TemperZone OSA 840RKTB User manual

SPLIT SYSTEMS
INSTALLATION GUIDE
(R410A Models)
Issue 12, December 2018

1 Piping
i. Use clean sealed refrigeration grade piping.
ii. Pipe to be cut ONLY with a pipe cutter.
iii. Use long radius bends (2 x pipe dia.)
iv. Insulate the suction (gas) line, seal all insulation joints and insulate the liquid
lines on all units with EEV's in outdoor unit.
v. By-owtypelterdryersmaybettedintheliquidline.
vi. Include a process point on the interconnecting pipework.
vii.Ensureallopenpipeendsaresealeduntilthenalconnectionismade.
viii. Purge pipes using Nitrogen during brazing.
ix. Immediatelybeforeremovinganybrazedsealsonpipestubconnections
of outdoor units, release any residual pressure using Schraeder valves
provided on the pipework after the shut-off valves. Warning: Failure to do so
maycauseinjury.
2 Oil Traps
Oiltrapsmustbettedtoverticalsuctionriserswhereoutdoorunitis
aboveindoorunit.Fitatrapatthebottomoftheverticalriseandthenat
8m(maximum)intervals.
INDOOR
UNIT
OUTDOOR
UNIT
slope
Oil trap in
suction line
INDOOR
UNIT
OUTDOOR
UNIT
For
maximum
rise refer
charts
overleaf
8metres
maximum
Suctionlinerecommendationfor
extended line lengths
Design
2
INSTALLATION REQUIREMENTS
3
Suction Liquid
3 Piping Insulation
4 Sizing of Extra Suction Accumulation
WhereextrasuctionaccumulationisstipulatedinTable2(p.9),itisbecause
thetotalchargeforthesystempipelengthexceedsthecombinedcompressor
shellandsuctionaccumulator(iftted)holdingcapacity.
Therearealternativewaystoprovideextraaccumulation;
i. Ifanaccumulatoristted,removeandreplaceitwithanaccumulatorone
sizelarger.IfthereisinsufcientroominsidetheOutdoorUnit,locatethe
replacementoutsidetheunit.
ii. Addanaccumulator(inseriesorparallelwithanyexistingaccumulator)
largeenoughtoaccomodatetheadditionalchargeat60%full.
 Example:
 AnadditionalaccumulatorisrequiredforanISD/OSAcombinationwith
anintendedlinelengthofover30m,wheretheadditionalchargerateis
100g/m.
Totallinelength:40m
 Additionalcharge:10mx100g=1000g=1kg
 SpecicvolumeofrefrigerantHFC-410A:0.87l/kg
 Volumerequired: 1x0.87 =1.45litres(i.e.1450ml)
    0.6(60%full)
Theextraaccumulatorisunlikelytotinsidetheunitsoitwillneedlocating
outside.Anaccumulatorwithconnectionsthesamesizeasthesuctionline
willbeaddedandthiswillusuallyhavemorevolumethanisrequired.
5 Evacuation Procedure
(Pre-Charged Outdoor Units)
EvacuatetheIndoorUnitplusinterconnectingpipeworktoachieveavacuumof
500micronswhichistobeheldfor15mins.Theuseofanelectronicvacuum
gauge is essential for this exercise.
Insulate both lines

4
6 Pre-Charged Units
 Pre-chargedcondensingunitsincludetheBaseChargefortheunitsetplus
chargesufcientforthelinelengthshowninthetablesandstatedintheunit's
installation instructions.
7Refrigerant Charging
 Refrigerantchargetobeintroducedasliquidonlyandbyweightorvolume
(notbysystempressureorsightglass).Sightglassesarenotrecommended
becauseofashgasinliquidline.
temperzone recommendsaccuratecharging/addingofrefrigerantusingdigital
refrigeration scales (spring balance is not acceptable).
Forunitssuppliedpre-charged,theactuallinelengthandthenalchargeis
crucialtocorrectoperation.Ifyoufearsomechargehasbeenlost,recoverall
the existing charge and re-charge accurately.
8 Superheat
Onunitswithoutelectronicexpansionvalves,superheatmustbecheckedat
theservicevalveoncoolingcycleduringcommissioning.Ensuresuperheatis
between3°Cto5°Cwhentheindoorairtemperatureisintherange21°Cto
27°Candtheoutdoorairtemperatureisintherange24°Cto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.
ForfurtherinformationonmeasuringSuperheat,visitourwebsite.
9 Refrigerant Pipe Sizes
 Suction/Liquidlinesizesgiveninthefollowingtablesareinterconnectingpipe
sizesandarenotnecessarilythesamesizeasthepipestubconnectionsexiting
the Indoor or Outdoor unit.
 Onanyunitwithvariablecapacitycompressors,donotoversizethe
interconnectingpipingasthiswillreducetherefrigerantvelocitiessignicantly
withtheassociateddangerofnotreturningtheoiltothecompressor.
10 Oil
Oil should be added on extended line lengths (refer tables overleaf).
Forcompressorswithasightglasstted,addoiltomaintainthelevelinthesight
glassafter15minutesrunningtime.
 RotarycompressorsandsomeinvertercompressorsdesignedforR410Ause
polyvinyletheroil(PVE).Whileitisacceptabletotopup(max.5%)withmineral
oil or polyolester oil (POE) it is best practice to use PVE oil.
 MostscrollcompressorsdesignedforR410Ausepolyolesteroil(POE),typically
Emcarate RL22CF, RL32CF or RL32-3MAFoil.Donotusemineraloil.
 Pleaserefertotheunitspecicationdatasheettoensuretheuseofthecorrect
oil.
11 Crankcase Heaters
 Crankcaseheatersarettedtoallcompressors.Disconnectthecrankcase
heaterifthetotallinelengthislessthan8m.
12 Pipe Length Capacity Loss
 Maximumlinelengthsgivenrepresentactual measuredlinelengthbetween
IndoorandOutdoorunits.Theequivalent linelengthissignicantlymorethan
actual line length because it includes an allowance for bends and vertical piping.
Usetheequivalentlinelengthwhencalculatingpressurelossesorperformance
losses.
13 Commissioning
 EachoutdoorunitissuppliedwithaCommissioningSheettoassistinstallers
completingtheStartUpProcedureoutlinedintheInstallation & Maintenance
pamphlet.Thesheetincludesapulleyadjustmentguideforbeltdrivenindoor
unitsifapplicable.Werecommendyoucompletetheform,sendacopyto
temperzone and keep the original yourself for possible future reference.
14 Manufacturer's Note
 Themanufacturerreservestherighttomakechangesatanytimewithoutnotice
orobligation.ShouldanyinstructioninthisguideconictwithanyInstallation
& Maintenancepamphletsuppliedwithaunit,thenthemostrecentlydated
publication should be considered correct.
5

Standard Unit Limitations Maximum Vertical Separation Refrigerant Charging Oil Charging
Oil Type
Model Compressor
Outdoor Unit
above
Indoor Unit
m
Indoor Unit
above
Outdoor Unit
m
Precharge for
10m Line Length
(R410A)
kg
Additional
Charge for Pipe
Line Length g/m
(R410A)
Add Oil
Beyond
m
Additional Oil
ml/m
Suction Liquid
Max. Line
Length
m
OSA 66RKS Scroll ZP24 KSE-PFZ 16 9.5 40 20 20 3.15 50 None up to 40 POE 32-3MAF (or equivalent)
OSA 87RKS Scroll ZP31KSE-PFZ 16 9.5 40 20 20 3.65*** 50 None up to 40 POE 32-3MAF (or equivalent)
OSA 116RKSG* Scroll ZPD42 KSE-PFZ 16 9.5 60 20 20 4.45* 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 116RKTG* Scroll ZPD42 KSE 16 9.5 60 20 20 4.45* 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 141RKSG** Scroll ZPD51 KCE-PFZ 16 9.5 20 20 20 4.50** 50 None up to 20 POE 32-3MAF (or equivalent)
19 9.5 60 20 20 4.50** 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 141RKTG** Scroll ZPD51 KSE 16 9.5 20 20 20 4.50** 50 None up to 20 POE 32-3MAF (or equivalent)
19 9.5 60 20 20 4.50** 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 164RKTG Scroll ZPD61 KCE 19 9.5 60 20 20 5.70 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 184RKTF Scroll ZPV038 19 9.5 60 20 20 5.95 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 194RKTG Scroll ZPD72 KCE 19 9.5 60 20 20 6.50 50 40 10 ml/m POE 32-3MAF (or equivalent)
OSA 224RKTF Scroll DA550A3F-11MD1 22 13 60 20 20 10.50 100 40 20 ml/m POE 32-3MAF (or equivalent)
OSA 224RKTG Scroll ZPD83 KCE 22 13 60 20 20 10.50 100 40 20 ml/m POE 32-3MAF (or equivalent)
OSA 294RKTF Scroll ANB66FVAMT 28 13 90 20 20 11.90 100 40 20 ml/m PVE FVC68D (or equivalent)
OSA 294RKTG Scroll ZPD104 28 13 90 20 20 13.00 100 40 20 ml/m POE 32-3MAF (or equivalent)
OSA 324RKTF Scroll ANB78FVAMT 28 13 90 20 20 13.10 100 40 20 ml/m PVE FVC68D (or equivalent)
OSA 324RKTG Scroll
ZPD122KCE-TFD 28 13 90 20 20 12.50 100 40 20 ml/m POE 32-3MAF (or equivalent)
Table 1 SPLIT SYSTEM PIPING REQUIREMENTS (UnitsSuppliedPre-Charged)
7
6
Estimating Effective Line Length for Performance Loss Suction Line Bend Equivalent Pipe Length Standard Unit Limitations allow the unit to be installed without
any extra protection other than adjustment of the refrigerantion
gas and/or oil charge.
When calculating performance losses for long line lengths allowances must be made for bends in the pipework.
The tabled data (right) is based on Long Radius 90° bends (2 x pipe dia.).
Add this allowance for every bend to the total line length to calculate an 'effective' line length for performance loss.
No allowance has been included for any effect from vertical lift.
16 mm 0.30 m
19 mm 0.42 m
22 mm 0.50 m
28 mm 0.61 m
35 mm 0.76 m
* For ISDL/OSA 116 combinations deduct 0.7kg when 10m or less.
** For ISU/OSA 141 combinations deduct: 0.5kg when 10m or less; or 0.75kg when 5m or less.
*** For ISDL/OSA 87 combinations deduct 0.5kg when 10m or less.

Table 2 SPLIT SYSTEM PIPING REQUIREMENTS
9
8
Standard Unit Limitations Common to Both Standard & Extended Line Lengths Extended Line Lengths
Model Compressor
Approximate
Performance
Loss
(Cooling Cycle)
% per 10m
Maximum Vertical Separation Refrigerant Charging Oil Charging
Suction Liquid
Max Line
Length
m
Outdoor Unit
above
Indoor Unit
m
Indoor Unit
above
Outdoor Unit
m
Precharge
for 10m Line
Length (R410A)
kg
Additional
Charge for Pipe
Line Length
g/m
Add Oil
Beyond
m
Additional Oil
ml/m Oil Type
Maximum
Line Length
when Extended
m Additional Requirements
OSA 310RKTB Scroll ZP57K3E (x2) 22 (x2) 13 (x2) 60 2.10 20 20 6.6 per system 100 40 20 POE 60
OSA 310RKTBG Scroll ZP57K3E
Scroll ZPD67KCE
22 (x2) 13 (x2) 60 2.10 20 20 6.6 per system 100 40 20 POE 60
OSA380RKTB Scroll ZP67KCE (x2) 22 (x2) 13 (x2) 60 2.10 20 20 6.55 per system 100 40 20 POE 60
OSA380RKTBG Scroll ZP67KCE
Scroll ZPD67KCE
22 (x2) 13 (x2) 60 2.10 20 20 6.55 per system 100 40 20 POE 60
OSA 465RKTB
Scroll ZP83KCE (x2) 22 (x2) 13 (x2) 30 2.10 20 20 7.6 per system 100 40 20 POE 60 Extra Suction Accumulation (c/w
accumulator heater) required
to be tted. Compressors and
accumulators must be tted with
heaters.
OSA 465RKTB
from serial number
800,000
Scroll ZP83KCE (x2) 22 (x2) 13 (x2) 60 2.10 20 20 7.6 per system 100 40 20 POE 60
28 (x2) 13 (x2) 90 0.75 20 20 7.6 per system 100 40 20 POE 90 As per "Bi-Flow..." below.
OSA 570RKTB Scroll ZP103KCE (x2) 28 (x2) 13 (x2) 60 1.50 20 20 10.3 per system 100 40 20 POE 60
35 (x2) 13 (x2) 90 0.70 20 20 10.3 per system 100 40 20 POE 90 As per "Bi-Flow..." below.
OSA 670RKTB Scroll ZP120KCE (x2)
28 (x2) 13 (x2) 60 1.50 20 20 12.5 per system 100 40 20 POE 60
35 (x2) 13 (x2) 90 0.70 20 20 12.5 per system 100 40 20 POE 90 As per "Bi-Flow..." below.
OSA 840RKTB
Scroll
SH161 (x2)
35 (x2) 16 (x2) 50 2.00 20 20 12.3 per system 170 per system 40 30 POE 90 Bi-Flow Liquid Migration Solenoid
Valve interlocked with the
compressor contactor to be tted in
liquid line
and/or extra Suction Accumulation
(c/w accumulator heater) required
to be tted. Compressors and
accumulators must be tted with
heaters.
For the sizing of extra suction
accumulation please refer to clause 4
on page 3 of this document.
41 (x2) 16 (x2) 50 0.80 20 20 12.3 per system 170 per system 40 30 POE 90
OSA 950RKTB
Scroll ZP182 (x2)
or
Scroll ZP180 (x2)
35 (x2) 16 (x2) 50 2.00 20 20 14.4 per system 170 per system 40 30 POE 90 As per "Bi-Flow..." above.
41 (x2) 16 (x2) 50 0.80 20 20 14.4 per system 170 per system 40 30 POE 90
Estimating Effective Line Length for Performance Loss Suction Line
Bend
Equivalent Pipe Length Standard Unit Limitations allow the unit to be installed
without any extra protection other than adjustment of
the refrigerantion gas and/or oil charge.
Extended Line Lengths require adjustment to oil
charge, refrigerant gas charge and the additional
requirements listed above.
When calculating performance losses for long line lengths allowances must be made for bends in the pipework.
The tabled data (right) is based on Long Radius 90° bends (2 x pipe dia.).
Add this allowance for every bend to the total line length to calculate an 'effective' line length for performance loss.
No allowance has been included for any effect from vertical lift.
28 mm 0.61 m
35 mm 0.76 m
41mm 0.80 m
(UnitsSuppliedPre-Charged)

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