Installation Manual
Contents
1. 14 r pel lu ld o eee 15 FAP TOD UI OI nd plc nies wate eae 15 FIDO VV TC DAA OI e cela Dea ve ainda a eo eae ine 15 15 Connec ina IE DOS 16 16 and 17 ho ie een bd 18 BStallali lkuu u anne 18 ELECTRICAL CONNEG TIONS curra 19 Outdoor UNC GC CANECUOIS ee ee ee es 19 Wiring Diagram Single Phase Outdoor Unit 20 Wiring Diagram 3 Phase Outdoor 21 COMMISSIONING uu da 22 COMMISSIONING MOCK un een een 22 Installation Instructions Page 3 DUAL CYCLE REFRIGERATED COOLING COMPONENT GENERAL Bonaire Dual Cycle air conditioners combine ducted gas heating and refrigerative cooling using an inline coil box to create a cooling and heating system The heater provides the controls and fan for the heating and cooling system The Bonaire Dual Cycle cooling component includes two separate units indoor coil and outdoor Unit The two components are interconnected by two refrigerant tubes and an electric cable WARNING The refrigerative cooling component must be installed by authorized technicians according to Climate Techno2. C JC CJC JC JC JC C JC C JC JC OC m Cable Entry Z ON NM W A A RA NS III B015RS N BO16RT US I N 1 QATAR amp BO19RT Connections Inside Unit 395 Connections Inside Unit Installation Instructions Page 5 DUAL CYCLE REFRIGERATED COOLING COMPONENT Dimensions amp Clearances OUTDOOR UNIT ACCESS AND CLEARANCES In selecting a proper location the following criteria must be considered a The outdoor unit and the indoor unit must be installed as close to each other as possible within 10m For longer tube specifications see table on page 13 or consult your technical sales rep b Outdoor unit installation should provide for 1 2 Easy service access Minimum disturbance to the owner and nearby neighbors A minimum distance of 100 mm from the wall Ifinstalled in a closed place balcony attic etc
3. COMPRESSOR S COMPRESSOR CONTACTOR BONAIRE 6602203 A Page 21 DUAL CYCLE REFRIGERATED COOLING COMPONENT Commissioning COMMISSIONING CHECK LIST Site Return panels and covers to their correct position and check that they are well secured Ensure all service caps are fitted and correctly tightened 1 Attach the electrical wires and pipes to the wall with clamps Check all the operations of the air conditioner Follow the operating manual for Instruction Indoor Coil Is the condensate drain fixed securely and has it been tested Are all ducting connections secured and free from air leaks Outdoor Unit L Check for any abnormal noise or vibrations during operation of the air conditioner 1 Check that the noise condensate drainage or air flow does not disturb the neighbors L Run the dual cycle system for cooling and check operation Customer Handover Explain to the customer together with the operating instructions How to remove clean and replace the filter How to turn the air conditioner on and off How to choose between heating and cooling and how to set the desired temperature How to operate the air conditioner from the controller u Ensure the warranty details are completed correctly The warranty section is found in the rear of the manual L Ensure the model and serial number sticker is inserted in the warranty section of
4. outdoor air vent must be provided to prevent hot cold air from recirculation through the outdoor unit If several outdoor units are installed in the same area make sure that the hot air outlet from one outdoor unit does not enter another outdoor unit Verify that any wall on which the outdoor unit is installed is capable of carrying the units weight Do not install on a light unstable structure susceptible to vibration When installing on a balcony above the first floor make sure that the outdoor unit location allows easy access for removal of the top cover and or the entire unit if necessary If the outdoor unit is installed in a non accessible location long and flexible refrigerant tubing and electrical cable must be installed to allow the unit to be moved for servicing Do not install the unit in a highly polluted area in which the air is contaminated by oil mist salt or sulfuric gas Multiple Units Lateral and Behind relationships l I 1 I 1 1 I 7 OO gt o e 5 Over 300mm 3 r I 1 I I 1 Installation Instructions BONAIRE When the back is close to the Wall The top and the front need to be open This includes protruding window sills When the top is blocked The front and the sides must be clear for these minimum clearances Over 100 mm Over 500 mm 4 When the back amp sides are blocked The
5. Installation Manual BONAIRE DUAL CYCLE REFRIGERATED COOLING COMPONENT ii SE NO ME ci iii 4 27 A N MITA wC NE 22 BE III Pill ii TOUT LAN EN I i cA N TUNU LITT O MI INS ZU mil gt ES ERROR 41 I Ea Ga tT HT Kiji ill EHE II BOO9RS DC B012RS DC BO15RS DC BO16RT DC BO19RT DC DUAL CYCLE REFRIGERATED COOLING COMPONENT Table of Contents GENEA a 4 Productselection ia 4 UNIT DETAILS talon 5 Outdoor UNIE DIMENSIONS sirrien a ne 5 Outdoor Unit Access and 6 Igea 7 MAOO COMIC SAAC SS ee ee 8 UNITINSTALLATION Z u i k uuu u nee ne aqasha oa qaku asss 9 NAO Gala 9 OO 9 Platon anne In a babi 10 a 10 EGG DEC 10 Oil oor 11 Condenser installalo a a een 12 Nterconnectnd TUDING en ol ae 12 an ON NDS 13 Intercohneeling TUDING Table 2 00 u uni ee 13 Recommendation for Interconnection Tubing Installation
6. INDOOR Outdoor Unit TRANSFORMER T CT12IF Kr x l L 24 COOLING SIGNAL INPUT I FROM THE DUAL CYCLE CONTROL RELAY SUPPLIED WITH THE CENTRAL HEATING UNIT NO lv A3SNLON 1504330 HOLIMS HOLIMS dH YALVAH dNNS YOLSINYAHL dOLSINY3HL AIRON DEFROST 7 JAILDV LNVYLSNOD SNINYVM V REVERSING VALVE OUTDOORFAN WHITE I FTEDTO i COMPRESSOR I B015RS E CAPACITOR MODELONLY 1 i l I E pol j EARTH 6602202 A Installation Instructions Page 20 DUAL CYCLE REFRIGERATED COOLING COMPONENT WIRING DIAGRAM 3 PHASE OUTDOOR UNIT I 24 VAC COOLING SIGNAL INPUT FROM THE DUAL CYCLE CONTROL RELAY SUPPLIED WITH THE CENTRAL HEATING UNIT I JOLSING3HL 3O1SIW33H1 AIRON DEFROST MAINS SUPPLY L2 415 L3 3 PHASE Installation Instructions Dual Cycle Connection COMMUNICATION LOOM TO INDOOR UNIT Outdoor Unit TRANSFORMER e P C B 1 L oO CT12IF gt z SUMP WARNING Hs COMP e DO NOT USE il RELAY I WITH 3 BOARD _ ke 8 SUMP FAN O 2 Dn e ee AY i E m 2 2 H LIMS di Be HOLIMS dH Die REVERSING VALVE
7. Oil trap every 3m Indoor Outdoor Unit Air Indoor Coil Liquid Line Gas Line Outdoor Unit eo gt d SEZ IE 27 SYA Page 14 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation PIPE INSTALLATION y WARNING This paragraph describes the necessary steps for setting the unit into operation Be sure to follow the instructions to assure proper functioning of the air conditioner The outdoor unit is pre charged with the correct amount of refrigerant In extended runs for additional refrigerant charge please refer to the outdoor unit name plate This process shall be performed only by qualified refrigeration technicians with a professional charging set Flare Preparation a Cut the tube using a tube cutter Make sure that the cut is perpendicular to the tube axis Ensure the pipe is de burred and free of metal shavings b Slip the flare nut over the tube secure the tube in the flaring tool and perform the flare on the tube end The tube projection length A from the flaring block varies with tube diameter and shall be set as indicated in the table c Apply few drops of refrigeration oil to the tube before flaring Flare Depth A TUBE OD 25mm 06 Z Y Penn 2 Flaring Too Pipe Welding Preparation The indoor outdoor unit final connections are made using flared couplings Where welded joints are required the following are the require
8. a minimum If bends are necessary perform them only by using professional tube benders and not manually Sheet Metal Hanger 4 Make sure that tubing is insulated on its entire length including tube end and quick connectors or flare nuts to avoid tube sweating and water dripping from it 5 Tubing shall be of refrigerant grade without any damage Tube inside walls must be kept absolutely clean prior to and during installation operations Insulated Gas Line INSULATION OF THE GAS LINE 6 The Gas line shall be individually insulated with a minimum 9mm 3 8 thick closed cell pipe insulation 7 For diameters length of liquid and gas lines and height difference see the table below for each model Ifthe liquid or gas tube diameters differs from the corresponding flare connector diameter mounted on the unit use a suitable reducing union for this purpose NOTE it is not a requirement to insulate the liquid line unless it is exposed to direct sun or extreme ambient temperatures Unit Interconnecting Tubing Table UNIT CONNECTING TUBING LENGTH UP TO METRES ONE rm MAXIMUM MAXIMUM MODEL LINE TUBING HEIGHT BOO9RS Gas 19 05MM 3 19 05MM 05MM 3 23mm 7 Liquid 9 58mm 9 58mm a 9 58mm 9 58mm BO12RS Gas 19 05MM 3 19 05MM 22 23mm 7 22 23mm 7 Liquid 9 58mm 9 58mm oe 9 58mm 9 58mm BO16RT Gas 19 05MM 3 22 23mm 7 22 23mm 7 22 23mm 7 Liquid 9 58mm 9 58mm 9 58
9. back and the side minimum clearances must be achieved When all the sides are blocked If all sides are blocked this will be an unacceptable installation 6 DUAL CYCLE REFRIGERATED COOLING COMPONENT BONAIRE N O 0 2 0 INDOOR DIMENSIONS SIDE Unit Dimensions Page 7 Installation Instructions DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation BONAIRE INDOOR MD 0 1279 Air On Coil Liquid Line Gas Line Condensate Drain Coil Location The indoor coil is designed for installation i conjunction with a duct gas central heater within a ceiling roof space or other compartment where there is no influence from outdoor conditions While selecting the location the following conditions must be assured a The location should assure free flow of the return air into the central heater without interference b The unit should not be installed close to Ducted Gas Heater rooms where noise should be avoided bedrooms children rooms etc Ducted Gas Heater Platform Transition duct air on SA es c Consider air distribution from the unit to Suspended hanging option the rooms and select a suitable location indoor fan coil for even air flow Indoor Coil d Avoid obstacles which may restrict the return air intake or the discharge supply air flo
10. ach of them the necessary wiring diagram is shown Connect the unit to the main power supply as per its applicable wiring diagram Use supply wire sizes as per local electrical codes and regulations OUTDOOR UNIT CONNECTIONS Mains Installation Control Rotation 1 Install a dedicated circuit from the mains switch Board LED board Circuit breaker requirements as per table below Fan Capacitors 2 Connect the mains cables to the incoming connection block on the outdoor unit Use supply wire sizes as per local electrical Penal codes and regulations Dual Cycle 24V In Connection Conn Recommended Full Load Recommended Circuit Breaker Amps Cable Size BOO9RS 32A 4 0mm BO12RS Contactor nnection 3 Phase Units Cable Anchor UA ALI HS PLEASE NOTE Circuit breaker and cable sizes are subject to cable run length refer AS 3000 wiring rules 3 Connect 1 0mm twin active cable between the ducted gas central heater and the outdoor unit ann ns sn This is for 24Volt switched voltage from the gas Sn central heater to activate the refrigerative system See wiring diagrams on the next pages for outdoor unit connections and the central heater instructions for the heater control connections Installation Instructions Page 19 DUAL CYCLE REFRIGERATED COOLING COMPONENT BONAIRE WIRING DIAGRAM SINGLE PHASE OUTDOOR UNIT Dual Cycle Connection COMMUNICATION LOOM TO INDOOR UNIT
11. all units 1 Valve Protection Plug N Insert 5mm Hex Allen key to open close the Refrigerant Valve Valve Protection Cap Refrigerant Valve Service Port cap Flare Nut Valve Mounting Bracket O O Copper Tube DRAIN LINE INSTALLATION a ltis recommended to prepare a drainage point with rigid 20mm plumbing pressure PVC pipe tube by a qualified technician b The drain run must be installed with a constant minimum down slope of 2 and equipped with a trap at the indoor unit Install a P trap in the drain Use the 25mm flexible plastic coupling hose provided to connect from the indoor unit primary drain point to the P and drain pipe Secure with clamps e To check the system fill the condense tray with water and verify its free flow through the drain line Verify that no leaks are present from the drain line or unit Installation Instructions Drain Pipe Hose Clamp 1 Snap LOCK Snap Lock Hose Clamp Flexible Hose Primary Unit Coupling Drain 25mm OD 25mm ID x 100mm long U Trap Field Supplied Drain Page 18 DUAL CYCLE REFRIGERATED COOLING COMPONENT A WARNING Electrical connection shall be made only by authorized electricians and in accordance with local electrical requirements and codes The system must be grounded Single phase models and three phase models are available for e
12. ay be deemed chargeable to the Dealer Installer Flare Distributor Teflon Seal Nipple Liquid Line Valve Retaining Flare Nut Piston Assembly Piston Piston Flare Should you need to remove or check either of the pistons during i AS Fa MM installation please ensure that m they are correctly refitted as per en the following diagrams DD Outdoor Unit Ce Assembly Piston Assembly opr Installation Instructions DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation EVACUATION AND SETTING IN OPERATION a Connect two charging hoses from the charging set to the outdoor unit as shown in the diagram below b Connect the centre hose of the charging set to a vacuum pump c CAUTION turn on the vacuum pump and make sure that the low pressure gauge reading moves from 0 kPa to 100 kPa then evacuate the system for a further 10 minutes If gauge needle does not move from O kPa to 100 kPa this indicates a leak Take following measures tighten all connections if leaking stops when the tubing connections are tightened proceed from step c If leaking persists even after connections are tightened detect the leak and repair it be sure to proceed only after all leaks have been eliminated d Close the valves of both the gas and liquid sides of the charging set and turn off the vacuum pump Make sure that the gauge needle does not move for abou
13. brackets and threaded rod to the indoor unit gt could cause it to fall and inflict injury or damage Te 0 2 Leveling Coil Box 1 Adjust the level of the unit as required The drainpipe end of the unit must be lower by at least 5mm for good drainage 10 15mm Fall 2 Take care not to damage the drain tubes or 0 5mm Fall coil when lifting to adjust unit level 3 For suspension mounting units tighten the locking nuts once revised position is determined gt Drain Point Installation Instructions Page 10 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation BONAIRE OUTDOOR UNIT N SU vg 22 De u Z Control 55 iim 2 ZZ 7752 1 lt AAA d 7 LA tty SY 7 lt D 22 2222 227 OA Electrical Connection Block fo Condenser Fans A I SSS INS Anchor no Liquid Line Gas Line A Refrigeration Pipe Support Bracket Front Cover Bottom Cover Electrical and Liquid Line pipe entry Gas Pipe Connection External for 009 5 BO12RS amp BO19RT ONLY Installation Instructions Page 11 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation CONDENSER INSTALLATION Installation on flat surface roof ground etc Install outdoor unit support in a position elevated at least 100 mm on a co
14. logies specifications and using recommended standard tubing electric cables and proper installation tools Failure to comply with the above may invalidate your warranty PRODUCT SELECTION MATRIX DUAL CYCLE DUCTED GAS HEATER REFRIGERATIVE UNIT BONAIRE VULCAN PYROX Outdoor Unit Indoor Coil BV4 BV5 BOO9RS 8 9kW BOO9DC 9 0kW o 21 B012RS 12 0kW 20 120 20XA 21 XA BO15RS 14 7kW B015DC 14 9kW 30 XA 30 XA B016RT 15 8kW B016DC 15 8kW 30 XA 30 XA 30 XA 35 BO19RT 18 5kW BO19DC 18 5kW 30 XA 30 XA 35 Text and Illustration Copyright Climate Technologies 2006 All rights reserved No part of this document may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying recording or by any information storage and retrieval system without prior permission in writing from Climate Technologies In the interest of continued product improvement Climate Technologies reserves the right to alter specifications without notice E amp O E Installation Instructions Page 4 DUAL CYCLE REFRIGERATED COOLING COMPONENT Dimensions amp Clearances BONAIRE OUTDOOR UNIT DIMENSIONS C GN AA TAN I B012RS EINEN MINI Irsa ATINADA DESC ec 0 JC IT OC JC JC J ITTTITTITITHITTIRITETTIITETTIITEHTELTTITITIITITITIETIU
15. ments 1 Keep piping capped at ends when storing handling and installing 2 Use locally supplied sealed clean refrigeration grade copper piping only 3 Using a flat surface hold down the pipe at one and roll out the requirements NOTE Take care not to dent flatten or damage the pipe 4 Use only a rotating wheel pipe cutter to cut the tube 5 Use only a de burring tool to de bur the pipe ends Pipe Welding Take care when using brazing flame torch ensure that hot pipes or flame do not cause a fire 1 Use quality brazing rod suitable for copper to copper joins on refrigeration grade tubing Installation Instructions Page 15 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation 2 Before brazing wrap a wet cloth around pipes next to the indoor unit to prevent hot pipes from melting foam insulation in the unit Make sure the flame or heat from the flame does not contact the unit casing or wiring or damage will occur Heat the pipe up as per the illustration 2 Heat the outer tube 1 Heat inner side evenly resulting in tube evenly Rubber Plug good flow of filler Use nitrogen gas for flowing though piping during pipe brazing If oxygen acetylene or fluorocarbon gas is used it will cause an explosion or poisonous gas Packeless Valve 5 Use a regulator valve when nitrogen gas High Pr Hose gt flowing is performed during brazing The ae 05 m h or slower gas
16. mm 3 9 58mm BO19RT 19 05MM 4 22 23mm 28 6 1 28 6 1 9 58mm 9 58mm 9 53 Ys 9 53 Bo45RS Gas 19 05MM 3 19 05MM 3 22 23mm 7 22 23mm 7 Liquid 9 58mm 9 58mm 3 9 58mm 3 9 58mm Installation Instructions Page 13 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation BONAIRE Recommendation for Interconnection Tubing Installation Three possible versions are schematically illustrated 1 The outdoor unit installed above the indoor unit such installation requires an oil trap in the gas line at the lowest point of the riser The radius of the oil trap should be as short as possible Horizontal runs of liquid line should follow the gas line except for trap In case the insulation must be partially removed for installation purposes it is imperative that lines be fully insulated after the installation has been completed SE A IN 2 The units are installed at the same level no trap is required KO EI ES i 3 The outdoor unit is installed below the indoor unit such installation requires an inverted gas line trap to be installed at the indoor unit The top of the trap must be greater than the height of the indoor unit 1 Air 2 Outdoor Unit 3 Gas Line 4 Liquid Line 5 Indoor Coil Installation Instructions Air Liquid Line N H l Gas Line R Dx4
17. ncrete pad concrete block or wooden beams in order to allow free water flow underneath Outside the building Outdoor Unit Floor Concrete slab or equivalent Wall Anchor bolts Serrated Rubber Waffle Pad 40x80 mm LS INTERCONNECTING TUBING The tubing between the indoor and outdoor units consist of two copper tubes and an electric cable routed through a 60 mm wall opening In addition a drainage hose is installed between the indoor unit and the closest drainage point Connect both sections taking the shortest most direct route Outside wall Gas Vapor Line Liquid Line Electric Cable Inside wall Ze Incline Angle Installation Instructions Page 12 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation BONAIRE Installation Notes 1 When laying the tubing for the installation make sure that the ends are sealed to prevent penetration of dirt moisture etc To prevent dust or moisture from entering the tubes seal them with caps or masking tape It is recommended to clean the inside space of the tubes with nitrogen before connecting them to the unit 2 Whenever possible avoid passing tubes through hot zones such as walls next to ovens chimneys etc In such cases additional insulation or other means of protection should be employed 3 Tubing route shall be kept in straight lines as much as possible When installing keep the number of tube bends to
18. pressure should be maintained within 0 03 to 0 05Mpa If an excessively high educer Valve 0 03 to 0 05 Mpa pressure is used it will cause an EN 0 3 to 0 5 G when suppyling explosion Connecting the tubes 1 Connect and tighten the flare nuts to the refrigeration valves on the outdoor unit and to the male connectors of the indoor unit 2 Coat the flared surfaces lightly with refrigeration oil to improve sealing Holding Spanner N Body Side 90 Torque Wrench Flare Nut Backup 3 Two spanners of the correct size should be de used A holding spanner should be used on the back up nut and a tightening spanner Torque spanner recommended on the flare nut 4 Tighten the flare nut with the tightening spanner while ensuring the holding spanner remains securely in place Backup Nut Flare Nut Note First manually tighten the flare nuts and then use wrenches See table for Description Tube Inches torque tightening values Sizes 9 58 15 88mm 19 05mm 5 Check for leaks Use leak detect solution or soap solution for leak testing electronic leak detector is recommended Torque 40 45 70 75 80 85 IMPORTANT If the recommended tightening procedure is not followed and the fitting is subsequently damaged or the thread stripped it will NOT be covered by our manufacturer s warranty Any service calls required to repair this fault m
19. t 5 minutes e Disconnect the charging hoses from the vacuum pump and from the service ports of both the three way valves f Replace the service port and valve caps of both tree way valves and tighten them with a torque wrench see table of torque values listed on the previous page CAUTION When performing the following steps avoid any exposure to the service valve ports remember that the system is under pressure g Remove valve caps from the service valves Position both valves to open using a 5mm Hex Allen key wrench Open each valve by rotating the centre spindle in an anti clockwise direction until fully back seated h Replace valve caps of both service valves Check for gas leakage with a leak detector or soapy water Charging Set Vacuum Pump Outdoor Unit Service Port Valve Cap 3 Way Gas Valve 3 Way Liquid Valve Valve Cap EN u 9 Gas Flare Connection 10 Liquid Flare Connection 11 Indoor Coil Installation Instructions Page 17 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation ADDITIONAL CHARGE 1 Each condenser unit is supplied pre charged for 10 meters of 9 53 3 8 liquid line For additional charge add 57 grams per meter for over and above the specified system pre charged length See the unit name plate for this information DO NOT exceed the maximum equivalent pipe length on each unit 2 Service port on the liquid service valve is not supplied on
20. the owner s manual The warranty section is found in the rear of the owner s manual Installation Instructions Page 22 CLE A IA Y E TECHNOLOGIES Excelling today for a better tomorrow Manufactured by Climate Technologies ABN 13 001 418 042 26 Nylex Avenue Salisbury SA 5108 Australia www climatetechnologies com au 6602212 A
21. w Platform Option Indoor fan coil Transition duct air off E N Discharge Air Grilles e Ifinstalling the indoor coil on a platform ensure that the structure is capable of supporting the indoor unit and platform NOTE The indoor unit should not be installed outside Installation Instructions Page 9 DUAL CYCLE REFRIGERATED COOLING COMPONENT Unit Installation Coil Floor or Platform Mounting 1 Create a platform using bearers and chipboard Place the unit platform over load bearing walls or on strategically located trusses in the roof space 2 Place serrated rubber pads or isolating springs under each corner of the unit to minimize eliminate any noise transmission Coil Suspension Mounting Use the accessory kit P n 6601905 Hanging Bracket Kit For installation detailed see the instructions supplied with this accessory kit 1 Fasten the hanging brackets to the indoor coil 2 Use field supplied threaded rod to suspend the unit M10 or greater is recommended to brace the unit mounting Fix the threaded rod to a structurally sound part of the roof or concrete pad Check with local and national building codes and or a structural engineer as to the fixing of the unit or building support structure if applicable 4 Secure the indoor fan unit to the threaded rods ensuring all fasteners are secure and tight Failure to correctly secure the suspension Coil Fixing
Download Pdf Manuals
Related Search