PAC PAU, PAS Installation Manual

INSTALLATION AND OPERATION MANUAL

PAC HEAT RECOVERY WATER HEATER Page 1

(PRODUCT INTRODUCTION )

Principle of Working
PAC Heat Recovery Water Heater

PAC Heat Recovery Water Heater are produce water heater from recover heat

removed by refrigeration or air conditioning as follows:

1. Cutting circuit of air conditioning at discharge refrigerant which out from

compressor.

2. The temperature from refrigerant will transfer heat to the heat exchanger in the

tank and make the lower temperature of water in the tank higher (Maximum higher

temperature is 60 C)

3. After heat Exchanged, refrigerant will run to the air condition system for release

to condensing unit as a normal system

Uniqueness

PAC Heat Recovery Water Heater is designed to recover waste heat from refrigerate

of the air conditioning system to utilize that heat for heating water. It is a heat recovery

system which heats and store hot water all in one unit. It is easily connected to existing

refrigeration unit, either air or water cooled. PAC Heat recovery Water Heater model PAS

is a de-Superheater which removes most or all of the latent heat of the hot discharge gas

from the compressor and uses the existing condenser to remove the remaining heat and

condense the refrigerant. It is not intended to and should not be used totally replace the

normal air-or-water-cooled condenser.

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PAU model PAS model

Figure 1 : PAC Heat Recovery Water heater PAU and PAS Model.

PAC Heat Recovery Water Heater of all models can operate in normal pressure 100

PSI, As the refrigerant integrated solution for creating heat to work at normal pressure as

250-300 PSI. By testing the ability of the pressure 150 PSI for water pressure and 600 PSI

circuit solution.

In order to back up heat or in the absence of air conditioning systems for long time or

the use of air conditioners in small quantities. The placement of this element for store up

water heater.

PAC Heat Recovery Water Heater for all models are access points to support the

electric Heater where the tank bottom when placed vertically.

The outer jacket of PAC Heat Recovery Water heater :-

- PAU model are made of powder coated steel 304 which it is high corrosion

resistance, non corrosive in case of install in the sea area.

- PAS model are made of a spray paint steel. It should not to clean with the

cleaning equipment or liquid mixture which it damage to the surface of tank, all

for protect the corrosion.

Figure 2 : The bracket of PAU and PAS model.

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Model Explaination

Figure 3 : Explaination for PAU model

Figure 4 : Explaination for PAS model.

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Specifications

PAC Heat Recovery Water Heater PAU and PAS model are designed for use with air

or water cooled refrigeration units. The size of the units and refrigeration systems on

which each model may be used are shown in Table 1

Model

Water

Connection

Size

(Liter)

No. of

Refrig.

Circuits

(Set)

Water

Connection

size(Inch) (Male

Thread)

Refrig.

Connection

Size

(Inch)

Dimension

ØxHigh

(cm)

Weight

(Kg)

PAU-050101
PAS-050101

50

50

1

1

1/2” male thread

1/2” male thread

3/8” Flare

3/8” Flare

47x61

47x61

16

16

PAU-075101
PAS-075101

75

75

1

1

1/2” male thread

1/2” male thread

3/8” Flare

3/8” Flare

47x78

47x78

19

19

PAU-100101
PAS-100101

100

100

1

1

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

47x101

47x101

23

23

PAU-100102
PAS-100102

100

100

2

2

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

47x101

47x101

24

24

PAU-150151
PAS-150151

150

150

1

1

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

56x113

56x113

43

43

PAU-150152
PAS-150152

150

150

2

2

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

56x113

56x113

44

44

PAU-200151
PAS-200151

200

200

1

1

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

56x134

56x134

62

62

PAU-200152
PAS-200152

200

200

2

2

3/4” male thread

3/4” male thread

3/8” Flare

3/8” Flare

56x134

56x134

63

63

Table 1 : PAC Technical Specifications

Pressure Testing

 General water pressure (normally) 100 PSI (6.89 Bar)

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 Maximum testing pressure 150 PSI (10.34Bar)

 Maximum testing refrigerant 600 PSI (41.37 Bar)

Product Content

1. PAC Heat Recovery Water Heater the components as below.

 The three layer of PAC Heat Recovery Water Heater :-

- Outer : The outer jacket of PAU model made of stainless steel 304 high resistant

to corrosion and rust. For the PAS model is made of powder coated steel to

protect against corrosion.

- Middle : The middle is a special thermal insulation, Poly Urethane. Prolong to

keep the heating and strong.

- Inner : The inner pressure tank is made of stainless steel 316L and seamless

Heat exchanger. Resistant to high corrosion, heat and pressure with clean and

safe.

 Heat Exchanger equipment. Made of seamless stainless steel 316L Resistant to

high corrosion and prevent leakage of refrigerant efficiently.

 Cold water inlet : Size 3/4” use for 50L and 75L tank and the size 3/4” use for

100L and 150L tank. The inlet must to connected to a water tank at the minimum

to prevent to mixing the cold water, hot water production.

 Hot water outlet : Size 1/2” use for 50L and 75L tank and the size ¾” use for

100L and 150L tank. The inlet must to connected to a water tank at the top of

efficient storage of heat and hot water temperatures up.

 Magnesium Anode (Mg. Anode) Size ¾” use for sediment trap and scale to

reduce contamination of the water, make a water safer and prevent the equipment

within the tank for more safety.

 Electric Heater : It on the button when placing a vertical cylinder. As an option

in case that does not turn on air conditioners for a long time.

Components within the tank made of Stainless Steel 316L it is do not all react the

same positive impact on the cleanliness of hot water and tank. Long-term need to install

control equipment, temperature and pressure that comes with the tank. To prevent

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damage from temperature and pressure is too high. PAC Heat Recovery Water Heater is
the water heater clean and safe energy truly.

2. Valves and Install Equipment .

- Ball Valves 2 sets Size 1/2” for 50L, 75L and Size 3/4” for model 100L, 150L, 200L

- Check valve + Pressure Relief valve 1 set. Size 1/2” for 50L, 75L and Size 3/4”

for model 100L, 150L, 200L

- Flexible Pipe Stainless steel 35 cm. + Flare + Insulation 2 set. Size 1/2” for 50L,

75L and Size 3/4” for model 100L, 150L, 200L.

- Spiral Tap 1 roll.

Figure 5 : The connection for installment of PAC Heat Recovery Water Heater.

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3. User Manual and Warranty card

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CONNECTING LIST

Pattern 1 : For Model PAS-050101 and PAU-050101.

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Pattern 2 : For Model PAS-075101 and PAU-075101.

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Pattern 3 : For Model PAS-100101, PAS-100102 and PAU-100101, PAU-100102.

Pattern 4 : For Model PAS-150151, PAS-150152 and PAU-150151, PAU-150152.

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Pattern 5 : For Model PAS-200151, PAS-200152 and PAU-200151, PAU-200152.

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Socket for Magnesium Anode 3/4”

DRAWING OF PRODUCTS

Pattern 1 : Size and Main equipment for PAS-050101 and PAU-050101 model.

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Pattern 2 : Size and Main equipment for PAS-075101 and PAU-075101 model.

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Refrigerant Inlet – Outlet of coil

Second coil for 2 coil model.

Pattern 3 : Size and Main equipment for PAS-100101 and PAU-100102 model.

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Refrigerant Inlet – Outlet of coil

Pattern 4 : Size and Main equipment for PAS-150151 and PAU-150152 model.

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Refrigerant Inlet – Outlet of coil

Pattern 5 : Size and Main equipment for PAS-200151 and PAU-200152 model.

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CAUTION

 Before installation, must to read the caution carefully for safety.
 Please contract the dealer if product had a problem when you are installing.

Warning : Means, Caution in the air conditioning and associated equipment to be

notice for avoid a dangerous to the user or workers.

Caution : Means, Precautions that should be observed to avoid the danger that will

happen to the machine.

After installation should be explain “Instructions for Safety” How to use and care to

the product to customer and need to test run the product for checking that it work well.

Have to give a manual of installation to user also.

Warning

 The system should be install by dealer or a technician.

 Installation should be follow the instructions in the manual and use the right tools for work.

 Installation should be follow the instructions in the manual to reduce the risk of

earthqauke or strom. Installed with the wrong method it might be the product falling to the

ground and damage.

 Should to install a product with a strong structure which it can get the weight.

 Should not to remove the product after installed.

Before installation or change location

Caution

 Move the machine carefully. Overhaul should be at least 2 people, because machine

weigh from 16 Kg up.

 Must be turn off an electricity of air conditioning before the operation.

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 Suction refrigerant to keep out of the system out, because when the connection pipe

Refrigerant may cause a serious explosion. Or when refrigerant in contact with fire it will

burn which causes toxic gases.

 Ware groves and goggles whenever working. Since refrigerants are generally very low

boiling point. If touched to the skin or eyes, it was time to get that serious.

 Keep the container of refrigerant in the indoor temperature does not exceeds 52 degree

Celsius. Because the refrigerant has a high growth rate, when the tank is heated it will

explode as a danger to life.

 Should be insulated with a heat pipe cooling editing.

 If water pipes are installed incorrectly it will cause a water leak, and may cause the

damage to the ceiling, furniture or other property.

 Betel nut is tightened all the selected points with a wrench mod, if the tightening nut may

be too premature to crack.

Caution Before Testing System

 Before start to testing the air condition system, need to checking all the valves and be

sure that it ready to work.

In case of need to move a large hot water tank and very much heavy For safety,

need to use the tool to move the hot water tank by using the cable hook and hold the handle 4

points. The balance must be aware of the weight before lifting.

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INSTALLMENT

PAC Heat Recovery Water Heater PAS model can be installed inside and outside

building. For installation should be check for capability of PAC tank PAS model because

it is an important point for investigation. The weight is showing on Table 1.

PAC Heat Recovery Water Heater PAS model should be located as near as

practical to the refrigeration unit. Careful planning of the Pac tank location and plumbing

can reduce installation costs and save time during installation and on maintenance in the

future.

1. Installations Location

1.1 In case of installed multi air condition need to choose the most frequently

used air and need to choose the size that most BTU.

1.2 Choose a location to install the machine near the condensing unit as much as

possible by taking into account the length of the tube-term solution that does not exceed

more than 8 meters, use the solution pipe as the same size as a solution pipe which out

from the compressor.

Should be extened pipe solution if you need to pipe more than 8 meters. If you have

any question, please contact manufacturer.

In normally the total length of solution pipe should not exceed more than 16 meters.

X < 8 m.

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1.3 Should be space for the water pipe, refrigerant pipe and heater as a

picture as below.

2. Installations Tank

Measure and capture the water level to the point and drill holes for cleat

embedded lead (Expansion Anchors) taken together with the machine screw

number M8 tightening to four points as a pictures as below.

Look from side Look from above

Knot (number M8) Expansion Anchors

X > 20 cm.

X > 40 cm.

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3. Pipeline installations

 PAC Heat Recovery Water Heater is equipped with 1 ½” and ¾” connections

for cold water inlet and hot water outlet.

 The water inlet connection is labeled “Cold” and the outlet connection is

labeled “Hot”

NOTICE :

Make sure that there are no leaks at the water connections which might cause

the insulation to become wet.

 IMPORTANT NOTE :

To reduce the risk of excessive temperatures and pressures in this water heater,

a pressure/temperature relief valve has been installed by the manufacturer and

should not be removed. The discharge opening must not be blocked or reduced in

size under any circumstances. Any additional protective equipment required by local

codes must also be installed. In the event that the pressure/temperature relief valve is

INSULATION

BALL VALVE FOR HOT WATER OUTLET
BALL VALVE FOR HOT WATER OUTLET

FLEXIBLE STAINLESS STEEL + NUT
FLEXIBLE STAINLESS STEEL + NUT

INSULATION

INSULATIONCHECH VALVE

+ RELIFE VALVE

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damaged or otherwise needs replacement should be installed. The valve must be

marked with a maximum set pressure of 150psi for use on all PAC tank.

If a water mixing valve is installed in the system, make sure that check valves are in

both hot and cold water lines. If this precaution is not taken, hot water may be drawn

into the cold water lines. If this precaution is not taken, hot water may be drawn into

the cold water system under certain system operation conditions.

 In some hot water systems, the expansion of heater may effected to leak at the

relief valve. That’s might occur a problem. Should be installed the expansion tank.

 In many multi-unit installations, it is advantageous to install a circulating pump

and form a loop plumbing circuit through the Heat Recovery Water Heater. This will

usually increase the heat recovery efficiency of the system by keeping the total

system water volume at a uniform temperature and picking up the most available heat

from any refrigeration unit which may be running. Consult a plumbing supply house

for a hot water circulating pump suitable for your particular installation. All pumps

used in a heat Recovery Water Heater circulation system must be suitable for potable

water use. Multiple Heat Recovery Water Heater installations may be piped in parallel

if care is taken to assure equal flow through all of the Heat Recovery Water Heater.

Parallel plumbing is usually reserved for installations having a common refrigeration

compressor on all of the Heat Recovery Water Heater.

 Under certain circumstances, it may be necessary to operate a high

temperature or booster heater loop at temperature above those attainable or

desirable in the PAC Heat Recovery Water Heater. At those times a piping scheme

should be used. This allows the PAC tank to operate at its optimum heat reclaim
while the system temperature is at a higher level.

WATER OUT PIPE ( RELIEF VALVE )

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Figure 5 : Pipeline system installations

Figure 6 : Installing PAC Fre-Heater (Through one circuit into another)

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Figure 7 : Installing PAC Fre-Heater in parallel series

4. Refrigerant system installations

 Heat Recovery Water Heaters are shipped with a dry nitrogen holding charge

that must be removed from the Heat Recovery Water Heater piping before installation

of refrigerant piping.

 Good refrigeration practices must be used while installing the heat Recover

Water Heater. These practices are of commom knowledge to the experienced

refrigeration serviceman should undertake the refrigeration connection portion of a

Heat Recovery Water Heater installation.

 Inlet and outlet stubs are copper tube for Freon applications and stainless steel

male pipe thread for ammonia applications. The sizes of refrigeration connections for

various PAC Heat Recovery Water Heater are shown in Table 1.

 On runs 8 meters or less, refrigeration lines to and from the Heat Recovery

Water Heater should be the same size as the compressor discharge line.

 Avoid long runs whenever possible. However, If necessary to have runs of

more than 8 meters, the lines should be upsized by one tube size. Should there be

any question about refrigeration line size, the equipment manufacturer’s

recommendation should be followed.

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 In most instances, refrigeration line runs of over 16 meters should not be used.

If they are, particular care must be taken to avoid oil traps and excessive pressure

drop in the line.

 The refrigeration lines going to and From PAC Heat Recovery Water Heater

could reach temperatures of 150 Celsius degree. The refrigeration lines must be

insulated to prevent a burn hazard for personal injury or combustible substances. The

insulation will also add to the efficient operation of the Heat Recovery Water Heater.

Caution

The insulated pipe solution in and out, should be wrapped separately from each

other freely, should not be insulated pipe to the solution together this will cause

the heat transfer efficiency decreased.

Image for pipe solution

 If in making tubing connections, It is necessary to cut openings into the air-

conditioning or refrigeration cabinet, the following must be observed and provided

for. Particular care must be taken if the equipment is located outdoors.

- Integrity and rain tightness of the cabinet must be maintained. Do not cut

into a control box or enclosure containing live mechanical parts or electrical

wining. Make openings below any enclosures containing live mechanical parts

or electrical wiring.

INSULATION

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- Tubing connections must be made by means of high-temperature

soldering or brazing.

- Tubing must be routed such that no possibility of contacting moving parts

occurs.

- Provide protection for tubing if the likelihood of accidental damage

occurring exists.

- Always use a gear-type tubing bender when making bends tubes. A

condit bender will flatten the tubing and restrict the flow of refrigerant.

- When installing tubing through walls or along a structural member, be

sure the tubing is isolated from these members to avoid any transmissions or

vibrations that might occur.

 Table 1 for the per circuit condensing unit capacity range of the various PAC

Heat Recovery Water Heater units. To assure proper condensing unit operation, stay

within the capacity range specified.

 A refrigeration unit exceeding the single circuit connections to a specific PAC

Heat Recovery Water Heater may be connected to two or more Heat Recovery Water

Heater circuits on one or more Heat Recovery Water Heater having a combined

circuit capacity equal to the refrigeration unit.

 When making multiple Heat Recovery Water Heater circuit connections to a

single refrigeration unit, the piping to the Heat Recovery Water Heater circuits should

be in parallel. Series (through one circuit into another) piping of the Heat Recovery

Water Heater should not be used.

 A refrigerant line discharge muffler is not necessary for proper operation or

warranty coverage in a Heat Recovery Water Heater installation. However, if the Heat

Recovery Water Heater is to be installed in an area where any machine noise would

be objectionable, a discharge muffler should be considered as a method of

eliminating the normal compressor pulsation noise present in all refrigeration system.

 For maximum refrigeration unit efficiency and Heat Recovery Water Heater,

head pressure controls must be used.

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Refrigerant Charge

It may be necessary to add additional charge in some refrigeration systems.

Check the sight glass and, if necessary, add refrigerant to clear the sight glass. Final

charging of the system must be done after the water in the Heat Recovery Water
Heater becomes warm.

Test Run

Turn on the water supply and fill the Model PAC Heat Recovery Water Heater with

water. Unsure that all water and refrigeration connections are leak-free. The unit is then

ready for use. Refrigerant charge should be checked after the system has achieved

normal operation conditions. Be sure to check for proper operation of any and all controls,

valves, etc., installed with or charged during the installation of the Heat Recovery Water

Heater, both in the refrigeration and water systems.

Caution :

When starting to work on the system by adding into the tank then, do not fill more a

solution because it would cause “Over Charge” and the compressor switch will cut off the

system. The air condition system will stop working immediately, It may result to damage to

the air system or compressor.

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The illustrate and connection of Heat Recovery Water Heater. Model PAS with

Heat Exchanger.

Figure 8 : Installing Refrigerant Charge with Air-Condition

Figure 9 : Typical Refrigeration Connections for Single Refrigeration Unit and

Single-Circuit Piping.

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Figure 10 : Typical Dual Refrigeration Unit Piping.

Figure 11 : Fre-Heater Location with Hot Gas Defrost Valve, Oil Separator,

and/or Discharge Muffler in System.

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Maintenance

In order to achieve the maximum life from your PAC Heat Recovery Water Heater the

following should be done annually :

1. Remove and check at least one of the two anode rods. Both anode rods should

be replaced.

2. Check the operation of the pressure/temperature relief valve by manually

operation it to see that it will freely flow water should it be required to do so. If there is any

doubt that it will not function properly, replace it.

3. Check all water fittings, valves, etc. to be sure there are no water leaks. Repair as

necessary.

4. Check the operation of all controls such as the hot gas by pass valve aquastat,

electric element controls, refrigeration head pressure controls, or any other controls

necessary for the proper operation of the Heat Recovery Water Heater and ion and/or air

conditioning systems it is connected to.

5. Recommend to check Mg. Anode every 6 months or 12 months (depends on the

real water condition usability), If find the Mg. Anode was corroded until small remaining.

Please change new Mg. Anode immediately.

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(Capability)

The result of Electric Power of Compressor without PAC Heat Recovery

Water Heater.

The result of Electric Power of air-condition and temperature of refrigerant by PAC

Heat Recovery Water Heater setting have water in but now flow out.

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The result of Electric Power of air-condition and temperature of refrigerant by PAC

Heat Recovery Water Heater setting and water flow out.

Temperature of water flow out from the Heat Recovery Water Heater