Page 1
0412118S
E
Eaattoonn--
W
Wiilllliiaa
m
mss
L
Lttdd
INSTALLATION MANUAL
ICUS CONDENSING UNIT
IF SUPPLIED AS A SYSTEM (ICC, QLC)
PLEASE REFER TO INDOOR UNIT INSTALLATION MANUAL
Eaton-Williams Ltd
Oldfields Business Park, Birrell Street, Fenton, ST4 3ES
Tel: +44 (0)1782 597124 Fax +44(0)1782 316633
www.eaton-williams.com
Page 2
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
CONTENTS
Page
1.
Installation & Safety
3
1.1
Installation
3
1.2
Handling
3
1.3
Application
3
1.4
Electrical connection
3
1.5
Warranty
3
1.6
Safety Procedures
3
2.
Introduction to Units
4
2.1
ICUS Outdoor Unit
4
2.2
Sizes & Weights
4
3.
Location & Mounting of Outdoor Unit
5
3.1
Location
5
3.2
Fixing
5
3.3
Service Connection
5
3.4
Air Entry
5
4.
Outdoor Unit Access
6
4.1
Access Details / Fixings
6
5.
General Service Connection
7
6.
Power & Control Connections
8
6.1
Wiring up the unit
9
6.2
Wiring Requirements
9
6.3
Terminations
9
6.4
Wiring Diagrams
9
7.
Refrigerant Pipe Connections
10
7.1
Expansion Device
11
7.2
Pipe Installation
10
7.3
Unit Connections
10
7.4
Insulation
10
7.5
Recommended Line Sizes
11
7.6
Example of Line Sizes
12
8.
Refrigeration Commissioning
13
8.1
Evacuation, Charging & Refrigerant Procedures
13
9.
Disposal Procedures
16
10.
Final Checks
17
Wiring Diagrams
18
C E Certificate
19
Page 3
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
1. INSTALLATION & SAFETY
1.1 Installation
The units making up the Air Conditioning System must only be installed by a qualified engineer,
following the mandatory and local codes of practice.
1.2 Handling
Care must be taken when the units are moved or lifted to ensure that everyone and everything is
safe. When lifting equipment is used, it must be suitable and approved.
1.3 Application
Ensure that the unit is only used for suitable purpose/application.
1.4 Electrical connection
Electrical work and connections must only be made by authorised electricians, in accordance with
mandatory regulations and local codes of practice.
1.5 Warranty
Failure to comply with the manufacturer’s installation instructions could affect the performance of the
unit and invalidate the warranty. Warranty is also subject to the implementation of a planned
service/maintenance agreement as documented in the warranty booklet supplied with the unit.
1.6 Safety Procedure
General
1. All works must be carried out in accordance with the manufacturer’s installation and operating
procedures.
2. Good working practices must be followed at all times so that Mechanical and Electrical hazards are
kept to a minimum.
3. The equipment has been fitted with doors and covers to prevent access during operation. These
must be kept in place and additional guards fitted, if necessary.
4. The equipment must be connected to an external electrical isolator if one is not supplied fitted to
the unit.
5. Servicing and maintenance must only be carried out by fully qualified and competent staff. Before
any work is started, electrically isolate the units to make sure that they cannot be switched on
accidentally and allow sufficient time for isolated parts to come to rest before removing panels.
Electrical isolation switches must be labelled to show that they are OFF during servicing and
maintenance operations.
Note: Some units are dormant in standby mode and can restart without warning if they are not
electrically isolated.
6. Care must be taken not to touch components or pipework which may be extremely hot or cold, for
a period after the unit is electrically isolated.
7. After completing any tasks ensure all guards, covers and doors are correctly refitted before
restoring the power supply to the unit.
8. Air conditioning equipment may generate unacceptable noise levels. If noise levels are
unacceptable sound and vibration attenuators may be required. For noise level guidance refer to
technical literature, or contact the supplier for advice.
SPECIAL NOTE
IF ANYTHING IS NOT CLEAR, PLEASE CONTACT YOUR LOCAL SUPPLIER FOR CLARIFICATION.
Page 4
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
2. INTRODUCTION TO UNITS
2.1 ICUS Outdoor Unit
The ICUS unit is a floor-standing condensing unit which can also be wall mounted using the ICUS Wall
Bracket Option Kit. The unit is supplied complete with axial fan and guard, hermetic compressor,
shut-off service valves, fan speed controller, low pressure switch, high pressure switch, winter start
timer and an electrical section.
FIGURE 2.1
2.2 ICUS Sizes & Weights
ICUS30
ICUS40
ICUS55
ICUS80
Width mm
720
720
800
800
Height mm
610
610
765
765
Depth mm
250
250
320
320
Weight kg
40
40
60
61
ICC INDOOR UNIT
ICUS OUTDOOR UNIT
Page 5
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
3. LOCATION & MOUNTING OF OUTDOOR UNIT (ICUS)
3.1 Location
The unit can either be mounted on a level surface or suspended from a vertical wall using the wall
mounting Optional kit (1) . The unit should always be mounted on a load bearing wall and not a
partition wall. Ensure there is sufficient free area around the unit as detailed in Figure 3.2.
3.2 Fixing
Two-off hole fixings (2) and two-off slot fixings (3) suitable for M10 fixings are provided in the base of
the unit to secure the unit to a suitable plinth, or to the wall mount bracket kit. If required, the
contractor should install the unit on anti-vibration pads.
3.3 Service Connections
The refrigerant pipe (4) and electrical connections (5) are located at the right hand end of the unit.
3.4 Air Entry
Ensure there is adequate air entry at the back of the unit as detailed in Figure 3.2 above.
SPECIAL NOTE
ENSURE CONDENSER HAS ADEQUATE CLEARANCE AROUND IT AND IS NOT AFFECTED BY
NEIGHBOURING CONDENSING UNITS AND OTHER OBSTRUCTIONS.
Figure 3.3 – ICUS Wall Bracket
Figure 3.1 ICUS Unit Positioning
Figure 3.2 ICUS Unit Fixing
ICUS30
ICUS40
ICUS55
ICUS80
Dim ‘y’mm
240
240
310
310
Dim ‘z’mm
570
570
620
620
Page 6
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
4. OUTDOOR UNIT ACCESS (ICUS)
Figure 4.1 – Unit Internal Access
4.1 Access Details/Fixings
Item No.
Unit Component
Access Details/Fixings
(1)
Fan guard
Front access set screw fixings
(2)
Fan/motor ((fixed to rear of fan guard)
Front access set screw fixings on guard
(3)
Condenser coil
Access from rear of unit
(4)
Compressor
Remove “service access panel”
(5)
Removable top panel
Front and side access screw fixings
(6)
Service access panel
Front access screw fixings
(7)
Reversing valve (Heat pump unit only) HP & LP
cut-outs.
Remove “service access panel”
(8)
Electrics/customers connection
Remove “service access panel”
(9)
Unit wiring diagram
Remove “service access panel”
SPECIAL NOTES
CHECK THAT INDOOR UNIT IS CORRECTLY MATCHED TO THE OUTDOOR UNIT. ALL PIPEWORK,
INSULATION AND ELECTRICAL CABLING IS TO BE SUPPLIED BY OTHERS.
UNIT WIRING DIAGRAM IS FIXED TO INSIDE OF FRONT ACCESS PANEL (6),
HP SWITCH IS LOCATED ON THE COMPRESSOR DISCHARGE; LP SWITCH ON THE COMPRESSOR
SUCTION CONNECTION.
Page 7
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S
5. GENERAL SERVICE CONNECTIONS
Figure 5.1 – Unit Connections and Interconnections
SPECIAL NOTES
CHECK LOCAL REGULATION FOR INDOOR / OUTDOOR ELECTRICAL ISOLATION REQUIREMENTS AND
REFRIGERATION PIPEWORK STANDARDS.
System Charge Weights
ICUS30
ICUS40
ICUS55
ICUS80
Base Charge
1050g
1500g
2000g
2300g
Top up charge/m > 5m
25g
25g
40g
40g
Refrigerant Connection Sizes – Refer to Section 8 for Extended Pipework
ICUS30
ICUS40
ICUS55
ICUS80
Liquid 7.1
1/4"
1/4"
3/8"
3/8”
Suction 7.2
5/8”
5/8”
5/8”
3/4”
Mains Power Cable – No of Cores
ICUS30
ICUS40
ICUS55
ICUS80
Single Phase System
3 3 3
3
Three Phase System
N/A
N/A
N/A
N/A
ICUS 1 Phase Fuse Rating
ICUS30
ICUS40
ICUS55
ICUS80
Run Current(A)
2
6.6
10.6
16.1
Locked Rotor Current (A)
28
28
53
82
HRC Fuse Rating (A)
10
10
16
20
7.1 – Liquid Connections
7.2 – Suction Connections
7.4 - Condensing Unit
7.5 – Interconnecting Cable
7.7 – Power Cable
7.8 – Isolator / Fuses
Page 8
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 8
6. POWER & CONTROL CONNECTIONS
ICUS SINGLE PHASE COOLING ONLY
ICUS Terminal
Customer Connections
PE
Customer Earth Connection
E
N
Customer Neutral Connection
L
Customer Live Connection
C
Cooling Signal (From Indoor Unit)
S
Fan switch link terminal
Table 6.1 – Electrical Connection Details
Page 9
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 9
6. POWER & CONTROL CONNECTIONS Cont
6.1 Wiring-up the Unit
Electrical terminations should be made onto the screw terminal side of the outdoor unit terminal blocks.
6.2 Wiring Requirements
Power supply – Connection of isolation power supply to the outdoor unit.
Interconnecting Wiring – Power and signal cables run between outdoor and indoor unit.
Details of the fuse ratings and cable requirements are given in the tables in Section 5 Page 7,
of this manual.
6.3 Terminations
Details of cable terminations and interconnections are given in Table 6.1.
6.4 Wiring Diagrams
These are fitted to the inside of the access door.
SPECIAL NOTES :
REFER TO KIT INSTRUCTIONS FOR ELECTRICAL CONNECTION OF SITE OPTION KITS!!
DO NOT MEGGER OR FLASH TEST WITH ELECTRONIC PCB’S IN CIRCUIT!!
INDOOR AND OUTDOOR UNITS SHOULD HAVE LOCAL ELECTRICAL ISOLATORS.
Page 10
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 10
7. REFRIGERANT PIPE CONNECTIONS
Figure 7.1 – Refrigerant Pipe Connections
7.1 Expansion Device
ICUS Cooling Only Units DO NOT HAVE an expansion device as this is supplied with the indoor unit.
7.2 Pipe Installation
Run the suction and liquid lines in appropriately sized refrigeration copper tubing, using the detailed
tables on pages 11 & 12 of this manual as a guide. When calculating the effective run take into account
any bends or oil traps as described in table 7.1 on page 12.
A filter drier and site glass should be fitted in the liquid line.
Where the vertical separation exceeds 3 metres, oil traps must be fitted at half the vertical distance as
shown on Figure 7.1 above. Ensure the refrigerant lines are adequately supported using refrigerant pipe
clips
7.3 Unit Connections
The ICUS unit connections are terminated in male flare connections as detailed in the tables in Section 5,
page 7, of this manual. Place flare nuts onto the copper tube before preparing the tube with a flaring
tool (7.1C). When connecting to the male flares ensure both surfaces are clean and coat the flared
surface with refrigerant oil to help ensure a leak-free joint. When tightening the joint use two spanners
to prevent twisting of the connections as detailed in figure 7.1B above.
7.4 Insulation
Suction lines must be insulated to a minimum thickness of 3/8”. Hot areas should be avoided when
routing liquid lines and consideration should be given to separate insulation of liquid lines, where
required, to prevent heat absorption.
SPECIAL NOTE
SLEEVE, SEAL AND WATERPROOF ANY BUILDER WORKS HOLES!
IT IS RECOMMENDED THAT A FILTER / DRIER IS FITTED IN THE REFRIGERATION CIRCUIT.
7.1B
7.1C
Page 11
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 11
7.5 ICUS – RECOMMENDED LINE SIZES
R407 Cooling Units
Horizontal or Downflow application (Suction Line)
Upflow application (Suction Line)
Based on 5psi (0.35bar) Pressure drop
Max
Max R407c – kg
Table A
5
10
15
20
25
30
Table B
Size
Lift
Additional Oil
Additional Charge
ICUS30
Suction
3/8”
½”
½”
½”
½”
5/8”
Suction
3/8”
5
None
>5m = 25g/m (¼” Liquid)
Liquid
¼”
¼”
¼”
¼”
¼”
¼”
ICUS40
Suction
½”
½”
½”
5/8”
5/8”
5/8”
Suction
½”
8
None
>5m = 25g/m (¼” Liquid)
Liquid
¼”
¼”
¼”
¼”
¼”
¼”
ICUS55
Suction
½”
5/8”
5/8”
5/8”
5/8”
¾” Suction
½”
10
None
>5m = 40g/m (3/8” Liquid)
Liquid
3/8”
3/8”
3/8”
3/8”
3/8”
3/8”
>30m = 105g/m (1/2” liquid)
ICUS80
Suction
5/8”
5/8”
¾”
¾”
¾”
¾” Suction
¾”
10
None
>5m = 40g/m (3/8” Liquid)
Liquid
3/8”
3/8”
3/8”
3/8”
½”
½” >30m = 105g/m (1/2” liquid)
Note:
a) Maximum pipe run stated in Table A, must include the reduction allowance (equivalent length) for vertical lifts and fittings indicated in Tables in this section.
Page 12
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 12
Fitting
Pipe Size
3/8”
½”
5/8”
¾”
45° Bend
0.12
0.15
0.18
0.21
90° Bend Short Radius
0.37
0.43
0.49
0.55
90° Bend Long Radius
0.24
0.27
0.30
0.37
180° Bend Short Radius
0.73
0.91
1.10
1.28
180° Bend Long Radius
0.46
0.55
0.64
0.76
90° Elbow
0.67
0.85
1.04
1.25
Page 13
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 13
8. REFRIGERATION COMMISSIONING
Figure – 8.1 Evacuation and Charging Connections
8.1 Evacuation, Charging and Refrigerant Procedures
After completing the refrigerant connections the following steps should be followed with reference to
Figure 8.1 above.
1) Service gauges - Connect the low pressure port (1) of a manifold gauge set to the suction line
outdoor unit shut off valve service port (2).
2) Vacuum Pump - Connect the centre line port (3) of the manifold gauge set to the vacuum pump (4)
and operate the pump to ensure a vacuum of 200 microns.
Note: Ensure gauge low pressure port (5) is open and high pressure port (6) is closed.
3) System Isolation - After achieving the specified system vacuum close the gauge low pressure port (5)
and switch off the vacuum pump. Leave the system for 1 hour and check that the vacuum is
maintained. If not, check for leaks, rectify and repeat the pumping down to 200 microns.
4) Refrigerant Charging - Open both the outside unit shut off valves (7 & 8). Weigh in the appropriate
charge using a charging station.
5) Disconnect the vacuum pump and connect the gauge high pressure port (9) to the discharge line of
the outdoor unit shut-off valve (10), ensuring that the gauge central port (3) is closed. Run the
system, allow pressures to stabilise and ensure correct operation. After final commissioning remove
the gauge set, fit all valve caps and carry out a final refrigerant leak test.
This being a stand-alone condensing unit, the match to the indoor unit and appropriate
charge are the responsibility of the installer.
Page 14
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 14
9. DISPOSAL PROCEDURES
NOTE!
All refrigerant, oils and other waste materials must be disposed of in a professional and responsible
manner in strict adherence to environmental regulations.
NOTE!
The greatest possible care should be taken at all times to avoid the release of refrigerants to
atmosphere.
The de-commissioning, dismantling and disposal of air handling units should be undertaken only by
experienced personnel and in full adherence to all safety rules, in particular protection of lungs, eyes and
skin from refrigerants, dust, etc. Only approved lifting gear and power tools should be used and access
to the work area be restricted to authorised personnel.
Disconnect the unit from the electrical supply.
Reclaim all refrigerant from the unit using approved reclaiming equipment according to the
manufacturer’s instructions. Recovery of refrigerant must be carried out only by
operatives registered to refrigerant safe handling.
Dispose of the reclaimed refrigerant through an approved recycling facility.
Separate the unit sections and remove to approved recycling facilities.
SPECIAL NOTE:
ENSURE ALL CONNECTIONS EXTERNAL TO THE UNIT CASING AND DRAIN PIPEWORK
ARE ADEQUATELY INSULATED TO PREVENT FREEZING OR CONDENSATION.
Page 15
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 15
10. FINAL CHECKS
Check
1) Have all options kits been fitted ?
2) Have units been mounted level and correct drainage been checked?
3) Have the suction line, expanded liquid line (if required) and condensate drains (if
required) been adequately insulated?
4) Has correct HRC external fusing / isolating been installed.
5) Has additional extended pipe-run refrigerant charge been measured into the system,
where necessary or heat pumps been charged correctly?
6) Is there adequate room and access to remove the access panels ?
7) Has the control system been explained to the customer and the operating manual sheet
handed over with the appropriate sections completed?
8) Has the warranty booklet been read and completed? Note:- If a service contract is not
taken out only a 1-year warranty is applicable.
Page 16
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 16
11. WIRING DIAGRAM NUMBERS
This page gives wiring diagram numbers for each type of ICUS Outdoor Unit. The diagrams themselves
are supplied with the unit and are located in the electrical section. Please ensure the correct issue
drawing is used with the relevant system – refer to supplier if necessary.
Unit Ref
Function
Type
Phase
Wiring Diagram
Part N°
ICUS30,
40
Cooling Only
Condensing Unit
1-ph
LBD170
LBD170
J91233
J91243
ICUS55,
80
Cooling Only
Condensing Unit
1-ph LBD171
LBD171
J91263
J91283
Page 17
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 17
CC EE CC EE RR TT II FF II CC AA TT E
E
Eaton-Williams Air Conditioning
(Eaton-Williams Ltd)
Station Road – Edenbridge - Kent - TN8 6EG - England
Telephone ... 44 (0)1732 866055
Telefax ... (0)1732 863461
Qualitair Edenaire Moducel
We declare that the equipment designated below,
on the basis of design and construction in the form marketed by us and
when installed and operated in accordance with our information and instructions,
conforms to the EMC Directive, the PED and the essential Health and Safety requirements of the Machinery
Directive.
If alterations are made to this equipment without our approval,
this declaration becomes invalid. Furthermore, this equipment may be
assembled into other systems which may also constitute machinery and shall
not be put into service until the assembled system has been declared in conformity
with the Machinery Directive.
Model
Serial N°
Standards Applied
BS EN 292-Pt2
EMC BS EN50081-1
EMC BS EN50082-1
Low Voltage EN60204 pt1
Pressure Equipment prEN14276-2
Controls Applied BS EN ISO 9001: 1994
BSI Registered Company Q5026
Gerry Stapley Gary Martin
Managing Directors
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
89/336/EEC
MACHINERY DIRECTIVE
EC Declaration of Conformity
As Defined by the EC Council Directive on Machinery
89/392/EEC Annex IIA and amended by
91/368/EEC - 93/44/EEC & 93/68/EEC
Page 18
ICUS CONDENSING UNIT INSTALLATION MANUAL
Jan 09:F\Qualitair Eng\Icu\Manuals\0412118S 18
OLDFIELDS BUSINESS PARK
BIRRELL STREET
FENTON
ST4 3ES
TEL: (01782) 597124
FAX:(01782) 316633
AN EATON-WILLIAMS COMPANY
As part of the policy of continuous product improvement, we reserve the ri ght to alter specifications without notice
Loading...