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5 Refrigerant Piping Installation

5.1 Procedure and Principles

5.1.1 Installation procedure

Notes for installers

Installation of the refrigerant piping system should proceed in the following order:

Pipe

insulation

Pipe brazing and

installation

Pipe flushing

Gastightness

test

Joint

insulation

Vacuum drying

Note: Pipe flushing should be performed once the brazed connections have been completed with the exception of
the final connections to the indoor units. That is, flushing should be performed once the outdoor unit have been

connected but before the indoor units are connected.

5.1.2 Three principles for refrigerant piping

Reasons

Measures

CLEAN

Particles such as oxide produced

during brazing and/or building dust

can lead to compressor malfunction

Seal piping during storage

Flow nitrogen during brazing

Pipe flushing

DRY

Moisture can lead to ice formation or

oxidization of internal components

leading to abnormal operation or

compressor damage

Pipe flushing

Vacuum drying

SEALED

Imperfect seals can lead to

refrigerant leakage

Pipe manipulation

and brazing

techniques

Gastightness test

Notes:

1. See Part 3, 5.2.1 “Pipe delivery, storage and sealing”.

2. See Part 3, 5.5 “Brazing”.

3. See Part 3, 5.7 “Pipe Flushing”.

4. See Part 3, 5.9 “Vacuum Drying”.

5. See Part 3, 5.3 “Manipulating Copper Piping”.

See Part 3, 5.8 “Gastightness Test”.

Содержание Amazon Unitario Top Discharge

Страница 1: ...DN4S K2UF 450 DN4S K2UF 500 DN4S K2UF 560 DN4S K2UF 615 DN4S K2UF 670 DN4S K2UF 730 DN4S K2UF 785 DN4S K2UF 850 DN4S K2UF 900 DN4S Thank you very much for purchasing our air conditioner Before using...

Страница 2: ...CONTENTS Amazon Unitario Top Discharge 1 CONTENTS Part 1 General Information 3 Part 2 Outdoor Unit Engineering Data 15 Part 3 System Design and Installation 134...

Страница 3: ...Kaysun Amazon Unitario Top DischargeEngineering Data Book Amazon Unitario Top Discharge 2...

Страница 4: ...Part 1 General Information Amazon Unitario Top Discharge 3 Part 1 General Information 1 Indoor and Outdoor Unit Capacities 4 2 External Appearance 6 3 Combination Ratio 8 4 Selection Procedure 9...

Страница 5: ...KS E F Floor Standing KPDF Medium Static Pressure Duct KSDF Console KPDHF High Static Pressure Duct Table 1 1 2 Standard indoor unit capacity range Capacity Capacity index KCOF KCIF KCIBF KPDF KPDHF K...

Страница 6: ...280 DN4S 12HP K2UF 335 DN4S 14HP K2UF 400 DN4S 16HP K2UF 450 DN4S 18HP K2UF 500 DN4S 20HP K2UF 560 DN4S 22HP K2UF 615 DN4S 24HP K2UF 670 DN4S 26HP K2UF 730 DN4S 28HP K2UF 785 DN4S 30HP K2UF 850 DN4S 3...

Страница 7: ...rance 2 1 Indoor Units 2 1 1 Standard indoor units Table 1 2 1 Standard indoor unit appearance One way Cassette Compact Four way Cassette KCOF KCIF Four way Cassette Medium Static Pressure Duct KCIF K...

Страница 8: ...neral Information Amazon Unitario Top Discharge 7 2 2 Outdoor Units Table 1 2 4 Outdoor unit appearance 10 12HP with single fan 14 16 18HP with single fan 20 22HP with dual fans 24 26 28 30 32HP with...

Страница 9: ...units the total capacity of the fresh air processing units must not exceed 30 of the capacity of the outdoor unit and the combination ratio must not exceed 100 Table 1 4 2 Combinations of Indoor and o...

Страница 10: ...ign temperature and humidity indoor and outdoor Required heat load of each room System peak load Piping length level differences Indoor unit specifications type and quantity Select indoor unit models...

Страница 11: ...5 12 00 6 6 7 1 5 1 5 1 7 4 6 8 4 0 4 0 46 1 14 00 9 0 9 4 4 9 4 9 7 3 6 8 4 2 4 2 50 7 16 00 10 6 10 7 3 9 3 9 6 3 6 2 3 8 3 8 49 2 The maximum piping lengths and level differences in this example ar...

Страница 12: ...W Table 1 5 3 Selected indoor units Room A Room B Room C Room D Peak heat load kW 10 6 10 7 5 1 5 1 Selected indoor unit KPDF 140 DN4 0 KPDF 140 DN4 0 KPDF 56 DN4 0 KPDF 56 DN4 0 Corrected TC kW 13 2...

Страница 13: ...nnected indoor units is within the limitation Calculate the corrected capacity of the outdoor unit a The sum of the indoor unit CIs is 706 and the CI of the 20HP outdoor unit K2UF 560 DN4S E is 560 so...

Страница 14: ...equivalent length of piping between farthest indoor unit and first outdoor branch joint the vertical axis shows the largest level difference between indoor unit and outdoor unit For level differences...

Страница 15: ...Kaysun Amazon Unitario Top Discharge Engineering Data Book Amazon Unitario Top Discharge 14...

Страница 16: ...ngineering Data 1 Specifications 16 2 Dimensions 19 3 Installation Space Requirements 23 4 Piping Diagrams 24 5 Wiring Diagrams 28 6 Electrical Characteristics 30 7 Functional Components and Safety De...

Страница 17: ...t Fan Type Propeller Motor type DC Quantity 1 Motor output kW 0 56 0 56 0 92 Airflow rate m3 h 11000 11000 13000 Drive type Direct Refrigerant Type R410A Factory charge kg 11 11 13 Pipe connections3 L...

Страница 18: ...Start up method Soft start Fan Type Propeller Motor type DC Quantity 1 2 Motor output kW 0 92 0 92 0 56 2 0 56 2 Airflow rate m3 h 13000 13000 17000 17000 Drive type Direct Refrigerant Type R410A Fact...

Страница 19: ...Quantity 2 Oil type FAmazon Unitario Top Discharge8H Start up method Soft start Fan Type Propeller Motor type DC Quantity 2 Motor output kW 0 92 2 0 92 2 0 92 2 0 92 2 0 92 2 Airflow rate m3 h 25000...

Страница 20: ...ing Data Amazon Unitario Top Discharge 19 2 Dimensions 10 12HP Figure 2 2 1 10 12 dimensions unit mm 1635 990 790 R 77 63 50 Detail R Table 2 2 1 10 12HP connection piping diameter unit mm Size 10HP 1...

Страница 21: ...uid pipe connection port A Gas pipe connection port B Check port used to measure system pressure and charge additional refrigerant in maintenance process Detail R Table 2 2 2 14 16 18HP connection pip...

Страница 22: ...ipe connection port A Gas pipe connection port B Check port used to measure system pressure and charge additional refrigerant in maintenance process Detail R Table 2 2 3 20 22HP connection piping diam...

Страница 23: ...s unit mm 1830 1730 850 R Liquid pipe connection port A Gas pipe connection port B 55 63 62 Check port used to measure system pressure and charge additional refrigerant in maintenance process Detail R...

Страница 24: ...1000 1000 1000 Front 1000 For multi row installation Figure 2 3 3 Multi row installation unit mm 100 500 100 500 100 500 100 500 1000 1000 1000 1000 1000 1000 Front Front Front 1000 1000 1000 1000 De...

Страница 25: ...g Diagrams 10 12HP Figure 2 4 1 10 12HP piping diagram 7 1 15 12 9 3 2 4 5 6 11 10 14 8 8 13 EXVA EXVC E S C T3 T4 T6B T7C1 T7C2 T6A SV8A SV4 SV5 SV6 14 16 18HP Figure 2 4 2 14 16 18HP piping diagram...

Страница 26: ...re 2 4 3 20 22 24HP piping diagram 7 1 1 15 12 9 3 4 5 6 11 11 10 10 8 13 EXVA E S C SV9 SV4 SV5 SV6 SV2 T3 T4 2 T7C1 T7C2 2 26 28HP Figure 2 4 4 26 28HP piping diagram 7 1 1 15 15 12 9 3 4 5 6 11 10...

Страница 27: ...igh pressure sensor T6A Plate heat exchanger inlet temperature sensor 5 Oil separator T6B Plate heat exchanger outlet temperature sensor 6 Four way valve T7C1 Compressor A discharge temperature sensor...

Страница 28: ...quicken the defrosting process Closed in cooling mode 7 Solenoid valve SAmazon Unitario Top Discharge Allows refrigerant to bypass the expansion valves Opens in cooling mode when discharge temperature...

Страница 29: ...High pressure sensor Solenoid valve L8 Current sensor CN50 BR1 CN31 CN32 Red Red Blue Blue Black Ferrite core N 1 FAN B CN100 N8_1 T6B CN7 EEV CN27 O FAN CN26 O C CN20 O O EEVA T6B CN25 N CN1 CN51 L1...

Страница 30: ...igh pressure sensor Crankcase heater Solenoid valve L8 Current sensor CN100 N8_1 T6B CN7 EEV CN27 O FAN CN26 O C CN20 O O EEVA T6B CN25 N CN1 CN51 L1 L2 L3 CN2 CN3 CN4 C e boa d Main board FAN B 1 O N...

Страница 31: ...1 26HP K2UF 730 DN4S 50 380 415 342 440 52 9 62 3 63 20 19 8 0 92 2 13 1 28HP K2UF 785 DN4S 50 380 415 342 440 58 7 64 1 63 22 21 8 0 92 2 14 9 30HP K2UF 850 DN4S 50 380 415 342 440 64 9 72 5 80 20 3...

Страница 32: ...top and discharge pipe temperature sensors 90 C 5k 3 Crankcase heater 30W 2 30W 4 Inverter module Inverter module temperature sensor 90 C 5k 5 Fan motor Safety thermostat On 115 C Off System High pre...

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Страница 116: ...10 17 58 8 5 9 1 51 90 22 33 48 57 21 07 45 00 19 83 43 33 19 09 41 43 17 93 38 10 16 57 7 7 6 51 90 21 50 48 57 20 17 45 00 19 14 43 33 18 45 41 43 17 24 38 10 15 85 5 5 6 51 90 20 70 48 57 19 43 45...

Страница 117: ...9 59 8 5 9 1 72 44 26 54 72 19 27 18 72 19 28 07 71 93 28 68 71 93 29 30 71 67 29 62 7 7 6 73 22 27 02 72 96 27 67 72 96 28 38 72 70 29 00 72 70 29 61 72 44 29 96 5 5 6 78 91 27 23 78 65 27 88 78 40 2...

Страница 118: ...9 1 71 67 31 37 71 41 31 67 71 41 31 89 70 63 30 40 67 79 28 94 62 10 26 11 7 7 6 72 44 31 40 72 44 31 24 72 19 31 44 70 63 29 99 67 79 28 53 62 10 25 74 5 5 6 78 14 31 46 77 88 29 89 73 48 30 13 70 6...

Страница 119: ...02 19 16 41 40 17 90 8 5 9 1 56 40 22 74 52 78 21 47 48 90 20 20 47 09 19 45 45 02 18 27 41 40 16 88 7 7 6 56 40 21 90 52 78 20 55 48 90 19 50 47 09 18 79 45 02 17 56 41 40 16 14 5 5 6 56 40 21 09 52...

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Страница 124: ...41 8 5 9 1 83 54 33 85 83 24 34 17 83 24 34 41 82 33 32 80 79 02 31 23 72 38 28 17 7 7 6 84 44 33 89 84 44 33 71 84 14 33 93 82 33 32 36 79 02 30 79 72 38 27 77 5 5 6 91 08 33 94 90 78 32 25 85 65 32...

Страница 125: ...48 20 68 48 25 19 32 8 5 9 1 65 75 24 54 61 52 23 16 57 00 21 79 54 89 20 99 52 48 19 71 48 25 18 21 7 7 6 65 75 23 63 61 52 22 17 57 00 21 04 54 89 20 28 52 48 18 95 48 25 17 42 5 5 6 65 75 22 76 61...

Страница 126: ...2 32 88 57 33 38 88 25 34 11 88 25 34 84 87 94 35 22 7 7 6 89 84 32 13 89 52 32 90 89 52 33 75 89 21 34 48 89 21 35 22 88 89 35 62 5 5 6 96 83 32 38 96 51 33 16 96 19 34 10 96 19 34 83 96 19 35 57 95...

Страница 127: ...73 76 19 31 31 8 5 9 1 87 94 37 30 87 62 37 66 87 62 37 92 86 67 36 15 83 17 34 42 76 19 31 05 7 7 6 88 89 37 35 88 89 37 15 88 57 37 39 86 67 35 66 83 17 33 93 76 19 30 60 5 5 6 95 87 37 41 95 56 35...

Страница 128: ...79 21 29 8 5 9 1 69 21 27 05 64 76 25 53 60 00 24 02 57 78 23 13 55 24 21 72 50 79 20 07 7 7 6 69 21 26 04 64 76 24 44 60 00 23 19 57 78 22 35 55 24 20 88 50 79 19 20 5 5 6 69 21 25 08 64 76 23 54 60...

Страница 129: ...ing between farthest indoor unit and first outdoor branch joint the vertical axis shows the largest level difference between indoor unit and outdoor unit For level differences positive values indicate...

Страница 130: ...nt of frosting which has occurred Corrected heating capacity values which take these factors into account can be calculated as follows using the correction factors for frost accumulation given in Tabl...

Страница 131: ...rature o C DB Range for continuous operat i on Range for intermittent operat i on Indoor temperature o C DB 15 10 5 0 5 10 10 15 20 25 30 35 Outdoor temperature o C DB Range for continuous operat i on...

Страница 132: ...62 16HP 65 18HP 65 20HP 66 22HP 66 24HP 67 26HP 68 28HP 68 30HP 68 32HP 68 Notes 1 Sound pressure level is measured at a position 1m in front of the unit and 1 3m above the floor in a semi anechoic ch...

Страница 133: ...63 125 250 500 1000 2000 4000 8000 A B d l e v e l e r u s s e r p d n u o s d n a b e v a t c O Octave band center frequency Hz NC 65 NC 60 NC 55 NC 50 NC 45 NC 40 NC 35 NC 30 NC 25 NC 20 NC 15 0 10...

Страница 134: ...2 Flat blade screwdriver 1 Adjusting indoor and outdoor unit dial switches 90 elbow 1 Connecting pipes Seal plug 8 Used in pipe flushing Connection pipe 3 Connecting pipes Matched resistor 2 Enhances...

Страница 135: ...Unit Placement and Installation 136 3 Outdoor Unit Ducting and Shielding 139 4 Refrigerant Piping Design 145 5 Refrigerant Piping Installation 154 6 Drain Piping 165 7 Insulation 168 8 Charging Refri...

Страница 136: ...for installers Notes for installers Notes for installers boxes contain important information which may primarily be of use during field installation rather than during desk based system design 1 2 De...

Страница 137: ...ose as possible to the indoor units 2 1 2 Spacing Outdoor units must be spaced such that sufficient air may flow through each unit Sufficient airflow across heat exchangers is essential for outdoor un...

Страница 138: ...r Figure 3 2 5 and Table 3 2 1 A drainage ditch should be provided to allow drainage of condensate that may form on the heat exchangers when the units are running in heating mode The drainage should e...

Страница 139: ...nd maintenance should be allowed To ensure a good cooling heating effect short circuit ventilation where outlet air returns quickly to a unit s air inlet should be avoided To prevent excessive noise o...

Страница 140: ...al section of ducting should be at least H h high Figure 3 3 1 Top of unit below top of adjacent wall h H h H 3 2 Design Considerations Outdoor unit ducting design should take account of the following...

Страница 141: ...s mm ESP Pa Remarks A A 300 0 Factory default B B 250 0 20 Remove steel mesh and connect to duct 3m long C C 3000 20 Customization option D 731 D 770 E E A 731 15 3 3 2 Option B Longitudinal ducting F...

Страница 142: ...rks A A 300 0 Factory default B B 250 0 20 Remove steel mesh and connect to duct 3m long C C 3000 20 Customization option D 770 D 800 E E A 770 15 3 3 4 Option B Longitudinal ducting Figure 3 3 5 Long...

Страница 143: ...re Dimensions mm ESP Pa Remarks A A 300 0 Factory default B B 250 0 20 Remove steel mesh and connect to duct 3m long C C 3000 20 Customization option D 630 D 660 E E A 630 15 3 3 6 Option B Longitudin...

Страница 144: ...sverse ducting for 24HP 26HP 28HP 30HP and 32HP units unit mm 1653 740 A C D B 90 100 E Table 3 3 13 Duct dimensions Table 3 3 14 External static pressure Dimensions mm ESP Pa Remarks A A 300 0 Factor...

Страница 145: ...fan performance Figure 3 3 12 24 28HP units fan performance 0 5 10 15 20 9800 10000 10200 10400 10600 10800 11000 11200 Figure 3 3 10 14 18HP units fan performance Figure 3 3 13 30 32HP units fan per...

Страница 146: ...side sides of the first indoor branch joint A in Figures 3 4 2 3 4 3 and 3 4 4 the system should as far as possible be equal in terms of number of units total capacities and total piping lengths 4 2 M...

Страница 147: ...m b The difference in length between the piping from first indoor branch joint A to the farthest indoor unit N10 and the piping from the first indoor branch joint A to the nearest indoor unit N1 does...

Страница 148: ...dexes L2 to L9 Indoor main pipes a to j Indoor auxiliary pipes A to I Indoor branch joints Table 3 4 3 Summary of permitted refrigerant piping lengths and level differences Permitted values Piping in...

Страница 149: ...door main pipes a to j Indoor auxiliary pipes A to I Indoor branch joints Table 3 4 4 Main pipe1 L1 indoor main pipes L2 to L16 and indoor branch joint kits Total capacity indexes of indoor units Gas...

Страница 150: ...312 38 1 22 2 KCMI 412 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 Table 3 4 6 Indoor auxiliary...

Страница 151: ...3 4 6 Indoor auxiliary pipes f KAYF i and j are 12 7 6 35 Step 2 Select indoor main pipes and indoor branch joints B to I The indoor units N1 and N2 downstream of indoor branch joint C have total cap...

Страница 152: ...e 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 500...

Страница 153: ...azon Unitario Top Discharge 152 Table 3 4 7 Indoor branch joint dimensions unit mm Model Gas side joints Liquid side joints KCMI 112 KCMI 212 KCMI 312 KCMI 412 108 ID 1 2 ID 5 8 ID 3 4 ID 7 8 ID 1 1 8...

Страница 154: ...centration of refrigerant in a room following 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 del...

Страница 155: ...have been connected but before the indoor units are connected 5 1 2 Three principles for refrigerant piping Reasons Measures CLEAN Particles such as oxide produced during brazing and or building dust...

Страница 156: ...rs Lubrication 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 selecte...

Страница 157: ...d connection is required Notes for installers Before flaring 1 2H half hard piping anneal the end of the pipe to be flared Remember to place the flare nut on the piping before flaring Ensure the flare...

Страница 158: ...on at the bend is greater than 2 3 of the original area Figure 3 5 3 Pipe bending in excess of 90 Wrinkles may appear 5 4 Refrigerant Piping Supports When the air conditioner is running the refrigeran...

Страница 159: ...per piping at 0 02 0 03MPa during brazing Start the flow before brazing starts and ensure that the nitrogen continuously passes through the section being brazed until the brazing is complete and the c...

Страница 160: ...ing overlap and gap for brazed joints A D B 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 Mi...

Страница 161: ...limitation is placed on how close branch joints may be installed to bends other branch joints and the straight sections of piping leading to indoor units Refer to Part 3 4 6 Branch Joints Figure 3 5 8...

Страница 162: ...gs except for the opening at the indoor unit which is furthest from the outdoor unit Indoor unit A in Figure 3 5 9 5 Start to open the nitrogen cylinder valve and gradually increase the pressure to 0...

Страница 163: ...least 3 minutes Observe the pressure gauge to check for small leakages If there is a small leakage the pressure gauge will drop distinctly If there are no small leakages charge the piping with nitrog...

Страница 164: ...nto the piping until the pressure reaches 0 5MPa c Use a halogen refrigerant detector to find the leak d If the leak source cannot be found continuing charging with refrigerant to a pressure of 4MPa a...

Страница 165: ...ssure side hose of a pressure gauge to the outdoor unit gas pipe stop valve the red high pressure side hose to the outdoor unit liquid pipe stop valve and the yellow hose to the vacuum pump Step 2 Sta...

Страница 166: ...ntal 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 inde...

Страница 167: ...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...

Страница 168: ...scharged through the air vent or water flow may be impeded Figure 3 6 7 Downward sloping section of drain piping 6 5 Drain Piping Installation Notes for installers Installation of the drain piping sho...

Страница 169: ...mperature of the refrigerant piping varies Insulation is required to ensure unit performance and compressor lifespan During cooling the gas pipe temperature can be very low Insulation prevents condens...

Страница 170: ...successfully completed The procedure 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 ar...

Страница 171: ...aution Only charge refrigerant after performing a gastightness test and vacuum drying Never charge more refrigerant than required as doing so can lead to liquid hammering Only use refrigerant R410A ch...

Страница 172: ...l refrigerant can be charged close the three valves on the pressure gauge run the outdoor unit in cooling mode and then open the yellow and blue valves Continue charging until the full R kg of refrige...

Страница 173: ...ed 9 2 Power Supply Wiring Power supply wiring design and installation should adhere to the following requirements Separate power supplies should be provided for the indoor units and outdoor unit Wher...

Страница 174: ...n wiring Using other types of cable can lead to interference and malfunction Indoor communication wiring The P Q E communication wires should be connected one unit after another in a daisy chain from...

Страница 175: ...er P Q E Connect between indoor units and master outdoor unit H1 H2 E Not available for Amazon Unitario Top Discharge Indi vidual series outdoor unit 9 4 Wiring example Figure 3 9 5 System power and c...

Страница 176: ...direct exposure to the sea air should be avoided A canopy should be added to shield the units from sea air and rain as shown in Figure 3 10 2 Ensure that base structures drain well so that outdoor un...

Страница 177: ...have been satisfactorily completed as per instructions 3 All condensate drain piping is complete and a watertightness test has been satisfactorily completed 4 All power and communication wiring is co...

Страница 178: ...the system to ensure that the crankcase heaters have heated the compressor oil sufficiently 5 Run the system a Run the system in cooling mode with the following settings temperature 17 C fan speed hig...

Страница 179: ...Book Amazon Unitario Top Discharge 178 12 Appendix to Part 3 System Commissioning Report A total of up to 5 report sheets should be completed for each system One Sheet A one Sheet B and one Sheet C pe...

Страница 180: ...door ambient temp Commissioning engineer Outdoor unit information Model Serial no Power supply V OUTDOOR UNIT Compressor suction pipe temperature Current A System pressure at check port Within normal...

Страница 181: ...on company Commissioning date Agent company Outdoor ambient temp Commissioning engineer Outdoor unit information Model Serial no Power supply V OUTDOOR UNIT Compressor suction pipe temperature Current...

Страница 182: ...location System name RECORD OF ISSUES SEEN DURING COMMISSIONING No Description of observed issue Suspected cause Troubleshooting undertaken Serial no of relevant unit 1 2 3 OUTDOOR UNIT FINAL CHECKLIS...

Страница 183: ...g refrigerant inlet T6A tempera ture C Actual value value displayed 15 Plate heat exchanger cooling refrigerant outlet T6B tem perature C Actual value value displayed 16 Inverter compressor A discharg...

Страница 184: ...Part 3 System Design and Installation Amazon Unitario Top Discharge 183 Table continued on next page...

Страница 185: ......

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