TemperZone OSA 300 Maintenance and service guide

OSA 300
Split System
Outdoor Unit Installation &
Maintenance
Recommended Pipe Sizes
Suction pipe : 28 mm OD
Liquid pipe : 16 mm OD
Line Lengths
For line lengths in excess of 50 m, contact
the manufacturer's nearest sales office for
additional piping requirements. Refer also to
Oil Charge overleaf.
Maximum extended line length is 70 m.
Height Separation Limits
Outdoor Unit above Indoor Unit : 18 m
Outdoor Unit below Indoor Unit : 12 m
Vertical Risers
If the outdoor unit is to be installed above
the indoor unit, then the suction riser should
be trapped at the bottom of the vertical rise
and then again at 5 m (maximum) intervals.
This is to ensure oil return to the compressor.
The trap to be a 'swan neck' curve in the
pipe, with no change in the pipe size.
Piping
1. Use clean sealed refrigeration grade
piping.
2. Cut pipe with a pipe cutter ONLY.
3. Use long radius bends (2 x pipe dia.).
4. Insulate the suction (gas) line and seal
all insulation joints.
5. Filter dryer may be fitted in the liquid
line (bi-flow type on reverse cycle
systems).
6. Include a process point on the
interconnecting pipework.
7. Ensure open pipe ends are sealed until
the final connection is made.
8. Immediately before removing brazed
pipe connection's seal, reduce holding
charge between connection points and
service valves to atmospheric pressure.
Warning: Failure to do so may cause
injury.
Charging
The unit is supplied with a 1 kg holding
charge of refrigerant HCFC-22 (R22). Add
7.0 kg of HCFC-22 to complete the base
charge, then add 105 g per metre of
pipework between indoor and outdoor units.
Procedure:
1. Evacuate Indoor Unit and
interconnecting pipework to a pressure
of 500 microns and hold for 15 mins.
2. Add refrigerant via the Schraeder
connection on the smaller of the
Outdoor Unit's two service valves.
3. Open the service valve at the Outdoor
Unit to allow refrigerant to flow
throughout the system.
Drains
Four drain holes are provided in the base of
the unit to release condensate and/or rain
water. If a totally drip free installation is
required then mount the unit in a separate
drain tray.
Coil Protection
A coil protection guard is available as an
optional extra.
REFRIGERATION PIPING
General
The OSA 300 is shipped with a holding
charge of refrigerant. The matched indoor
unit is shipped with a holding charge of
nitrogen. OSA 300 units have one flare and
one brazed pipe connection.
GENERAL
OSA 300 - A general designation for outdoor unit
OSA 300C - Outdoor unit, cooling only version
OSA 300R - Outdoor unit, reverse cycle version
This OSA 300 Outdoor Unit must be
installed in accordance with all national and
local safety codes.
INSTALLATION
Positioning
Refer to dimension diagram below for
minimum clearances. Fasten the unit down
to a firm flat horizontal base using the four
holes provided in the mounting rails.
When the unit is being installed on a roof it
is recommended that the unit is installed on
a substantial structure with vibration
isolating springs beneath the unit. These
springs are not supplied with the unit.
Dimensions (mm) OSA 300
PROJECTION
Not to Scale
SERVICE
ACCESS
PANEL
685
MTG CTR
20 DIA.
ELECTRICAL
CONDUIT
HOLES
1140
OVERALL
1400 OA
1084 MTG CTR
13 DIA. HOLES
205
20 DIA.
DRAIN
HOLE
750
500 MIN. CLEARANCE
500 MIN. CLEARANCE
2000 MIN. CLEARANCE
REFRIG.
CONN'S
ELECTRICAL
ACCESS
PANEL
1000 MIN. CLEARANCE
500 MIN. CLEARANCE
20 DIA.
DRAIN
HOLE
20 DIA.
DRAIN
HOLE
W
Z
X
Y
18
Net Weight
OSA 300C 220 kg
OSA 300R 226 kg
CORNER LOADS (kg)
WX Y Z
50 70 63 43

OUTDOOR UNIT CONTROLLER (OUC)
(OSA 300R only)
The Outdoor Unit Controller (OUC) includes
a temperature sensing head pressure
control which enables the system to
compensate for outdoor ambient tempera-
tures below 20°C on cooling cycle, and
above 15°C on heating cycle. The OUC also
has features which protect against icing or
overheating of coils, rapid cycling of the
compressor and loss of refrigerant charge.
If the outdoor unit fans take some time to
begin rotating when the system is powered
on, or they don't appear to be rotating
appropriately while the compressor is
running, consult the OUC label on the
electrical box. If necessary, refer to
temperzone for further diagnostic
information.
MAINTENANCE
Weekly For First Four Weeks
1. Check indoor unit air filters (if fitted) and
vacuum or wash clean as necessary.
2. Check condensate drain for free
drainage.
3. Check compressor compartment for oil
stains indicating refrigerant leaks.
4. Check tightness of electrical
connections.
Three Monthly (or every 1200 hrs of operation)
Check the indoor unit's fan belt tension and
adjust if necessary.
Six Monthly
1. Check the tightness of all fan and motor
mountings.
2. Check the tightness of electrical
connections
3. Check that fan motors are free running.
4. Check suction and discharge operating
pressures.
5. Replace indoor unit air filters (if fitted).
6. Check condensate drain for free
drainage.
Yearly
1. Check all refrigerant piping for chafing
and vibration.
2. Check the operation of electric heaters if
fitted.
3. Check air supply at all diffusers.
4. Check for excessive noise and vibration
and correct as necessary.
5. Check for insulation and duct damage
and repair as necessary.
6. Remove lint and dust accumulation from
outdoor coil fins.
7. Touch up any outdoor unit paintwork
damage to prevent corrosion.
NOTE
The manufacturer reserves the right to
change specifications at any time without
notice or obligation. Certified dimensions
available on request.
Refer to separate pamphlet for approved
thermostats, or contact the manufacturer's
nearest sales office.
A 24 hour power supply to the compressor
crank case heaters is required, otherwise
the warranty is void.
SYSTEM CHECK TESTS
1. Leave the remote switch in the off
position and close the mains isolating
switch.
A four hour delay period is required to
allow the crankcase heater to drive any
liquid refrigerant out of the compressor
oil.
2. Check that all fan motors are free
running.
3. Check that the thermostat is correctly
wired to the unit and is set at the desired
temperature.
4. Check that the air filters, if any, have
been correctly installed.
5. Check any supply air diffuser dampers
are open.
START UP PROCEDURE
Use the supplied Commissioning Sheet to
help you complete the following procedure:
1. After the four hour delay period has
expired switch on the unit.
2. Check the supply voltage.
3. Fit gauges and measure the suction and
discharge pressures.
4. Check for correct rotation of the
compressors. If rotation is incorrect a
compressor will not pump, be noisy, and
will draw minimal current. To correct
motor rotation, change the phasing at
the main power terminal.
5. Measure the current draw on each
phase to the compressor motor and
measure the current draw of each fan
motor. Check all readings against the
specified values - particularly the indoor
fan amps if the unit is installed in a free
blow application.
6. Test the operation of the high pressure
safety control by switching off the
outdoor unit's fan.
7. Test the operation of the reversing valve
by running the unit in both the heating
and cooling mode (OSA 300R only).
8. Check that the air flow over the outdoor
unit's coil is adequate and that the fan is
running smoothly.
9. Check the superheat - refer charging
procedure.
10. Check the supply air flow at each outlet.
11. Touch up any outdoor unit paintwork
damage to prevent corrosion.
4. Leak check all brazed and fitted joints.
IMPORTANT :
Step 9 of the 'Start Up Procedure' requires
you to check that the superheat on the
suction line (where it enters the Outdoor
Unit) is between 3°C – 5°C on cooling cycle
with an indoor air temperature in the range
21°– 27°C and outdoor air temperature in
the range 24°– 35°C. If the conditions of the
day do not allow this, use the heating cycle
(on a reverse cycle unit) or other heat
source to raise the indoor air temperature to
about 24°C and blank off the outdoor coil to
raise the head pressure to 240–280 psig
(1750–1950 kPag). Alter charge up or down
to establish correct superheat.
WARNING:
This unit is designed for use ONLY with the
refrigerant HCFC-22. The use of other
refrigerants is NOT authorised or approved
by the manufacturer and may cause
operational problems such as poor
performance and efficiency, loss of capacity,
degradation of materials and refrigerant
leaks. The use of flammable or explosive
materials as a refrigerant creates the
additional risks of fire and explosion
which may result in property damage,
personal injury or death.
Oil Charge
For line lengths in excess of 30 m,
Emcarate RL22CF polyol ester oil (or
similar) should be added to the refrigerant
at the rate of 25 ml/m of suction piping.
Note: This oil absorbs moisture quickly if
exposed to open air. Do not use mineral oil.
ELECTRICAL REQUIREMENTS
Electrical work must be done by a qualified
electrician. The outdoor unit must be wired
directly from a distribution board by means
of a circuit breaker or H.R.C. fuse, and a
mains isolator provided - preferably close to
the Outdoor Unit.
Note: DO NOT USE REWIRABLE FUSES.
The OSA 300 is provided with a 24V AC
control circuit for a thermostat, on/off switch
and/or time clock.
The control transformer 240V primary
voltage is used for countries with 230-240V
power supply. For countries with supply
voltages 200-220V, change the primary
voltage on the transformer to 208V.
OSA 300R only - It is recommended
electricians run a spare wire between
Outdoor Unit and Indoor Unit in case
boost electric heat becomes a
requirement. Note: Leave the wire
unconnected until required.
Standard units are suitable for use with
thermostats with either manual Heat/Cool
selection or automatic changeover
subject to the contact ratings of the
thermostats.
Pipe Length Capacity Loss
On Cooling Cycle Due to Pressure Drop
Note : Loss percentages are approximations only, due to piping variations. No allowance made for vertical piping.
Pipe Size (mm) Equivalent Line Pipe Length (m)
Liquid
16
16
Suction
28
35
28 mm
0.61 m
35 mm
0.76 m
30
4 %
1.5 %
10
1 %
-
20
2.5 %
1 %
40
6 %
3 %
Additional Pipe Length to allow per Bend
This pamphlet replaces the previous
issue no. 2648 dated 09/06.
Wiring revisions C & B.
Suction Pipe Size OD
Long 90°Radius
(i.e. 2 x pipe dia.)

© temperzone ltd 200701/07 Pamphlet No. 2711