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Installation

Preface

.................................................................................................

Unit

Placement

and

Installation

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Outdoor

Unit

Ducting

and

Shielding

......................................................

Refrigerant

Piping

Design

Drain

Piping

........................................................................................

Insulation

...........................................................................................

Charging

Refrigerant

...........................................................................

Electrical

Wiring

..................................................................................

10 Installation

Areas

High

Salinity

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11 Commissioning

...................................................................................

12 Appendix–

System

Commissioning

Report

...........................................

2016

Centralized Controllers

.................................................................55

Network Control System and Building Management Systems ........

Individual Controllers

...................................................................55

..................................................................

Refrigerant

Piping

Installation

.........................................................

.11

Summary of Contents for X Series

Page 1: ...TRUST AIR CONDITIONING EQUIPMENT CO Prepared By Engineering R D Department Shiraz May 2017 X SERIES INVERTER VRF SYSTEM ...

Page 2: ...ng 33 7 Insulation 36 8 Charging Refrigerant 39 9 Electrical Wiring 41 10 Installation in Areas of High Salinity 45 11 Commissioning 46 12 Appendix System Commissioning Report 49 2016 14 Centralized Controllers 55 15 Network Control System and Building Management Systems 55 13 Individual Controllers 55 10 5 Refrigerant Piping Installation 11 ...

Page 3: ...Data Book the term applicable legislation refers to all national local and other laws standards codes rules regulations and other legislation that apply in a given situation 1 3 Precautions All system installation including installation of piping and electrical works must only be carried out by competent and suitably qualified certified and accredited professionals and in accordance with all appli...

Page 4: ...utdoor units must be spaced such that sufficient air may flow through each unit Sufficient airflow across heat exchangers is essential for outdoor units to function properly Figures 3 2 1 to 3 2 3 show spacing requirements in three different scenarios If the particular circumstances of an installation require a unit to be placed closer to a wall than specified in Figures 3 2 1 to 3 2 3 a discharge...

Page 5: ... structures of sufficient strength to support the units weight Bases should be at least 200mm high to provide sufficient access for installation of piping Either steel or concrete bases may be suitable A typical concrete base design is shown in Figure 3 2 5 A typical concrete specification is 1 part cement 2 parts sand and 4 parts crushed stone with Φ10mm steel reinforcing bar The edges of the bas...

Page 6: ... shipment If there is damage to the surface or outside of a unit submit a written report to the shipping company Check that the model specifications and quantity of the units delivered are as ordered Check that all accessories ordered have been included Retain the Owner s Manual for future reference Notes for installers Do not remove any packaging before hoisting If units are not packaged or if th...

Page 7: ...jacent wall 3 2 Design Considerations Outdoor unit ducting design should take account of the following Each duct should contain no more than one bend Vibration isolation should be added to the connection between the unit and the ducting to avoid vibration noise Installing louvers is not recommended as doing so decreases airflow impacting upon cooling heating performance and energy efficiency If th...

Page 8: ...ing Figure 3 3 3 Longitudinal ducting for 8HP 10HP and 12HP units unit mm Table 3 3 3 Duct dimensions Dimensions mm Table 3 3 4 External static pressure A A 300 ESP Pa Remarks B B 250 0 Factory default C C 3000 0 20 Remove steel mesh and connect to duct 3m long D D A 750 θ Θ 15 20 Customization option 750 Support Radius Radius Air outlet louver optional 731 A C D B 90 100 θ E 750 340 320 704 8 φ3 ...

Page 9: ...gure 3 3 5 Longitudinal ducting for 14HP 16HP 18HP 20HP and 22HP units unit mm Table 3 3 7 Duct dimensions Dimensions mm Table 3 3 8 External static pressure A A 300 ESP Pa Remarks B B 250 0 Factory default C C 3000 0 20 Remove steel mesh and connect to duct 3m long D D A 1290 θ Θ 15 20 Customization option 1290 Support Radius Radius Air outlet louver optional 630 A C D B 90 100 θ E 1290 1020 300 ...

Page 10: ...10 20 30 40 50 B C u s t o m i z e d A D e f a u l t Static pressure Pa Air volume m3 h B C u s t o m i z e d A D e f a u l t 10 800 11 000 11 200 11 400 11 600 11 800 12 000 12 200 0 10 20 30 40 50 Static pressure Pa Air volume m3 h 13 200 13 400 13 600 13 800 14 000 14 200 14 400 14 600 0 10 20 30 40 50 B Customized A Default Static pressure Pa Air volume m3 h 15 750 15 800 15 850 15 900 15 950 ...

Page 11: ...in Figures 3 4 2 and 3 4 3 the system should as far as possible be equal in terms of number of units total capacities and total piping lengths 4 2 Material Specification Only seamless phosphorus deoxidized copper piping that complies with all applicable legislation should be used Temper grades and minimum thicknesses for different diameters of piping are specified in Table 3 4 1 Table 3 4 1 Piping...

Page 12: ...r branch joint A to the farthest indoor unit N9 and the piping from the first indoor branch joint A to the nearest indoor unit N1 does not exceed 40m That is Ʃ L7 to L10 i Ʃ L2 to L3 a 40m Measures a Increase the diameter of the indoor main pipes the piping between the first indoor branch joint and all other indoor branch joints L2 to L12 as per Table 3 4 2 except for indoor main pipes which are a...

Page 13: ...irement 1 above 2 Refer to Requirement 2 above 3 Refer to Requirement 3 above 4 Refer to Requirement 4 above 5 Refer to Requirement 5 above First indoor branch joint Largest level difference between indoor unit and outdoor unit H 90m Largest level difference between indoor units H 30m Piping between farthest indoor unit and first indoor branch joint L 40m Equivalent length of piping between farthe...

Page 14: ...QZHN 03D 92 Capacity 135 Φ38 1 Φ19 1 FQZHN 04D 135 Capacity 180 Φ41 3 Φ22 2 FQZHN 05D 180 Capacity Φ44 5 Φ25 4 FQZHN 05D Notes 1 The main pipe L1 and first indoor branch joint A should be sized according to whichever of Tables 3 4 4 and 3 4 5 indicates the larger size N1 140 N4 140 N7 140 N8 140 N10 28 N12 56 N11 140 N3 71 N6 28 N13 56 A B G H K I L C E L1 L2 L3 L5 L7 L8 L11 L12 L9 a c d f g h j l...

Page 15: ...r of Tables 3 4 4 and 3 4 5 indicates the larger size Table 3 4 6 Outdoor connection pipes g1 to g4 G1 G2 Table 3 4 7 Outdoor branch joint kits N to O Pipes Outdoor unit capacity Gas pipe mm Liquid pipe mm No of outdoor units Branch joint kit g1 to g4 8 12HP Φ25 4 Φ12 7 2 FQZHW 02N1D 14 22HP Φ31 8 Φ15 9 3 FQZHW 03N1D G1 Φ38 1 Φ19 1 4 FQZHW 04N1D G2 Φ41 3 Φ22 2 Table 3 4 8 Indoor auxiliary pipes a ...

Page 16: ...indoor branch joint B have total capacity of 14 x 4 7 1 2 8 65 9kW Refer to Table 3 4 4 Indoor main pipe L2 is Φ28 6 Φ15 9 Indoor branch joint B is FQZHN 03D The other indoor main pipes and indoor branch joints C and E to L are selected in the same fashion Step 3 Select main pipe and indoor branch joint A The indoor units N1 to N13 downstream of indoor branch joint A have total capacity of 14 x 7 ...

Page 17: ...16 There are three outdoor units in the system Refer to T able3 4 7 Outdoor branch joints M and N are TFQZHW 03N1D ...

Page 18: ... 9 in Installation Manual 5 6 Branch Joints Indoor branch joints may be installed either horizontally or vertically To ensure even distribution of refrigerant branch joints should not be installed within 500mm of a 90 bend another branch joint or the straight section of piping leading to an indoor unit with the minimum 500mm being measured from the point where the branch joint is connected to the ...

Page 19: ... 4 ID 9 5 ID 28 6 ID 31 8 OD 28 6 ID 28 6 ID 19 1 ID 22 2 OD 28 6 ID 19 1 ID 22 2 OD 28 6 ID 15 9 ID 15 9 OD 15 9 ID 19 1 ID 12 7 OD 15 9 ID 9 5 ID 15 9 ID 12 7 OD 15 9 ID 9 5 ID 6 4 ID 19 1 ID 22 2 ID 28 6 OD 34 9 ID 34 9 OD 34 9 ID 38 1 ID 22 2 ID 28 6 OD 34 9 ID 34 9 ID 12 7 ID 15 9 OD 19 1 ID 19 1 OD 19 1 ID 19 1 ID 22 2 ID 12 7 ID 15 9 OD 19 1 ID 9 5 ID 34 9 ID 41 3 ID 34 9 ID 41 3 ID 41 3 ID...

Page 20: ...Q1 Q2 Q7 ID 38 1 ID 41 3 ID 31 8 0D 31 8 ID 31 8 ID 25 4 Q1 Q5 ID 15 9 ID 15 9 ID 19 1 ID 15 9 0D 15 9 ID 12 7 ID 12 7 0D 15 9 Y1 Y6 Y2 ID 19 1 ID 22 2 ID 15 9 0D 15 9 ID 15 9 ID 12 7 Y1 Y7 0D 22 2 ID 19 1 Y4 ID 31 8 0D 34 9 ID 31 8 ID 38 1 ID 34 9 0D 31 8 ID 25 4 0D 31 8 ID 31 8 ID 25 4 Q1 Q2 Q7 ID 38 1 ID 41 3 ID 31 8 0D 31 8 ID 31 8 ID 25 4 Q1 Q5 ID 41 3 ID 44 5 ID 31 8 0D 31 8 ID 31 8 ID 25 4 ...

Page 21: ...owing a leak can be calculated as follows Calculate the total amount in of refrigerant in the system A as the nameplate charge the charge in the system when delivered from the factory plus the additional charge added as per Installation Manual 8 1 Calculating Additional Refrigerant Charge Calculate the total volume B of the smallest room into which refrigerant could potentially leak Calculate the ...

Page 22: ...onnections have been completed with the exception of the final connections to the indoor units That is flushing should be performed once the outdoor units have been connected but before the indoor units are connected Notes for installers Vacuum drying Joint insulation Pipe insulation Pipe brazing and installation Pipe flushing Gastightness test CLEAN DRY Particles such as oxide produced during bra...

Page 23: ...ication oil used during some copper pipe manufacturing processes can cause deposits to form in R410A refrigerant systems causing system errors Oil free copper piping should therefore be selected If ordinary oily copper piping is used it must be cleaned with gauze dipped in tetrachloroethylene solution prior to installation Caution Never use carbon tetrachloride CCl4 for pipe cleansing or flushing ...

Page 24: ...anneal the end of the pipe to be flared Remember to place the flare nut on the piping before flaring Ensure the flared opening is not cracked deformed or scratched otherwise it will not form a good seal and refrigerant leakage may occur The diameter of the flared opening should be within the ranges specified in Table 3 5 1 Refer to Figure 3 5 2 Table 3 5 1 Flared opening size ranges Figure 3 5 2 F...

Page 25: ...htly otherwise stress concentrations may occur in the piping with the potential for rupturing Table 3 5 2 Refrigerant piping support spacings Pipe mm Interval between support points m Horizontal Piping Vertical Piping Ф20 1 1 5 Ф20 Ф40 1 5 2 Ф40 2 2 5 Piping bending methods Hand bending is suitable for thin copper piping Ф6 35mm Ф12 7mm Mechanical bending using a bending spring manual bending mach...

Page 26: ...e that the nitrogen continuously passes through the section being brazed until the brazing is complete and the copper has cooled down completely Figure 3 5 4 Flowing nitrogen through piping during brazing Legend 1 Copper piping 2 Section being brazed 3 Nitrogen connection 4 Hand valve 5 Pressure reducing valve 6 Nitrogen When joining a shorter section of piping to a longer section flow nitrogen fr...

Page 27: ...ap and gap for brazed joints A D B Brazing Legend A Inner diameter of larger pipe D Outer diameter of smaller pipe B Inlaid depth overlap Table 3 5 3 Piping overlap and gap for brazed joints1 D mm Minimum permissible B mm Permissible A D mm 5 D 8 6 0 05 0 21 8 D 12 7 12 D 16 8 0 05 0 27 16 D 25 10 25 D 35 12 0 05 0 35 35 D 45 14 Notes 1 A B D refer to the dimensions shown in Figure 3 5 7 Filler Us...

Page 28: ...l branch joints must be installed at an angle to the horizontal not exceeding 10 in order to avoid uneven distribution of refrigerant and possible malfunction Refer to Figure 3 5 8 Figure 3 5 8 Branch joint orientation Figure 3 5 9 Installation of outdoor branch joints To ensure even distribution of refrigerant a limitation is placed on how close branch joints may be installed to bends other branc...

Page 29: ...r piping should be installed in a metal casing to protect against exposure to sunlight rain wind and other potential causes of damage 5 8 Pipe Flushing 5 8 1 Purpose To remove dust other particles and moisture which could cause compressor malfunction if not flushed out before the system is run the refrigerant piping should be flushed using nitrogen As described in Installation Manual 5 1 1 Install...

Page 30: ...thest from the outdoor units Indoor unit A in Figure 3 5 11 5 Start to open the nitrogen cylinder valve and gradually increase the pressure to 0 5MPa 6 Allow time for nitrogen to flow as far as the opening at indoor unit A 7 Flush the first opening a Using suitable material such as a bag or cloth press firmly against the opening at indoor unit A b When the pressure becomes too high to block with y...

Page 31: ...bient temperature over the test period by adjusting the reference pressure by 0 01MPa per 1 C of temperature difference Adjusted reference pressure Pressure at pressurization temperature at observation temperature at pressurization x 0 01MPa Compare the observed pressure with the adjusted reference pressure If they are the same the piping has passed the gastightness test If the observed pressure i...

Page 32: ...on in addition to the gastightness test The general methods for identifying the source of a leak are as follows 1 Audio detection relatively large leaks are audible 2 Touch detection place your hand at joints to feel for escaping gas 3 Soapy water detection small leaks can be detected by the formation of bubbles when soapy water is applied to a joint 4 Refrigerant leak detection for leaks that are...

Page 33: ...p valve the red high pressure side hose to the master unit liquid pipe stop valve and the yellow hose to the vacuum pump Step 2 Start the vacuum pump and then open the pressure gauge valves to start vacuum the system After 30 minutes close the pressure gauge valves After a further 5 to 10 minutes check the pressure gauge If the gauge has returned to zero check for leakages in the refrigerant pipin...

Page 34: ...potential complications two horizontal drain pipes should not meet at the same level Refer to the Figure 3 6 2 for suitable connection arrangements Such arrangements also allow the slope of the two horizontal pipes to be selected independently Figure 3 6 2 Drain piping joints correct and incorrect configurations Drain pipe Tee joint Tee joint Drain pipe Tee joint Branch drain piping should join ma...

Page 35: ...d or water being blown back into the drainage pan Traps should be arranged as in Figure 3 6 6 The vertical separation H should be in excess of 50mm A plug may be fitted to allow cleaning or inspection 6 3 Selecting Piping Diameters Select branch drainage piping the drain piping connection to each unit diameters according to indoor unit flow volume and select main drainage piping diameters accordin...

Page 36: ...nits with lift pumps should take account of the following additional considerations A downward sloping section should immediately follow the vertically rising section adjacent to the unit otherwise a water pump error will occur Refer to Figure 3 6 7 Air vents should not be installed on vertically rising sections of drain piping otherwise water may be discharged through the air vent or water flow m...

Page 37: ...drain piping is all connected conduct a watertightness test and water flow test Do not connect air conditioner drain piping to waste rainwater or other drain piping and do not let air conditioner drain piping come into direct contact with the ground For units with drain pumps test that the drain pump functions properly by adding water to the unit s drainage pan and running the unit To allow inspec...

Page 38: ...re at each joint is as follows 1 Cut a section of insulation 50 to 100mm longer than the gap to be filled Ensure that the cross sectional and longitudinal openings are all cut evenly 2 Embed the section into the gap ensuring that the ends abut tightly to the sections of insulation either side of the gap 3 Glue the longitudinal cut and the joints with the sections of insulation either side of the g...

Page 39: ... suitable adhesive to seal seams and joints in the insulation and then bind with cloth reinforced tape of width not less than 50mm Ensure tape is fixed firmly to avoid condensation Ensure the drain piping insulation adjacent to the indoor unit drainage water outlet is fixed to the unit itself using adhesive to prevent condensation and dripping 7 3 Ducting Insulation Suitable insulation should be a...

Page 40: ...ing a gastightness test and vacuum drying Never charge more refrigerant than required as doing so can lead to liquid hammering Only use refrigerant R410A charging with an unsuitable substance may cause explosions or accidents Use tools and equipment designed for use with R410A to ensure required pressure resistance and to prevent foreign materials from entering the system Refrigerant must be treat...

Page 41: ... three valves on the pressure gauge run the outdoor units in cooling mode and then open the yellow and blue valves Continue charging until the full R kg of refrigerant has been charged then close the yellow and blue valves Note Before running the system be sure to complete all the pre commissioning checks as listed in Installation Manual 11 3 Pre commissioning Checks and be sure to open all stop v...

Page 42: ...tionally liquid refrigerant returning directly to the compressor from the powered off unit would cause liquid hammering potentially damaging the compressor For outdoor unit power wire sizing and circuit breaker sizing refer to Table 2 6 1 in Technical Manual 6 Electrical Characteristics Caution All installation and wiring must be carried out by competent and suitably qualified certified and accred...

Page 43: ...nit GND Outdoor unit GND Outdoor unit GND Outdoor unit GND Outdoor unit GND Outdoor unit Power facilities 1 with leakage protector Power facilities 2 with leakage protector Leakage protector Manual switch Branch box Indoor unit 1 9 2 10 3 11 4 12 5 13 6 14 7 15 8 16 The 3 phase 380 415V 50 or 60Hz power supply should be connected to the outdoor unit power supply terminals as shown in Figure 3 9 3 ...

Page 44: ... form a closed loop The P and Q communication wires and should NOT be grounded The shielding nets of the communication wires should be connected together and grounded Grounding can be achieved by connecting to the metal casing adjacent to the P Q E terminals of the outdoor unit electrical control box Outdoor communication wiring The H1 and H2 communication wires should be connected one unit after ...

Page 45: ...Communication wiring has polarity Care should be taken to connect the poles correctly Figure 3 9 5 Master outdoor unit communication terminals Table 3 9 1 Communication connections Terminals Connection K1 K2 E Connect to outdoor unit centralized monitor O A E Connect to digital energy meter X Y E Connect to indoor unit centralized controller P Q E Connect between indoor units and master outdoor un...

Page 46: ...and evaporator fins could cause product malfunction or inefficient performance Outdoor units installed in seaside locations should be placed such as to avoid direct exposure to the sea air and additional anticorrosion treatment options should be selected otherwise the service life of the outdoor units will be seriously affected Air conditioning installed in seaside locations should be run regularl...

Page 47: ...nclude the condenser the refrigerant piping system the outside surface of the unit casing and the outside surface of the electric control box Regular inspections should check for corrosion and if necessary corroded components should be replaced and or anti corrosion treatments should be added 11 Commissioning 11 1 Outdoor Unit Address and Capacity Settings Before running a system for the first tim...

Page 48: ...ty Settings and all other indoor and outdoor unit field settings have been set as required 9 The additional refrigerant charge has been added as per Installation Manual 8 Charging Refrigerant Note In some circumstances it may be necessary to run the system in cooling mode during the refrigerant charging procedure In such circumstances points 1 to 8 above should be checked before running the system...

Page 49: ...ture 30 C fan speed high d After one hour complete Sheet B of the system commissioning report then check the system parameters using the SW2 system check button on each outdoor unit s main PCB and complete the heating mode columns of one Sheet D and one Sheet E of the system commissioning report for each outdoor unit 6 Finally complete Sheet C of the system commissioning report 11 4 2 Commissionin...

Page 50: ...12 Appendix System Commissioning Report A total of up to 11 report sheets should be completed for each system One Sheet A one Sheet B and one Sheet C per system One Sheet D and one Sheet E per outdoor unit ...

Page 51: ...ave unit 2 Slave unit 3 Model Serial no COOLING MODE PARAMETER RECORD After running in cooling mode for one hour OUTDOOR UNITS Master unit Slave unit 1 Slave unit 2 Slave unit 3 Compressor suction pipe temperature System pressure at check port A B C A B C A B C A B C Phase currents A Within normal range INDOOR UNITS Sample of over 20 of the indoor units including the unit furthest from the outdoor...

Page 52: ... Master unit Slave unit 1 Slave unit 2 Slave unit 3 Compressor suction pipe temperature System pressure at check port A B C A B C A B C A B C Phase currents A Within normal range INDOOR UNITS Sample of over 20 of the indoor units including the unit furthest from the outdoor units Room no Model Address Set temp C Inlet temp C Outlet temp C Drainage OK Abnormal noise vibration ...

Page 53: ...ription of observed issue Suspected cause Troubleshooting undertaken Serial no of relevant unit 1 2 3 OUTDOOR UNIT FINAL CHECKLIST Master unit Slave unit 1 Slave unit 2 Slave unit 3 SW2 system check performed Any abnormal noise Any abnormal vibration Fan rotation normal Commissioning engineer Dealer Midea representative Name Signature Date ...

Page 54: ... Fan B speed index Refer to Note 3 11 Evaporator pipe temperature C Sensor T2B T2 Actual value value displayed 12 Condenser pipe temperature C Sensor T3 Actual value value displayed 13 Outdoor ambient temperature C Sensor T4 Actual value value displayed 14 Inverter compressor A discharge temperature C Actual value value displayed 15 Inverter compressor B discharge temperature C Actual value value ...

Page 55: ...yed x 10 31 Reserved 32 Most recent error or protection code 000 is displayed if no error or protection events have occurred since start up 33 Error clearance metric Actual value value displayed 34 End Notes 1 Outdoor unit capacity setting 0 8HP 1 10HP 2 12HP 3 14HP 4 16HP 5 18HP 6 20HP 7 22HP 2 Operating mode 0 off 2 cooling 3 heating 4 forced cooling 3 The fan speed index is related to the fan s...

Page 56: ...representations of system layouts Remote anytime anywhere access via PC tablet computer or smart phone using VPN WAN connection Patented calculation method estimates the energy consumption of each indoor unit to equitably divide electricity charges among building occupants Software IMM software BACnet gateway MD CCM08 Enables communication between VRF and BMS Control and monitoring of air conditio...

Page 57: ...36341070 Fax 98 71 36341094 Tehran office No 19 koohe nour St Motahhari St TEHRAN IRAN Post code 15876 73111 Tel 98 21 89389 Fax 98 21 88541903 Ahwaz office No 309 Kaveh St AHWAZ IRAN Post code 61939 47911 Tel 98 61 32230647 8 Fax 98 61 32230647 E mail info trustacs com Web site http www trustacs com Air Conditioning Systems Cooling Heating ...

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