AIREDALE CUS Series Installation & Maintenance Download Page 19

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Condensing Units

CUS 15 - 60 / HCU 20

30D

Chillers & Condensing Units

Installation & Maintenance:Part No: 6259592 IM 07/14

Commissioning Procedure

Example

CONDENSERS/CONDENSING

UNITS - C/CUS/CUHS/HCU/CFCUS

Ai r e d a l e I n t e r n a t i o n a l

Ai r C o n d i t i o n i n g L t d

TO BE COMPLETED IN CONJUNCTION WITH COMMISSIONING PROCEDURE

RETURN WHITE COPY TO AIREDALE/RETAIN PINK COPY

Leeds Road, Rawdon, Leeds

LS19 6JY ENGLAND

Tel: 0113 239 1000

Fax: 0113 250 7219

Engineer:

Company:

Date:

Model:

Serial No:

Site Ref:

Pre Commissioning Checklist

1.1

Unit Condition Satisfactory

Comment:

1.2

Holding charge retained

Circ 1

Yes/No Circ 2

Yes/No

1.3

Electrical connections tight

1.4

Voltage at mains supply

L1-L2

V L2-L3

V L3-L1

1.5

System pressure test:

Initial test pressure

Circ 1

Barg

Circ 2

Barg

Final test pressure

Circ 1

Barg

Circ 2

Barg

iii

Test duration

Circ 1

Hrs

Circ 2

Hrs

Commissioning Checklist

2.1

Final system vacuum

Circ 1

mBar

Circ 2

mBar

2.2

Vacuum hold time

Circ 1

Min

Circ 2

Min

2.3

Refrigerant type

2.4

Refrigerant charge

Circ 1

Circ 2

2.5

Timer settings correct and operational (if fitted)

Low pressure override - 3mins

Circ 1

Mins

Circ 2

Mins

Defrost - 30 mins

Circ 1

Mins

Circ 2

Mins

Anti cycle timer -10 mins

Circ 1

Mins

Circ 2

Mins

2.6

Head pressure control set

Circ 1

Barg

Circ 2

Barg

2.7

HP/LP switch cut outs:

Circ 1

Barg

Circ 2

Barg

LP cut out - 2.0 barg

LP Cut Out

Barg

LP Cut Out

Barg

LP cut in - 3.0 barg

LP Cut In

Barg

LP Cut In

Barg

iii

HP cut out - 27.0 barg

HP Cut Out

Barg

HP Cut Out

Barg

2.8

HGBP valve setting (if fitted)

Circ 1

Barg

Circ 2

Barg

2.9

Superheat at compressor

Circ 1

°C

Circ 2

°C

2.10 Added oil volume (if applicable)

Circ 1

Circ 2

2.11 Operating conditions:

Suction pressure

Circ 1

Barg

Circ 2

Barg

Discharge pressure

Circ 1

Barg

Circ 2

Barg

2.12 Compressor Amps

(CU & CFCU)

Amps

2.13 Condenser Fan Amps

Amps

Other comments

IMPORTANT: THIS IS AN IMPORTANT WARRANTY DOCUMENT AND WARRANTY COULD BE

INVALIDATED SHOULD AIREDALE NOT HOLD A COPY ON FILE.

QTYENG 10 - 08/98

Summary of Contents for CUS Series

Page 1: ...i n s t a l l a t i o n m a i n t e n a n c e C O N D E N S I N G U N I T S C U S 1 5 6 0 H C U 2 0 3 0 D ...

Page 2: ...3 238 7789 uk sales airedale com International Enquiries 44 0 113 239 1000 enquiries airedale com Spares Hot Line 44 0 113 238 7878 spares airedale com Airedale Service 44 0 113 239 1000 service airedale com Technical Support 44 0 113 239 1000 tech support airedale com Training Enquiries 44 0 113 239 1000 marketing airedale com For information visit us at our Web Site www airedale com AIAC Ltd end...

Page 3: ...10 Dimensions Page 11 Refrigeration System Refrigeration Pipework Schematics Page 14 System Holding Charge Page 15 Pipework Sizing Oil Addition Page 15 Pressure Testing Page 15 Evacuation Page 15 Refrigerants Page 15 Electrical Information Electrical information Control panel components Page 16 Electrical Data Sheet Page 17 Terminal Blocks External Connections Page 18 Commissioning Procedures Comm...

Page 4: ...aeder access connector to facilitate connection of a service gauge manifold The suction line connection is capped and sealed ready for customer connection A large capacity filter drier is supplied loose for on site installation A manual high pressure and automatic low pressure cut out switch is fitted on each circuit for system safety All units are configured to operate without pump down CONTROL P...

Page 5: ...tandards and codes of practice 5 Refrigerant No 22 and 407C used in this range of products is classified under the COSHH regulations as an irritant with set Occupational Exposure Levels OEL for consideration if this plant is installed in confined or poorly ventilated areas 6 A full hazard data sheet in accordance with COSHH regulations is available should this be required SPARES A recommended spar...

Page 6: ...aluation Parts fitted under warranty shall be warranted for the unexpired period of warranty of the equipment or 3 months from delivery whichever period is the longer This excludes compressors on which a further 12 months warranty is granted PROCEDURE When a component part fails a replacement part should be obtained through our Spares department If the part is considered to be under warranty the f...

Page 7: ...nnecessary delays incurred in return of defective component RETURNS ANALYSIS All faulty components returned under warranty are analysed on a monthly basis as a means of verifying component and product reliability as well as supplier performance It is important that all component failures are reported correctly Loose Items List FILTER DRIER A suitably sized liquid line filter drier is shipped loose...

Page 8: ... It carries all the necessary breakers contactors and terminals required to operate the unit CUS 40 60D This is mounted in the enclosed end of the unit It carries all the necessary breakers contactors and terminals required to operate the unit CONDENSER FAN AND MOTOR UNITS These are integral fan motor units and are mounted so as to give a vertical discharge of air from the condensing units COMPRES...

Page 9: ...shall be used to ensure that any slings or chains used in the lifting process do not crush the framework of the unit or damage the coil faces Due note shall also be made of the fact that the compressor is at one end of the unit and therefore the centre of gravity will also be towards that end If the unit is dropped it shall immediately be checked for damage POSITIONING AND LEVELLING The condensing...

Page 10: ... 1 1 8 1 3 8 1 5 8 2 1 8 2 1 8 Machine Weight Kg 440 540 550 695 978 1119 1356 Notes 1 Based on 5 C evaporating and a 30 C ambient 2 Refrigeration charge is for information purposes only The units do not leave the factory charged 3 All terminations are suitable for sweat connections HCU 20 30D HCU 20D 25D 30D Nominal Capacity kW 58 6 69 5 81 0 Nominal Airflow m sec 6 80 6 80 6 80 Max Fan Speed rpm...

Page 11: ...00 200 1250 1250 25 1050 CUS 25D mm 1438 2900 1100 200 1250 1250 25 1050 CUS 30D mm 1438 3000 1100 200 1300 1300 25 1050 Point Loadings kg Centre of Gravity mm A1 B1 C1 D1 E1 F1 Y Z CUS 15D 146 101 101 156 1330 560 CUS 20D 130 120 56 56 121 140 1770 560 CUS 25D 130 122 57 57 123 141 1765 560 CUS 30D 174 140 78 77 138 179 1785 550 Notes 1 Suction and liquid connections terminate underneath the cond...

Page 12: ... ISOLATOR ACCESS TO COMPRESSOR AIRFLOW A B C D E F G H J K CUS 40D mm 1693 2440 1800 200 1020 75 1650 155 595 100 CUS 50D mm 1693 2440 1800 200 1020 75 1650 155 595 100 CUS 60D mm 1693 2440 1800 200 1020 75 1650 155 595 100 Point Loadings kg Centre of Gravity mm A1 B1 C1 D1 E1 F1 Y Z CUS 40D 148 174 174 174 174 149 1169 896 CUS 50D 157 206 206 208 206 156 1136 900 CUS 60D 180 254 254 258 255 180 1...

Page 13: ...G 20D mm 1993 2280 805 30 2370 150 505 25D mm 1993 2280 805 30 2370 150 505 30D mm 1993 2280 805 30 2370 150 505 Point Loadings kg Centre of Gravity mm HCU A1 B1 C1 D1 Y Z 20D 140 157 139 131 1088 391 25D 140 157 139 131 1088 390 30D 186 2 206 7 155 7 151 4 1098 372 1 Suction and liquid connections terminate on the opposite side of the unit to the condenser coil face 2 Allow 1000mm clearance on th...

Page 14: ... Refrigeration System REFRIGERATION PIPEWORK SCHEMATICS COIL SHUT OFF VALVE CONDENSING UNIT COMPRESSOR SOLDER CONNECTIONS LIQUID STUB PIPE SUCTION IN LINE PRESSURE SWITCHES P P Notes 1 Compressor connections are diagrammatic only not actual 2 For clarity only one circuit is shown although all units are twin circuit ...

Page 15: ...hould be connected to the high and low pressure sides of the system via a gauge manifold fitted with compound gauges A high vacuum gauge should be fitted to the system at the furthest point from the vacuum pump Triple evacuation should be used to ensure that all contaminants are removed or at least reduced to significantly low proportions There are no hard and fast rules when applying this method ...

Page 16: ...Relay Circuit No 2 6 R6 HP LP Trip Relay Circuit No 1 Other components are as follows some are option dependent 1 Compressor Sequence Switch 2 T1 Delay Start Timer Circuit No 1 3 T2 Delay Start Timer Circuit No 2 4 In line pressure switches HP 2 off LP 2 off 5 Electronic pressure operated condenser fan speed controller One Off CUS 40 60D 7KH IROORZLQJ 0 V DUH ILWWHG DV VWDQGDUG 1 Single phase cont...

Page 17: ... 50 50 75 50 50 75 75 Type of Start Direct on Line Condenser Fan Motor Rating kW 0 55 0 55 0 55 0 55 0 55 0 55 0 55 Full Load A 2 50 2 50 2 50 2 50 2 50 2 50 2 50 Locked Rotor Amps A 5 80 5 80 5 80 5 80 5 80 5 80 5 80 1 Nominal Run Amps based on 5 C evaporating and a 35 C ambient 2 CUS40 60 units do not require a separate permanent fused supply HCU 20D 25D 30D Unit Data Nominal Run Amps 1 A 38 46 ...

Page 18: ...act 527 CUS 40 60 UNITS L1 L2 L3 Î Mains Incoming N 400 3 50 E L4 Î L4 N1 Permanent Supply N1 230 1 50 500 Î 0V 502 Î 24VAC XVWRPHU V RQWURO 506 Î 502 506 Stage One Cool Customer s Control 513 Î 502 513 Stage Two Cool Customer s Control 522 Î 522 552 Stage Three Cool Customer s Control 552 523 Î 523 555 Stage Four Cool Customer s Control 555 507 Î 507 500 Liquid Line Solenoid 1 Circuit 1 Customer ...

Page 19: ...2 mBar 2 2 Vacuum hold time Circ 1 Min Circ 2 Min 2 3 Refrigerant type 2 4 Refrigerant charge Circ 1 kg Circ 2 kg 2 5 Timer settings correct and operational if fitted Low pressure override 3mins Circ 1 Mins Circ 2 Mins Defrost 30 mins Circ 1 Mins Circ 2 Mins Anti cycle timer 10 mins Circ 1 Mins Circ 2 Mins 2 6 Head pressure control set Circ 1 Barg Circ 2 Barg 2 7 HP LP switch cut outs Circ 1 Barg ...

Page 20: ... Bar 400 psi CUT OUT LOW PRESSURE SWITCH 0 5 Bar 7 psi CUT OUT 3 8 Bar 55 psi CUT IN REFRIGERATION CIRCUIT CHARGING Procedure The system should be charged in accordance with accepted good practice and the suction and discharge pressures should be constantly monitored whilst charging is in progress At the same time the compressor current should be monitored The system should be charged to the relev...

Page 21: ...peed operation in one of two possible modes The head pressure is controlled by a separate head pressure controller for each refrigeration circuit The head pressure controllers are enclosed in a plastic box which contains all the necessary components including the pressure transducer Connection to the respective refrigeration circuit is via a capillary of suitable length There are Two control knobs...

Page 22: ...r Check winding resistances replace compressor If burnt out follow burn out procedure using suction line burn out drier Noisy Compressor Lack of oil Repair leaks if any add oil if required but not too much remember too much is as bad as too little Investigate pipe system and trapping Best method to pump down to see if oil can be encouraged back If no oil still drain compressor and measure in corre...

Page 23: ...djust replace as appropriate Lack of refrigerant bubbles in sight glass only as indication Check for leaks reclaim refrigerant repair evacuate and recharge system Clogged filter drier pressure temperature drop across it Replace once the cause has been identified and rectified Condenser fan running at full speed in winter full airflow Check fan speed controller setting if faulty replace Suction Pre...

Page 24: ...ad pressure controller to suit Faulty pressure sensor Check electrical connections are secure at controller and pressure sensor Replace controller and sensor as they are matched sets Faulty Controller LQN ZLUHV OLQH DQG ORDG WR E SDVV controller If motor runs full speed replace unit Condenser fan runs too fast High ambient condition or excessive re circulation of air around condenser coil Check in...

Page 25: ...and corrosion REFRIGERATION CIRCUITS 1 Check the suction and discharge pressures using a service gauge manifold and compare them with the commissioning sheet If there is any significant variation then the fault should be found and corrected Refer to the troubleshooting section 2 Check that the high and low pressure switches are cutting out the compressors at the correct settings High pressure swit...

Page 26: ...sing a mild detergent Treat any paint damage or rust as necessary ELECTRICAL 1 Check all electrical connections for signs of overheating or arcing 2 Check all cables for signs of chafing or physical damage SERVICE CHECKS YEARLY As three monthly plus the following 1 Check all electrical connections for tightness 2 Check all refrigeration connections with leak detector ...

Page 27: ...Condensing Units CUS 15 60 HCU 20 30D Chillers Condensing Units Installation Maintenance Part No 6259592 IM 07 14 27 Notes ...

Page 28: ... Find Us Head Office Airedale International Air Conditioning Ltd Leeds Road Rawdon Leeds LS19 6JY United Kingdom Tel 44 0 113 239 1000 Fax 44 0 113 250 7219 e mail enquiries airedale com website www airedale com ...

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