CCU Fusion Installation Manual
Contents
1. om om ms WniN3Jd 1 W 0001 Sz40 n99oH3P YW ZHAT ACON licenze T QC NC Ou Page 12 Issue February 2009 Health and Safety Important Note Only a qualified refrigeration engineer who is familiar with refrigeration systems and components including all controls should perform the installation and start up of the system To avoid potential injury use care when working around coil surfaces or sharp edges of metal cabinets All piping and electrical wiring should be installed in accordance with all applicable codes ordinances and local by laws Genera information Ensure the unit received is the correct model for the intended application e Ensure refrigerant voltage MWP FLC and LRC are all suitable for the proposed application e Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations and experienced with this type of equipment e he condensing unit contains moving machinery and electrical power hazards which may cause severe injury or death Disconnect and shut off power before installation or service of the equipment e Refrigerant release into the atmosphere is illegal Proper evacuation recovery handling and leak testing procedures must be observed at all times e Units must be earthed and no maintenance work should be attempted prior to disconnecting the electrical supply e The electrical covers and condenser fan guards must remain f2. Installation amp Service Manual Contents Nomenclature B Standard Product Configuration 3 Specifications General Data 4 Dimensional Drawings for Units 2 6 Performance Data Medium Temperature Performance Data Low Temperature 8 Electrical Wiring Diagrams 9 12 Health amp Safety General Information 13 Installation Unit Site Location 14 Installation Clearances 15 Field Piping 15 Leak Detection 16 Pressure Testing 16 Safety Pressure Switch Settings 16 High Pressure Safety 16 Low Pressure Safety 16 Vacuum Moisture Removal 17 Service amp Maintenance 18 Technical Information Fan Speed Controller 19 Dual Pressure Switch 20 Issue February 2009 Page 2 Nomenclature JEH2 0150 M 1 1 Single Phase 3 Three Phase Application M Medium Temperature L Low Temperature Nominal Capacity in Horse Power 0150 1 5 HP JEH2 J amp E Hall International Fusion Standard product configuration SGTIGS 2 3 4 IP54 rated control panel Combined mains isolator MCB overload Maneurop Hermetic compressor Compressor solder connections Compressor contactor Liquid receiver with fusible plug Drier Sight glass Oil separator and discharge non return valve on low temperature models Crankcase heater Manual high amp auto low pressure safety switch with Gomax flexible hoses Acoustic lining Compressor jacket Pressure actuated fan speed controller Issue February 2009 Page 3 Specificat
3. be sufficient To ensure good oil return Use only clean dehydrated refrigeration grade copper tube with long radius bends Avoid flare type connections and take great care when brazing Use only silver alloy rods Run braze without over filing to ensure there is no leakage into the tube To prevent oxidation blow nitrogen through pipework when brazing Install insulation on all suction lines and on all pipes penetrating walls or passing through hot areas Adequately support all pipe work at a maximum of 2 metre intervals In vertical pipework the use of U trap and double suction risers is offen required These suction risers must always be fitted with a U trap at the bottom and a P trap at the top and never be higher than 4m unless a second U trap system is fitted Correct line sizing will minimize the pressure drop and maintain sufficient gas velocity for proper oil return Important Nofe One of the main factors affecting equipment reliability and compressor service life is refrigeration circuit contamination During installation circuit contamination can be caused by Brazing amp Welding Oxides Filings amp Particles from de burring pipework Brazing Flux Moisture amp Air Issue February 2009 Page 15 Installation Leak detection e Perform a leak pressure test of the system using oxygen free nitrogen e The use of leak testing fluids is not recommended as this may interact with the lubricants own additives Pressure te
4. j28uuoo QL 0 julod yui DUI198UUO9 a ouey 9jON U0 Jasuapuo Wal 4D J340aH 350 uoJ7 ang E anig u834J0 40 3J 404 904 U04 J dossauduon ma j Jag UMOJg 13 cy dog P 2132u43p actu J E Ng p Ty i i ang A D ii u94 owa L AT is NN Opa SUNT ae Jajjo44uo2 paads uo p Ad aun th 2 dH eJnsseJg al x I Vy TI C L TET N TIGLIONIIHIP 3 cH luse cO 3 Hf TI Eee0IMJHT cHal INDOEONDIHIP 3 CHA TWOSTONSOHIFM 3 HI TALON poe Page 9 Issue February 2009 J amp E Hall JEH2 0150 M 3 JEH2 0175 L 3 JEH2 0225 M L 3 JEH2 0300 M 3 Wiring diagram for models JojbJodb e Ul 1D1SQUUJSH O 198UUQq QL 0 1UIGd yui bunosuuoo aA0WUayj 91ON S U04 3SuaDMOJ Barili dI J840aH 8502 u047j UaddQ MONO 1 404294005 cd SY Jossauduo 7 ang Neg UDLIMS 12 044U05 UMOUA lel 1 peeds UD Q b 0 L eo 349 UMOUG a E 1 L IGAWNOIA B char CM5ecUJJHHT 8 CHa 4 N EL l Il I5cclJJH cHl ENOOEONIIHAM 3 CHAP EWOSTONIDHAF 3 Hr 1300 Page 10 MI JO4 0 ST Issue February 2009 J amp E Hall JEH2 0350 L 3 JEH2 0400 M L 3 JEH2 0500 M 3 JEH2 0600 M 3 JEH2 0675 M 3 Wiring diagram for models jojpiodbAe Ul D1SOUJJSH 0 198uuco Q 0 quod xui Bunosuuco a ouigM 9 ON uaaJt MO aJA U0 4asuepuo PHT IN 49308H 28502 5u04 and amg 404207009 JossaJuduo 5 T 2 don 28 UMO AG i ma N UO 4 S TN dj a ang UMO AY
5. 1 z N 1 1 1 1 1 8 1 Ia N N ae Powe 0 4 707 448 500 500 500 500 560 560 48 1109 448 48 707 4 BIB AL Oo 00 O1 O1 O11 OT O 1O 1 las Lael Lael La Issue February 2009 Page 4 J amp E Hall Dimensional drawings JEH2 0150M1 JEH2 0150M3 JEH2 0225M 1 JEH2 0225M3 JEH2 0300M 1 JEH2 0300M3 JEH2 0175L1 JEH2 0175L3 JEH2 0225L1 JEH2 0225L3 Series 2 mm 5 3 448mm pp pum 1 C 1109mm 1051mm JEH2 0400M3 JEH2 0500M3 JEH2 0600M3 JEH2 0675M3 JEH2 0350L3 JEH2 0400L3 Series 3 746mm 33 2 I Bl 1500mm fd 1529mm LS p gt 1335mm 1270mm IG C SN co N Issue February 2009 Page 5 J amp E Hall Dimensional drawings JEH2 0725L3 JEH2 0825M3 JEH2 0825M3 JEH2 1000M3 Series 4 Issue February 2009 Page 6 Performance data Medium Temperature Cooling Capacity Watts Absorbed Power Watts mo I ISO NEO DODO e 660 962 1338 1781 2287 2860 se 853 945 1040 1137 1227 1999 1444 JEH2 0
6. 150 M 1 amp 3 R404A 1s s 558 887 1180 1589 2082 2601 seo4 ese eso oes 1169 1276 1385 1495 se 481 ere sez 1956 p 1700 2271 eto 666 073 1084 1197 1313 1401 1552 JEH2 0225 M 1 amp 3 R404A Leo 8o i208 1820 2420 soro s787 aseo seo sane 1657 1859 2081 zaoe 2551 Le res sos soss sez 4811 sese 7006 1600 1996 2193 2460 2737 s024 3321 RA seT 1520 2120 2015 sors aso sos ev uro vo 2213 2484 277o son 3307 133 1261 taco asas sara ar71 stro erse ser 201s 2262 2sao 2817 3125 sasa a f s2 f 2061 2000 s924 s133 esez s106 saro 2973 2686 004 327 sess s988 4328 Ese e 2482 sao 502 6750 ziee eoo 2408 2751 sosa 3407 s7eo 129 4496 perf 3220 4eee s556 zos2 e712 rosea ieeel 2600 s149 s610 4076 asa7 5023 ss04 Ese 293 sse sass 5750 7100 sers vosse 2647 sg s780 4278 azes 5307 sa er 3320 cos soro zza 9606 11664 13916 soss a517 4001 450s 5029 5573 6197 pez 2070 ara soo rao 2097 10809 12066 s47 3608 4008 4604 5139 5700 6285 oo c 2
7. 1845 2567 s420 a02 i963 1087 2021 2065 2719 es se i080 1605 2272 soss aosa f lll tao noo 1955 zoo zs so 179 2405 sooo sase sees ll 2878 soro sem aere seo 27 2060 3485 4717 6oso 7511 al f 278 asa 4220 sose soe f ooo 8 25 2890 4276 5818 7514 93686 11372 4037 4868 l 5805 6846 7993 e44 oo s13 sn eso sase frosts 91 ser eose soss ooo TE Evaporating Temperature C TA Ambient Temperature C Rating Codition Superheat 10K Sub cooling 0K All duties are 10 Important Note On some applications the use of a Suction Accumulator may be required Warnings 1 The use of an expansion valve with maximum operating pressure MOP or a starting regulator is compulsory 2 Use only R404a specified components e g filter drier TXV 3 The factory fitted crankcase heater must be permanently energized self regulating PTC Source Maneurop Issue February 2009 Page 8 J amp E Hall O300 M 1 M L 1 JEH2 JEH2 0225 L iagram for models a JEH2 0150 M 1 JEH2 0175 L 1 iring All wiring and connections to the condensing unit must be made in accordance with all local codes of practice Electrical Important Note JOjDJodp e ui 1D18OLUJ8U 0
8. 471 sess aas 6907 zoos orso voz 3222 seso a173 4701 5204 5002 5405 99 2694 soso ssas rise see 10724 120001 sasa 4047 asse soto sero 6678 7502 Le 3692 sse 7407 059911942 14404 17257 4227 4916 5601 6282 oso 7032 soot 625 se s922 sei cote 2625 noro 19369 15904 44o sora seos coeo 7002 7608 sss oo ET seo soss 7892 0007 12056 ort 4504 5148 sei 6511 7200 7074 eres 10 sl 4952 6931 9020 11219 13528 15947 18476 Po 5504 6286 7127 8029 8990 10012 11093 K3 2 he 3 4351 6154 8073 10106 12255 14518 16897 Ex sx 5627 6424 7281 8198 9175 10212 11309 TE Evaporating Temperature C TA Ambient Temperature C Rating Condition Superheat 10K Sub cooling 0K All duties are 10 Issue February 2009 Page 7 Performance data Low Temperature Cooling Capacity Watts Absorbed Power Watts IEEE a aa po lan EN o eo or ree or rene ee 175 Ge 00o eso ser m pen o pe pem m nso sifone el se soo vce too ere o ae e Ese t017 1410 taos 2o zoo 1449 reos 1955 2046 20 27 096 1506 2141 2001 ares aoo 1206 sem 1959 2296 oe so 35 se roo 1252
9. d when the pressure decreases below the value Pmin F V S Full Voltage Set Point pressure setting for maximum speed EPB Effective Proportional Band Pmin PMS E P B The RGE controls the speed of the condenser fan in refrigeration and air conditioning units that work all year long lt keeps the condensing pressure at a steady level by changing the speed of the fan according to the required condensing pressure Part namas T Adivsting Screw 4 Change over switch 2 Bellows 5 Terminal board 3 Range selling pointer B 4 Nars with depression nun duas maring 11 and Tabar 216 20 UNF 4A 6A SA single phase type Ground Circum Breaker or Fuse MD Fan Motor Cn Full speed External Of Auto speed Forced Operation Switch 4 terminals External forced operation switch On fan is forced to operate at Maximum speed regardless of the pressure Off fan operates according to the RGE function with speed varying according to pressure For single phase type if an external forced operation switch is required then the switch and connecting cables not supplied should have current rating higher than the fan motor rating For example a 4A switch is recommended for the 3A RGE model For three phase type use a forced operation switch with non voltage contact signal single phase type Effoctive Voltage R N S V M The operating characteristics may vary according to voltage frequency and fan mo
10. during test run e Check the compressor oil levels and top up if required The oil level should be 2 to 34 way up the sight glass Compressor Type Cil Type Order Reference MTZ Medium Temp Ester 160 PZ N23020046 NTZ Low Temp Ester 160 SZ N23020066 2 Condenser Fan Motor amp Blade Clean and inspect at regular intervals Check for abnormal noise vibration and fan imbalance Ensure that the fan motor is clean and spins freely Check that the condenser fan blade is clean and free from restriction Note The Fan Motor is pre lubricated and factory sealed so no maintenance is necessary 3 Condenser Coil Clean and inspect at regular intervals e Check and remove the dirt and debris between the fins using a suitable chemical coil cleaner e Check and remove any obstacles which may hinder the airflow through the condenser coll 4 Power Supply Inspect at regular intervals e Check the running current and voltage for the condensing unit e Check the electrical wiring and tighten the wires onto the terminal blocks if necessary Issue February 2009 Page 18 Technical Information Fan Speed Controller Setting point is increased by turning the range adjusting screw clockwise lt is decreased by turning the screw counter clockwise Adjustment should be within the range indicated for the setting pointer Cut off Fan motor stops when the pressure decreases below the value Pmin Min Speed Fan motor operates at the Minimum Spee
11. ions General Data Dry Weight Kgs 82 120 120 126 126 204 205 92 92 125 125 203 205 Fan Connections Receiver Vol uction Liquid Litres 4 2 4 2 4 2 4 2 4 2 4 2 7 1 7 1 7 1 7 1 Model O EH2 0150 M 1 EH2 0150 M 3 EH2 0225 M 1 MTZ28 5VM EH2 0225 M 3 7 5 EH2 0300 M 1 MTZ36 5VM 220 60 0 MTZ36 4V IO TPO ale CO N CO 00 00 EH2 0300 M 3 EH2 0400 M 3 MTZ50 4VM 6133 NI OO O11O11 maf gt 7 CO Oo PO G G OG T gt Bm NI CO Oo 00 NI CO N EH2 0500 M 3 MTZ64 4VM 6133 EH2 0600 M 3 MTZ72 4VM 5165 EH2 0675 M 3 MTZ81 4VM 5165 s OO N k BIR 1 1 Lr Sa CO _ N EH2 0825 M 3 MTZ100 4VM 22 0 90 0 6375 37 EH2 1000 M 3 MTZ125 4VM 27 0 105 0 6375 CO N CO aa N EH2 0175 L 1 EH2 0175 L 3 C1 CO CO _ CO EH2 0225 L 1 NTZ68 5VM EH2 0225 L 3 NTZ68 4VM EH2 0350 L 3 NTZ96 4VM EH2 0400 L 3 EH2 0725 L 3 NTZ215 4VM 6 11 8 EH2 0825 L 3 NTZ271 4VM 270 960 6375 2 16 Noise levels given are sound pressure 10m free field O1 Gn 00 00 CO 1 CO __ 00 00 s CO s CO NI 3 N Aja ei ha AI NINININ 6 6
12. itted at all times e Use of the condensing units outside of the design conditions and the application for which the units were intended may be unsafe and be detrimental to the unit regardless of short or long term operation e The condensing units are not designed to withstand loads or stresses from other equipment or personnel Such extraneous loads or stress may cause failure leak injury e n some circumstances a suction accumulator not supplied may be required It offers protection against refrigerant flood back during operation and also against off cycle migration by adding internal free volume to the low side of the system e Tests must be conducted to ensure the amount of off cycle migration to the compressor does not exceed the compressor s charge limit e Wherever possible the system should be installed to utilize a pump down configuration e After installation the system should be allowed to run for 3 4 hours The oil level should then be checked and topped up as necessary The oil level should be visible at least 2 up the compressor oil sight glass For details of the oil requirements please refer to page 18 in the service and maintenance section Issue February 2009 Page 13 J amp E Hall Installation Unit site location In order to achieve maximum cooling capacity the installation location for the condensing unit should be carefully selected e Install the condensing unit in such a way so that hot air ejected by the co
13. le 0 15 bar The LP stop pressure is the LP start pressure minus the differential Note The LP stop pressure must be above absolute vacuum pe 1 bar If with low stop pressure the refrigeration compressor will not stop check to ensure that the differential value has not been set too high Contact systems Imm oe Dual pressure HEHP Dual pressure i SPOT LP HP signal Dual pressure LP HP Pressure controls with automatic reset HP Set the HP pressure on the CUT OUT scale One rotation ofthe HP spindle 2 3 bar Set the HP differential on the DIFF scale One rotation of the differential spindle 0 3 bar The HP start pressure is the HP stop pressure minus the differential Start and stop pressures for both the LP and HP sides of the system should always be checked with an accurate pressure gauge Pressure controls with manual reset Set the stop pressure on CUT OUT scale range scale Low pressure controls can be manually reset when the pressure is equal to the stop pressure plus the differential High pressure controls can be manually reset when the pressure is equal to the stop pressure minus the differential Page 20 J amp E Hall Limited Hansard Gate West Meadows Derby DE21 6JN England Tel 44 0 1332 253400 Fax 44 0 1332 371061 Email helpline jehall co uk Web www jehall com Issue February 2009 Page 21
14. mi s al and Ed R als E T L EN us 4 ETT HINA Peg Dal J QJ1U0 a ans paads up 51 bo a4nssaJg dH Hal yong UMO ug c d 20 g DE FI 10 Ki 3 ETP ka M 1J VOTE ue 420 96 S6 VIRATA 3804 UMOJA ang eh el un ul S J070 05 CNSZ90fI 9H3C eHif EWDOOSONIIHIN HIN EWQOF0ONJIH N 3 Har UIBID MONAT z Q O EWO090NJIHIN 3 HE WOPONIIHA 3 char E 0SEONIIHAM 3 CHI HUHM i N EL eL IL Page 11 Issue February 2009 J amp E Hall for Models 0825 M L 3 JEH2 1000 M 3 iagram ing d JEH2 0725 L 3 JEH2 iring JojpJodp e Ul jpjsouujSu 0 J2auuoa Q 0 ZL quod xui BUHoauuo9 saoway BJON ueeJ9g Mo 9SA i 48SUBPUDY pay JI JS1DeH SSDOMUDII JOJIDIUCY ma Na JosseJdujo5 n nua NH Neg LV f f pag Q go LK kom U ala mag ma _ E UH Di ped PA ER EE EE EE T 1 kaa Na JalIOnuo9 paads up 9JnSS9Jd PS Of ol jong va sul Lf T E EEME C mas sang d NEA a 9 vele E VST 8L i zi Lin ut oiplos
15. mportant Note There must be no more than 12 starts per hour A higher number reduces the service life of the compressor If necessary use an anti short cycle timer in the control circuit A five minute time out is recommended Vacuum moisture removal Important Nofe Moisture prevents proper functioning of the compressor and the refrigeration system Air and moisture reduce service life and increase condensing pressure causing abnormally high discharge temperatures likely to destroy the oil s lubricating properties The risk of acid formation is also increased by air and moisture and copper plating can be generated in this way All these phenomena can cause mechanical and electrical failure Important Nofe Ensure that a good quality vacuum pump is used to pull a minimum vacuum of 250 microns 0 33 mbar Issue February 2009 Page 17 Service amp Maintenance Important Nofe P y Warning Disconnect the mains electrical supply before Servicing or opening the unit The condensing units are designed to give long life operation with minimum maintenance However they should be routinely checked and the following service schedule is recommended under normal circumstances The removal of the top side and front panels ensures that all parts are accessible 1 Compressor Inspect at regular intervals e Check for refrigerant leaks on all joints and fittings e Ensure that no abnormal noise or vibration is detected
16. ndensing unit cannot be drawn in again short circuit of hot discharge air Allow sufficient space for maintenance around the unit Ensure that there is no obstruction to air flow into or out of the unit Remove obstacles which block air e intake or discharge io X Kee Q a e The location must be well ventilated so the unit can draw in and distribute plenty of air thus lowering the condensing temperature e To optimize the unit running conditions the condenser coil must be cleaned at regular intervals nstallation clearance e The installation location should allow sufficient space for air flow and maintenance around the unit SSR SA N H X LA M ba o DESTACLE a hu a n a M Tat C v The a 9 x e A i 4 si 1 S r Z ee e m P a d T di F P 5 AME PF 4 a AU r 9 ECOL cul Pd A e F P 4 Fa i m og s Fo d a Fo wg Go Go Go E P 4 P 6 out Gr FF Issue February 2009 Page 14 Installation Field piping Important Note Line sizing should only be determined by qualified personnel All local codes of practice must be observed in the installation of refrigerant piping To ensure safisfactory operation and performance the following points should be noted for field piping arrangements Pipework routes must be as simple and as short as possible Avoid low points on pipework where oil can accumulate Suction gas velocity must
17. sting e Whenrunning a pressure test always use an inert dry gas such as oxygen free nitrogen e The pressure differential between the high and low side shall not exceed 24 bar 350 psig e Maximum test pressures are 25 Bar 362 psig on the Low Side 30 Bar 435 psig on the High Side Safety pressure switch settings The Danfoss KP 17 HP LP pressure switch fitted to JEH model condensing units with auto reset for Low Pressure and manual reset for High Pressure is NOT factory preset Be sure that the high pressure setting does not exceed the receiver s maximum service pressure High pressure safety The high pressure safety switch is required to stop the compressor should the discharge pressure exceed the values shown in the following table The high pressure switch can be set to lower values depending on the application and ambient conditions R404a R134a Rate HP Setting barg 28 202 HP Setting psig Source Maneurop Low pressure safety The low pressure safety switch protects the compressor against deep vacuum operation a potential cause of failure due to internal arching The low pressure safety cut out should never be set below 0 1 bar 2 psig as shown in the following table For systems without pump down the LP switch signal contact shall be used to energize a low pressure safety alarm R404a R134a R407c Cut Out bar Cut In bar Source Maneurop Issue February 2009 Page 16 Installation I
18. tor characteristics Emin FALS adjustable Issue February 2009 Page 19 Technical Information Dual Pressure Switch Technical leaflet Technical data Setting Issue February 2009 Pressure controls type KP Ambient temperature 40 65 C 80 C for max 2 hours DIN approved units 25 65 C 80 C for max 2 hours Max working pressure LP PB 17 bar HP PB 32 bar KDG PB 46 5 bar Max test pressure LP p 20 bar HP p 35 bar KP 6 p 46 5 bar Contact load Alternating current ACT 16 A 400 V ACS 16A 400V ACTS 10 A 400 V Max starting current L R 112 A 400 W Direct current DC1x 12 W 220 V control current Properties according to EN 60847 Wire dimensions solid stranded flexible w out ferrules 0 75 2 5 mm 0 7 2 5 mm flexible with ferrules 0 5 1 5 mm Tightning torque max 2 NM Rated impulse voltage d kV Pollution degree 3 short circuit protection fuse 10 Amp Insulation 400V IP 30 44 Cable connection The cable entry can be used for 6 14 mm dia cables A Pg 13 5 screwed cable entry can also be used for 6 14 mm cable With 8 16 mm cable a standard Pg 16 screwed cable entry can be used Pressure controls with automatic reset LP Set the LP start pressure on the CUT IN scale range scale One rotation of the low pressure spindle 0 7 bar Set the LP differential on the DIFF scale One rotation of the differential spind
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