioning of the screws on
the brackets.
d) Install the brackets (figure 3) underceiling by using
the screws, nuts and washers.
e) The unit should be positioned so as to distribute the
air flow uniformly in the room.
5.3.2 - POSITIONING
C
792
1172
1552
1932
12 and 18.000
24 and 30.000
36 and 42.000
48 and 60.000
A
1000
1380
1760
2140
B
822
1202
1582
1962
Capacity
(BTU/h)
FIGURE 2 - EVAPORATING UNIT POSITION IN ROOM
CORRECT
WRONG
WRONG
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FIGURE 4 - UNDERCEILING INSTALLATION
MINIMUM MINIMUM
300 mm 300 mm
FIGURE 5 - CONSOLE ASSEMBLY (ON THE FLOOR)
FIGURE 6 - BRACKET ASSEMBLY
SEE DETAIL A
DETAIL A
SCALE 1:4
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5.3.3 - CONDENSATE DRAIN
FIGURE 7 - POSITION WHERE COVERS MUST BE BROKEN
FIGURE 8
FIGURE 9 - INEFFECTIVE DRAINING SCENARIO
UNDERCEILING
MODE
Accordingto the type ofinstallation(console or under
ceiling), there are two positions on the side plastic parts
where the drain and interconnection pipes must pass
through. The following picture shows where the cover
must be broken.
a) Make sure that the unit is leveled, with a slight slant
towards the drain so as to assure a proper draining.
b) Connect the 1/2” PVC piping to the drain connection
(Figure 8).
c) The unit uses drain by gravity. The drain pipes should
have declivity, though. Avoid scenarios like the ones
indicated on Figure 9.
When connecting the PVC hose to the machine,
do not do it with sudden movements or too much
force, as this may cause leaks. If necessary, heat
the PVC before connecting it or use a flexible hose.
WARNING
CONSOLE
MODE
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6.1. SUSPENSION AND FIXATION OF
INTERCONNECTION PIPES
6.2. EVACUATION OF INTERCONNECTION
PIPING
6. INTERCONNECTION PIPING
Always try to fasten the interconnection piping in a
convenient way through brackets or porches, preferably
both together.
Seal them with circular neoprene bushing and then
pass finish ribbon around.
Test all the welded and flared connections looking
for leaks (maximum tested pressure: 200 psig). Use
pressure regulator in the Nitrogen cylinder. If necessary,
pass the electric interconnection by the copper tube, as
shown on Figure 10.
The outdoor unit is shipped with enough refrigerant
charge for use in a system with interconnection piping up
to 3m, that is, charge for the outdoor unit, charge for the
indoorunit and the necessarychargeforan interconnection
piping up to 3m. Since the interconnection pipes are
providedinthe field,youshouldproceedwith theevacuation
of the lines and of the indoor unit. The access points are
the service valves close to the outdoor unit.
The valves come shut from the plant to retain the
refrigerant in the outdoor unit.
To do the evacuation, maintain the valve shut and
connect one side of the manifold hose to the vent’s valve
and the other to the vacuum pump. It is recommended to
proceed the evacuation through both connections of the
service valves simultaneously. The range to be reached
should stay between 250 and 500 microns.
OBS:Afterdoingtheevacuation,addpositivepressure
with R-22 so that the vacuum is broken (see figure 4).
For all the necessary information about diameter,
charge and connections, see topics 13 and 14.
To proceedwiththerefrigerantcharge,just maintain
theservice valve in theoriginalposition(shut) and connect
the manifold hose to the vent (valve Schrader) of the
service valve.
OBS: Do not forget to purge the air from the hose.
Before turning on the equipment and after completing
the refrigerant charge (if necessary), open the service
valves close to the outdoor unit.
WARNING
Never carry liquid in the suction service valve. Whenever
you want to do it, use the service valve of the liquid
line.
CAUTION
FIGURE 10 - INTERCONNECTION PIPES
ELECTRICAL
INTERCONNECTION
DUCT (OPTIONAL)
SUCTION
LINE
LIQUID
LINE
ISOLATION
TAPE
TUBES
TAPE
ISOLATION
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7 - ELECTRIC INTERCONNECTIONS
7.1 - US A COMMAND 220 V ELECTRIC CHART
1 - MOTOR USED ONLY IN 36, 42, 48, 60K MACHINES
2 - USED ONLY IN HEAT PUMP MACHINES
3 - MOTOR USED ONLY IN SWEEP MOTOR DRIVED MACHINES
CAPTION
- - - - LOCALLY MADE WIRING
FACTORY MADE WIRING
RV - REVERSION VALVE
On condensors that operate on cooling with the
reversion valve energized, the electric
interconnection must be made between P9 and
P10 of the Printed Circuit Board and the reversion
valve.
CAUTION
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