Heatcraft IV Series Manuel utilisateur

Part No.: IM_010A

Page No.: 1of 17

EN No.: 56667

Issue: A

Date: 30/4/18

Heatcraft Subco Pty Ltd ACN 42 624 910 041

HEATCRAFT FRIDGEBOX SERIES IV HANDBOOK

For Units 2 –6 HP

THANK YOU FOR CHOOSING THE HEATCRAFT FRIDGEBOX SERIES IV CONDENSING UNIT.

TO ENSURE TROUBLE FREE INSTALLATION AND COMMISSIONING, PLEASE REFER TO THE

CONTENTS OF THIS HANDBOOK.

IMPORTANT INFORMATION -

REFER TO THE SECTIONS ON “WARNINGS AND SAFEGUARDS”, AND “INSTALLATION

INSTRUCTIONS” BEFORE ATTEMPTING TO COMMISSION THIS CONDENSING UNIT.

Heatcraft Subco Pty Ltd Document No.: IM-010A

Page No. : 2of 17

CONTENTS

End User Notes......................................................................................................................................... 3

General Notes....................................................................................................................................... 3

Auto Start-Up ....................................................................................................................................... 3

Auto Reset............................................................................................................................................ 3

Routine Maintenance of Unit ............................................................................................................. 3

Warnings and Safeguards.......................................................................................................................... 4

Important Notes.................................................................................................................................. 4

No Smoking..................................................................................................................................... 4

Warning –Electrical Hazard......................................................................................................... 4

Caution –Unit Pressurized............................................................................................................. 4

Caution –Refrigerant Type............................................................................................................ 4

Caution –Lubricant Oil Type ........................................................................................................ 4

Caution –Sharp Edges ................................................................................................................... 5

Warning –Qualified Personnel.......................................................................................................... 5

Personal Protective Equipment.......................................................................................................... 5

Caution –Lifting of Unit .................................................................................................................... 5

Caution –High and Low Temperatures ............................................................................................ 5

Caution –Deep Vacuum..................................................................................................................... 5

Caution –Motor Protection................................................................................................................ 5

Caution –Internal Pressure Relief (IPR) Valve ................................................................................ 6

Purpose.................................................................................................................................................... 6

Standard Design Conditions................................................................................................................... 7

Installation Instructions............................................................................................................................. 7

Unpacking of Unit ................................................................................................................................ 7

Installation Location ............................................................................................................................. 7

Refrigeration Piping.............................................................................................................................. 7

Electrical Connection............................................................................................................................ 8

Lubrication ........................................................................................................................................... 8

Compressor Starting.............................................................................................................................. 9

Compressor Crankcase heater ........................................................................................................... 9

Scroll Compressor Operating Sounds................................................................................................ 9

Scroll System Charging Procedure........................................................................................................ 9

Internal Pressure Relief Valves (IPR valves)..................................................................................... 9

ZB Scroll Compressor Functional Check ........................................................................................ 10

System Holding Charge ...................................................................................................................... 10

Pressure Settings................................................................................................................................. 10

General Commissioning & Decommissioning Guide .............................................................................. 12

Warning –Commissioning............................................................................................................... 12

Warning –Decommissioning.............................................................................................................. 13

Material Safety Data Sheets –M.S.D.S............................................................................................ 13

Important Notes................................................................................................................................ 13

General Arrangement Drawing ............................................................................................................. 14

WIRING SCHEMATIC DIAGRAMS.................................................................................................... 15

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End User Notes

General Notes

Heatcraft FRIDGEBOX SERIES IV condensing units fall under the requirements for commercial

electrical equipment as per Standards Heatcraft guidelines. Installation and major service of this

unit must be carried out by a licensed contractor and in accordance with local regulatory guidelines.

Under no circumstances should anyone other than a qualified person attempt to gain

access to the interior of the unit without first ensuring electric power is disconnected.

FRIDGEBOX SERIES IV condensing units have been designed for use in an outdoor or indoor

environment. HTS condensing units are not suitable for mobile and explosion-proof applications.

Auto Start-Up

FRIDGEBOX SERIES IV condensing units may start automatically without any warning. Please

see “Installation Instructions” for further details.

Auto Reset

Kirby Fridgebox condensing unit fans and compressors are thermally protected. When tripped,

these components will not operate. Once sufficiently cooled however, the component will

automatically reset and may operate without warning.

The unit is equipped with a High/Low pressure switch as standard. The switch is either a universal

selectable auto or manual reset or fixed auto/auto-reset type on both high and low sides. If

universal switch used then it is set to auto/auto at the factory. Please check the unit regarding the

appropriate pressure switch.

Routine Maintenance of Unit

Condenser:

The Fridgebox Series IV utilises an all-aluminium microchannel condenser coil that is flexibly

mounted to the adjoining sheetmetal at the non-header end. The mounts should be periodically

checked for condition and freedom of movement.

The Condenser should be cleaned at 3 monthly intervals using low pressure water spray.

For repair of microchannel coils, please refer to your local Heatcraft representative.

System operation:

System operation should be checked every 6 months. Checks should include:

Operating conditions such as condensing and evaporating temperatures, compressor

discharge temperature, superheat and sub-cooling, etc.

Refrigerant charge, oil level and quality

Electrical connections, current draw and voltage level, etc.

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Warnings and Safeguards

Heatcraft is very conscious of safety issues when designing and manufacturing these products, but it is

essential that the end user, installer or service personnel also exercises care when working with the units.

Important Notes

Do NOT remove access panels without isolating power.

Do NOT operate unit with access panels removed due to the presence

of rotating equipment.

Do NOT operate unit with access panels removed as there will be no

air flow over the condenser.

All controls are 230/240V.

No Smoking

Heatcraft recommends No Smoking within a distance of 15 metres of the unit.

Warning –Electrical Hazard

A qualified Electrician must carry out all electrical work. All field wiring must conform to the

requirements of the equipment and all applicable National and Local Codes.

Always isolate the power to the unit before checking and / or diagnosing the units. Never work on

any electrical item without isolating or disconnecting the power supply.

Caution –Unit Pressurized

All units are pressurised with dry air or Nitrogen gas. Care must be taken to discharge the

pressurized gas prior to installing or commissioning the equipment.

Caution –Refrigerant Type

All units are designed to work effectively with fluorocarbon refrigerants including R404A and

R134a. Under no circumstances can a refrigerant such as R410A, Ammonia, Hydrocarbon, Water

or Glycol be used in this product.

Refrigerant can be harmful if it is inhaled and/or makes contact with exposed skin.

Refrigerant must be used and recovered responsibly. Extreme care must be taken when

handling refrigerant, as personnel injury or death may occur.

Caution –Lubricant Oil Type

All compressors are charged with PolyolEster (POE) oil. POE can be used with HCFC refrigerants,

such as R22, and HFC refrigerants, such as R404A, R507, R407C and R134a. Use ONLY POE oil,

do NOT mix POE with other oils, when using HFC refrigerants.

Caution –Sharp Edges

Warning

This indicates contents for which, if disregarded, the possibility of human death or

severe injury can be assumed.

Caution

This indicates contents for which, if disregarded, the possibility of human injury or

the possibility of material damage can be assumed.

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All units are manufactured with sheet metal and in this process all care is taken to ensure the edges

are concealed. Avoid contact with sheet-metal edges and the coil fins. They can be sharp and are a

potential personal injury hazard. Please take care when accessing in or around the unit.

Warning –Qualified Personnel

All units may only be installed, commissioned, decommissioned and serviced by qualified and

trained personnel (refrigeration mechanics and/or electricians) who have sufficient knowledge in

this type of equipment. It is the purchaser’s responsibility to co-ordinate with qualified personnel

as required.

Personal Protective Equipment

Heatcraft recommends as a secondary safety precaution that all personnel working with the unit

wear appropriate Personal Protective Equipment (PPE) such as gloves, eyewear and footwear.

Caution –Lifting of Unit

The compressor end of the unit is to the left looking from the front (fan discharge) side. Forks

should be placed toward the left hand mounting foot when lifting. Slings can be placed through

the mounting feet but care must be taken to adjust the lengths appropriately to account for the

weight distribution.

UNIT APPROX.WEIGHT

MODEL UNPACKED PACKED

FBH043MHZ1-2 84 99

FBH051MHZ1-2 86 101

FBH066MHZ1-2 83 103

FBH075MHZ1-2 84 104

FBH086MHZ1-2 93 113

FBH103MHZ1-2 94 114

FBH116MHZ1-2 96 116

Always take care to ensure a proper weight balance before lifting and moving unit.

Caution –High and Low Temperatures

Compressor housing and discharge line temperatures may reach 150°C due to failure of system

components. Wiring and other materials which could be damaged by these temperatures should not

come into contact with the housing or discharge line.

Moreover, even in normal working operation, the unit can generate very high (may exceed 100°C)

and very low (below -40°C) temperatures on compressor housing and tubing surfaces resulting in

the possibilities of severe contact burns. Special caution must be taken when working around the

unit.

Caution –Deep Vacuum

Do NOT operate compressors in deep vacuum conditions as this can cause electrical failure.

Compressors should never be used to evacuate refrigeration or air conditioning systems.

Caution –Motor Protection

WARNING: Do not insert any object into operating fans. Ignoring this warning may result

in personal injury and/or severe equipment damage and consequences.

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Copeland ZB/ZF hermetic scroll compressors, and the fan motors fitted to these units, are fitted

with inbuilt motor protection. The protection may be internal line break, or externally connected

control break type. After opening, the protector may not reset for several hours until the motor

cools sufficiently. Do not assume that the motor has suffered an open circuit failure without first

allowing it to cool.

Scroll compressors can only run in one direction. Refer to Installation and Commissioning

Instructions for details of how to identify if the compressor is running correctly.

In addition to the above, thermal over-current protection is fitted to the compressor contactor(s),

and MP15 phase failure protection is provided as a standard configuration.

The MP15 start delay function has been utilised as follows-

HP/LP alarm to pin 5- delay with memory function and light

Compressor contactor K1 Thermal Overload N/O 97-98 to pin 8 (start delay without

memory or light).

Compressor restart will be delayed by 15 minutes when activated by these 2 fault conditions.

Restarting the MP15 (toggle Circuit Breaker CB1 Off/On) will re-initialize the MP15 timer.

Please refer to your Heatcraft sales representative for details.

Caution –Internal Pressure Relief (IPR) Valve

ZB/ZF scroll compressors include an IPR valve. The IPR valve will open when the discharge

pressure exceeds the suction pressure by a certain value, which is set by the compressor

manufacturer. When it has opened, the compressor sump will become warm and the compressor

will trip out on the motor protector. The unit may take 2 to 3 hours to reset and restart

automatically if this happens.

Do NOT assume that a compressor that is running, but not pumping, is faulty.

Stop the compressor and allow the pressures to balance, and then start the compressor again.

Caution –ASTP compressor temperature protection

ZB scroll compressors may be equipped with an ASTP device which is designed to prevent

overheating of the scroll components, by opening a valve which bypasses discharge gas to the

suction side and heating the compressor thermal protection device which switches the compressor

off. This may take some time and the compressor will appear to not be pumping, and making a

hissing noise. The compressor will restart once the thermal protection device cools sufficiently.

The fitment of the device will be noted on the compressor itself.

Purpose

FRIDGEBOX SERIES IV condensing units are standard OEM products of Heatcraft including

high, medium (ZB) and low (ZF) temperature application ranges. They are designed for

continuously supplying and receiving the refrigerant to and from the evaporator(s), and rejecting

the heat extracted from the cold space to the surrounding atmosphere where the units are installed.

FRIDGEBOX SERIES IV condensing units are intended for installing in a typical ventilated

indoor or outdoor environment (Refer to the General Arrangement Drawing section for details)

with the condensing temperature no greater than 60°C and compressor return vapour temperature

no greater than 20°C.

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They are not intended for environments that may have harmful, corrosive or flammable

atmospheres. Marine environments are considered corrosive; please consult Heatcraft before

installing in this environment.

Standard Design Conditions

MAXIMUM ALLOWABLE PRESSURES (PS, PSS)

Maximum allowable pressure (PS, PSS) is based on the design pressure or maximum allowable

pressure of the lowest rated component in the system.

MAXIMUM AMBIENT

Maximum ambient condition is based on calculated maximum condensing pressure for various

permitted refrigerants. Calculations have been verified by testing sample units of each unit range

UNIT DATA

PS PSS Refrig

FRIDGEBOX kPAg kPag

43°C 2880 2100

A1:

R404A/

R134a

AS/NZS5149.2 INFORMATION.

MAX AMB

STD- ZB COMPRESSORS

Medium temperature range condensing units are typically designed, for primary refrigerant

R404A, to be used in commercial cool room applications ranging from -15°C to +10°C saturated

suction temperature for ZB compressors. R404A and R22 are recommended refrigerants.

For R134a usage, please refer to other sections of this booklet for control setting information etc.

For special design requirements (non standard conditions and/or refrigerants), please inquire with your local

representatives and/or Heatcraft local branches, or call our national telephone number 13 23 50 for your

nearest available information resources.

Installation Instructions

Unpacking of Unit

When unpacking, check for any damage to packing material or the unit itself which may affect the

unit’s performance. If any such damage is evident, please contact your local Heatcraft branch.

Installation Location (Refer to the General Arrangement Drawing section)

If the unit is to be located in close proximity to a wall or similar obstruction, the minimum distance

from the coil face to the obstruction shall comply with the general arrangement drawing. The unit

shall be mounted on a horizontal plane surface.

The liquid sight glass is located inside the left hand side compartment (looking from the front).

Allow sufficient space around the access panels for opening the panels.

Connection of gauges can be achieved from the compressor compartment of the unit, refer to the

section on pressure settings for more detail.

It is particularly important for the units to allow sufficient unobstructed air-discharge space

in front of the unit to prevent warm air recirculation to the condenser.

Refrigeration Piping

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Refrigeration piping work shall be carried out professionally by qualified refrigeration

mechanics in accordance with applicable national and local regulations and in conformance

with good engineering practices required for the proper operation of the refrigeration

system.

All FRIDGEBOX SERIES IV condensing units manufactured by Heatcraft are supplied clean and

internally charged with dry air or nitrogen to prevent oxidation and ingress of moisture or foreign

matter. Care shall be taken during installation of the piping to prevent entrance of foreign matter or

moisture by minimising the time that the piping is uncapped.

The interconnecting refrigeration pipe size is not necessarily the same size as the outlet on the unit.

The pipe sizes shall be selected / calculated based on the best compromise of minimizing

refrigerant pressure drop and refrigerant velocity to ensure efficient oil return. Heatcraft can

provide a software program to assist in the calculation of pipe sizes.

Horizontal suction lines shall slope towards to the units to allow the oil return freely to the

compressor by gravity. A 1:100 slope is considered sufficient. The use of oil trap and double risers

may be necessary on vertical sections. Suction line piping shall be insulated to minimise the

superheat effect to the vapour.

If in doubt during the installation, please consult with your local sales representatives and/or

application engineers from Heatcraft for technical support.

Electrical Connection All electrical connections must be carried out by a licensed

electrical contractor and in accordance with the relevant

regulations.

Both the mains supply and the control cabling must be brought into the electrical section from the

side of the unit. The cables should be passed though the glands provided before being run to the

terminals (Refer to Wiring Schematic inside electrical box cover). Refer to the name plate for all

the information regarding voltage and current for the unit.

Mains supply cabling must be in accordance with relevant standards and / or codes, Control circuit

is 240 volts. Terminals are supplied for connection of control circuit (Refer to Wiring Schematic

inside electrical box cover).

Warning –Electrical Hazard

Only qualified personnel should attempt to bypass the interlock. Caution must be exercised

when working on the unit if the interlock is bypassed.

Lubrication

FRIDGEBOX SERIES IV Copeland Hermetic ZB Scroll compressors use polyolester oil. In the

field if the original manufacturers specification oil is not available, the oil level could be topped up

with ICI Emkarate RL 32. The oil charge must be checked before commissioning (see below).

Check the oil level again after a minimum of 10min operation at nominal conditions. This

operation should be repeated at least twice to make sure the proper oil level has been achieved.

OIL LEVELS:

Copeland ZB & ZF Scroll Compressors: The oil level should be maintained at 1/2 of the oil

sight glass.

Caution - Notes on POE Oils

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Use only POE oil with HFC refrigerants. Do NOT mix POE oil with other oils when using

HFC refrigerants (eg R404A).

Compressor Starting

DOL START

All compressors are 380-420V 3Ph 50Hz STAR connected motors for Direct-On-Line starting.

Care should be taken to establish starting requirements for the larger compressors due to high in-

rush current.

Maximum compressor starts per hour

Scroll compressors = 10

Compressor Crankcase heater

The crankcase heater is mounted below the oil removal valve located on the bottom shell. The

crankcase heater remains energised during compressor off cycles.

Scroll Compressor Operating Sounds

Start Up - Normal

During the very brief start-up, a short metallic sound may be audible.

Start Up - Incorrect Wiring

Because scroll compressors are directionally dependant, 3 phase compressors must be wired to

rotate in the correct direction. Correct rotation can be verified by observing that a drop in suction

pressure and a rise in discharge pressure occurs. Also, reverse rotation results in a sound level

higher than that produced when rotation is correct.

Note that no damage will be caused by operating scroll compressors in the reverse direction, and

after several minutes of operation, the compressor’s internal protector will trip.

The rotation direction can be reversed by swapping any two of the phase connections.

Shut Off

During shut off, a brief audible sound may occur.

Scroll System Charging Procedure

Avoid rapid charging from the suction side as this can cause a temporary no-start condition due to

scroll component characteristics. The best method for initial charging is to simultaneously charge

from both high and low sides (Please refer to Commissioning Section for more details).

Should a scroll compressor fail to start and the above condition is suspected, reverse any two of the

3 phase leads and momentarily power the compressor (1-2 seconds) in the reverse direction.

Internal Pressure Relief Valves (IPR valves)

All FRIDGEBOX SERIES IV compressors are fitted with IPR valves with a discharge to suction

differential of 26~31bar.

ASTP temperature protection.

ZB scoll compressros may be fitted with ASTP over-temperature protection. The compressor may

run for a short period of time but will not pump refrigerant once the protector has been triggered.

The compressor will stop on the motor thermal overload device. The fitment of the device will be

noted on the compressor itself.

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Scroll Compressor Functional Check

Since scroll compressors do not have internal dynamic suction or discharge valves, it is not

necessary to perform valve plate efficiency tests, ie running the compressor with the suction

service valve closed. This type of test may damage a scroll compressor.

System Holding Charge

The system as supplied is pressurised at the factory with Dry Air or Nitrogen gas.

If the system is not pressurised on delivery, please contact your Heatcraft branch. Care must

be taken to release the pressure before attempting to gain access to any part of the

refrigeration system.

The unit should be evacuated to a pressure of 500 microns (mHg) prior to commissioning.

Pressure Settings

PRESSURE RELIEF VALVES (Where required)

High Side- Pressure relief valves must be selected based on the system PS. The maximum

allowable pressure of the pressure vessel may not determine the PRV setting if it is not the

lowest rated system component. Please note the condensing unit may NOT be the lowest

rated component in the system.

Low Side (where applicable)- Pressure relief valves must be selected based on system PSS.

Please note that the low side of the condensing unit may NOT be lowest rated component in

the system.

HP CONTROL SETTING

Compressor HP (where fitted)- Setpoint must be equal to or less than 90% of the compressor

PS.

Unit HP- Setpoint must be equal to or less than 90% of the PRV setting (where fitted), or less

than or equal to Unit PS if no PRV fitted.

Please note this setting may not be adequate to protect other parts of the system with a lower

PS rating. If required the Unit HP may be set to less than or equal to the sysetm HP.

Note when setting the HP control- Consideration must also be given to the type of refrigerant

used and the maximum ambient temperature to ensure compliance with AS/NZS5149.2 and

avoiding nuisance tripping.

Heatcraft also recommends the LP switch to be used as a safety protection device. Depending on

the application and compressor, LP cut-in and differential points should be set with the following

considerations:

Set the cut-out points at 3–5 K below the respective minimum design saturated suction

temperatures (Refer to the Standard Design Conditions section for saturated suction

temperature ranges).

Set the differential to no more than 2 Bar.

The cut-out pressure shall be in the positive pressure region.

When the unit is installed in a cold ambient, the cut-out pressure shall be lower than the

pressure corresponding to the ambient temperature.

Access points for gauges are located on post valves in the compressor compartment. They

can be accessed from the compressor compartment access panel.

Fan Speed Control

A fan speed controller is fitted as a standard item to all Fridgebox condensing units from 2 –7 hp.

The factory setting is suitable for R404A on medium temperature applications. For other

applications and other refrigerants, please refer to the setting instructions below.

Units are installed with direct mount pressure actuated condenser fan speed controller as follows.

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