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ICU Application Manual

HS L/M 3100 Series

Semi-hermetic Single Screw Air Cooled

Industrial Condensing Units

Application Manual


Issue 1.2 : 05/08 Page 3 of 38

Contents

1. The standard Industrial Condensing Unit ........................................................... 5 1.1. Main Features........................................................................................................................ 5 1.2. Scope of supply ..................................................................................................................... 6

2. Description of Operation ............................................................................................ 7 2.1. Refrigerant System................................................................................................................ 7 2.2. HS Compressor...................................................................................................................... 7 2.3. Oil Management .................................................................................................................... 7 2.3.1. Oil Separator/Reservoir .................................................................................................... 8 2.3.2. Oil Filter............................................................................................................................. 9 2.3.3. Oil Heater .......................................................................................................................... 9 2.3.4. Oil Low Level .................................................................................................................... 9 2.3.5. Oil High Level Sensor ....................................................................................................... 9 2.3.6. Lubricating Oils ................................................................................................................. 9 2.4. Liquid Injection Control .......................................................................................................... 9 2.5. Air Cooled Condenser ........................................................................................................... 9 2.6. Liquid Receiver.................................................................................................................... 10 2.7. Economiser (if applicable) ................................................................................................... 10 2.8. Capacity Control and Volume Ratio .................................................................................... 10 2.9. MicroTech II C Plus Controller............................................................................................. 11

3. Integration into the Refrigeration Circuit .................................................................. 12 3.1. Applications ......................................................................................................................... 12 3.2. Suction Line......................................................................................................................... 13 3.3. Liquid Separation in the Suction Line.................................................................................. 13 3.4. Electrical connections.......................................................................................................... 13 3.5. Safety Requirements for Compressor Protection................................................................ 13

4. Installation Guide ..................................................................................................... 14 4.1. Shipment ............................................................................................................................. 14 4.2. Post - Delivery Inspection.................................................................................................... 14 4.3. Lifting and Moving System Components............................................................................. 14 4.4. Storage and Preservation.................................................................................................... 14 4.4.1. Store Location................................................................................................................. 15 4.4.2. Protection During Storage............................................................................................... 15 4.4.3. Storage Inspection Routine............................................................................................. 15 4.4.4. Taking the Plant out of Storage ...................................................................................... 16 4.5. Siting the Plant .................................................................................................................... 16 4.5.1. Installing Packaged Components ................................................................................... 18 4.6. Connecting System Components........................................................................................ 19 4.6.1. Pressure Equipment Directive (PED).............................................................................. 19 4.6.2. Refrigeration Pipework.................................................................................................... 19 4.7. Electrical Connections ......................................................................................................... 21 4.8. Lubricating Oil Charge......................................................................................................... 22


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List of Figures

Fig 1 Oil Separator/Reservoir Oil Levels ................................................................................................. 8 Fig 2 Typical cold store complex with Daikin industrial condensing units ............................................. 12 Fig 3 Space requirements...................................................................................................................... 17 Fig 4 General arrangement.................................................................................................................... 31 Fig 5 Flow and instrumentation diagram ............................................................................................... 33 Fig 6 Flow and instrumentation diagram of the economiser circuit (optional) ....................................... 34 Fig 7 Flow and instrumentation diagram of the liquid injection (optional).............................................. 35

List of Tables

Table 1 ICU’s minimum capacity load ................................................................................................... 10 Table 2 Standard High Temperature Units............................................................................................ 25 Table 3 Standard Low Temperature Units............................................................................................. 26 Table 4 Economised High Temperature Units....................................................................................... 27 Table 5 Economised Low Temperature Units ....................................................................................... 28 Table 6 Economised Low Temperature Units ....................................................................................... 29 Table 7 Oil charge ................................................................................................................................. 29 Table 8 Dimensions and Weight............................................................................................................ 30 Table 9 Liquid receiver capacity ............................................................................................................ 30


Issue 1.2 : 05/08 Page 5 of 38

1. The Standard Industrial Condensing Unit

Daikin Europe NV set out to meet the demand for a range of

standard screw compressor package units which combine the economic use of energy with design flexibility and reliability. These essential criteria are realised in the Industrial Condensing Units (ICU), the most advanced design available in oil injected single screw refrigeration technology with air cooled condenser that are ready to install in a wide range of different applications.

Incorporated in the ICU package design, are several novel features for energy saving, together with the proven efficiency and dependability of

the advanced HS single screw compressor. Thousands of

HS compressors are now operational in units installed in many

countries all over the world, and have earned an excellent reputation in the fields of refrigeration, air conditioning and heat recovery.

These factory-built industrial condensing units are easy to install. They

include air cooled condenser, HS compressor, oil separator, liquid

receiver, filter drier and are fully wired with all motor starters and controls. Only the mains electrical supply, start-stop signal wiring and interlocking with process is required on site.

With a small footprint the units can be installed where there isn’t space available to install a plant room. If there is room for an air cooled condenser, there is room for the ICU.

The units offer great value for money with up to 30% less than the cost of the equivalent site installed system.

1.1. Main Features

• Flexible operation thanks to the Variable Speed Drive capacity control to eliminate energy wastage.

• Fitted with a microprocessor based MicroTech II controller, incorporating a PID control algorithm for close control of the set point pressure

• Oil injection by system pressure difference, no continuously running oil pump – hence, energy savings

• Economiser option providing substantial capacity increase and improved energy efficiency, especially at low evaporating temperatures. Combined with VSD controls the economiser option gives the best part load performance operation

• Space saving construction due to the compact design of the condenser coils (‘W’ configuration)

• Low noise levels down to 75 d(B)A or 80 d(B)A at 1 meter for standard option

• 100% standby compressor capacity for critical cooling system (for “one run – one standby compressor” units)

• High ambient operation. The units are designed for 35°C dry bulb but will operate in ambient up to 38°C (at reduced cooling capacity)

• The units are also easy to maintain. External oil filters and filter driers can be replaced without turning off the compressors. Isolating and drain valves allow the oil filter cartridges to be changed within minutes.


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• Liquid receiver is sized to allow refrigerant pump down for most systems

• Design and manufacture complies with BS EN 378: 2008. CE marking complies with The Supply of Machinery (Safety) Regulations: The Pressure Equipment Directive (PED) Survey by customer’s appointed independent inspection authority can be arranged

1.2. Scope of supply

Standard features for the Air Cooled Condensing Unit include the following:

• HS single screw compressor(s).

• Vertical oil separator with dual safety pressure relief valves.

• Air cooled condenser

• Condensing pressure control

• Large liquid receiver with dual safety pressure relief valves

• A filter drier after the liquid receiver with isolating valves

• Liquid sightglass with moisture indicator

• Suction and delivery isolating valves

• Pressure transducers for LP and oil pressure cut out

• Starter and control panel (suction pressure control) incorporating electronic controller suitable for remote monitoring via modem or GSM supervision program

• Oil injected screw compressor for maximum reliability.

• Two oil filters with isolating valves

• Variable speed drive for capacity modulation

• Internal suction/discharge safety relief valve

• High pressure safety cut-outs

• Thermistor high temperature protection to motor

• Thermistor discharge gas high temperature protection

• Oil level sensor

• Liquid Injection Oil Cooling

• Economiser facility provided to improve operating efficiency,

especially at low suction gauge (as an option).


Issue 1.2 : 05/08 Page 7 of 38

2. Description of Operation

The description which follows is included to impart a basic understanding of how the plant functions before describing its construction in detail.

2.1. Refrigerant System

Refer to flow and instrumentation diagram Fig 5,6 and 7.

The HS compressors act as gas pumps, drawing slightly

superheated low pressure refrigerant gas from the suction line, compressing it and discharging superheated high pressure gas into the air cooled condenser via the oil separator.

All the oil injected into the compressors for lubrication, sealing and cooling ends up in the discharge gas stream. The oil separator removes most of the oil from the gas and returns the oil to the lubrication circuit.

The discharge gas enters the air cooled condenser where the gas is first desuperheated and then condensed as it passes through the air-cooled condenser coils. The liquefied refrigerant flows out of the condenser into the liquid line. At this point the refrigerant is in its liquid phase, at high pressure and slightly subcooled.

The liquefied refrigerant drains down to the liquid receiver which acts as a reservoir for surplus charge during evaporator defrost or pump down.

The liquid refrigerant flows through a filter/drier where any moisture and/or dirt are removed before flowing to the liquid line:

• If used - the economiser with subcooled liquid flowing to the evaporators (by others).

The pressure, and hence the temperature of the liquid refrigerant in the evaporators is maintained at its low level by the compressor, drawing the vapour into and through the suction line, the process being a continuous. Design of the evaporator and refrigerant controls must ensure that the suction vapour is in a superheated condition when it reaches the compressor.

2.2. HS Compressor

Daikin air-cooled Industrial Condensing Units (ICU) use the

HSML 3100 semi-hermetic compressors with a wide range of cooling capacities with up to 164 kW (220 hp) of installed power.

HSM 3100 series compressors are capable of operating without cooling over a limited range, but when indicated, a suitable cooling system is required (refer to the selection table).

The compressors are of the positive displacement, single screw semi-hermetic type driven by an integral stator/rotor (motor) unit with Variable Speed Drive.

A separate instruction manual has been prepared detailing the

construction and operation of the HS compressor. It is essential to

have a copy of this publication - the Operators and Application Manuals - as reference is made to it throughout this publication.

2.3. Oil Management

The method of oil separation utilised by the oil separator is achieved by a vertical vessel with mesh pad, two sight glasses, heater, dual safety pressure relief valve and oil flow sensor.


Page 8 of 38 Issue 1.2 : 05/08

Deciding the required level of efficiency is important and is dependant not only on the compressor but also on the system design. No oil separator is 100 % efficient and some oil will always be carried over into the system. On a small direct expansion system this oil will be rapidly recirculated back to the compressor travelling with the refrigerant through the system and returning via the suction line. Sufficient oil need to be maintained in the oil separator to ensure an adequate level of oil to match the specified oil flow rate from the separator into the compressor.

Note: In systems such as those incorporating flooded evaporators where oil carried over from the separator is not so readily or quickly returned, greater care is required of the system design to achieve oil return to the compressor. For the systems with long liquid and suction lines the oil charge must be increased.

For each compressor, a solenoid valve is provided in the oil injection line. The solenoid valve is electrically interlocked to energise (open) when the compressor starts and de-energise (closed) when the compressor stops.

For each compressor, a stop/check valve is provided in the discharge line before the inlet to the oil separator. This dispenses with the need for a suction non-return valve.

2.3.1. Oil Separator/Reservoir

This is a vertical vessel which removes most of the entrained oil from the discharge gas.

As the discharge gas/oil mixture enters the separator there is a sudden change of velocity and direction which removes large droplets of entrained oil. The mixture flows through a knitted wire mesh pad insert where the remaining oil mist forms large droplets on the wire strands; these droplets fall under gravity to the bottom of the separator.

Oil removed from the discharge gas drains into the lower portion of the separator shell which is used as an oil reservoir. The oil level can be observed through the oil level sight-glasses.

The correct oil level with the compressor running is illustrated in Fig 1.

The separator reservoir is fitted with an opto-electronic liquid sensor. If the oil level falls dangerously low, sufficient to uncover the sensor, relay contacts open and stop the compressor.

A dual relief valve protects the separator against excess pressure.

• For details of the relief valve, refer to publication 4-64 in Section 4.

• For details of the opto-electronic liquid sensor, refer to publication 4-97 in Section 4.

Two Separate Sight-Glasses

Working oil level (compressor running)

The standing oil level (compressor stopped) will be above the running level

Fig 1 Oil Separator/Reservoir Oil Levels

The oil separator is insulated with “Armaflex” for operation down to -10ºC ambient.

Maximum: ½ Full Minimum: Empty

Maximum: Full Minimum: ½ Full


Issue 1.2 : 05/08 Page 9 of 38

2.3.2. Oil Filter

Two oil filters (one run - one standby) with a micronic, disposable, paper element cleans the oil before it enters the compressor. Isolating valves and a pressure release allow easy renewal of the filter element without switching the unit off.

• For details of the oil filter, including the procedure for changing the filter element, refer to publication 4-115 in Section 4.

2.3.3. Oil Heater

The separator is fitted with an oil heater of sufficient capacity to maintain

an oil temperature minimum 20 °C above the ambient temperature, thereby preventing refrigerant migration into the oil and the resultant loss of viscosity and potential foaming. The oil heater is also electrically interlocked to energise when the compressor stops to prevent refrigerant condensing in the oil body.

2.3.4. Oil Low Level

An opto-electronic liquid sensor is fitted to the oil separator at a point corresponding to a dangerously low oil level. The sensor is electrically interlocked to prevent the compressor starting unless there is sufficient oil in the reservoir, and stop the compressor if the oil level falls below the danger level.

2.3.5. Oil High Level Sensor

Level sensor is fitted to the compressor casing at a point corresponding to a dangerously high oil level. The sensor is electrically interlocked to prevent the compressor starting if the oil level exceeds the danger level.

2.3.6. Lubricating Oils

The choice of lubricant depends on the refrigerant, the type of system and the operating conditions.

For applications using HFC refrigerants, ester lubricants will be used.

2.4. Liquid Injection Control

The temperature of the discharge gas/oil mixture is maintained at a constant level by the evaporation of liquid refrigerant, this is injected into the compressor via an electronic expansion valve controlled from the discharge temperature. The injection valve effectively ensures that the temperature of the oil for injection, and more especially for compressor bearing and gland seal lubrication remains within the design limits.

Liquid injection is used for all the units. A thermostat is used to open/close an electronic expansion valve in the liquid injection line according to changes in discharge temperature. The thermostat is set to

open the expansion valve when discharge temperature rises to 95 °C

(max) and close when the temperature falls to 85 °C.

Also a strainer and sight-glass for visual indication that liquid is present, are provided in the liquid injection line.

2.5. Air Cooled Condenser

Industrial Condensing Units are constructed with internally enhanced seamless copper tubes arranged in a staggered row pattern and mechanically expanded into lanced and rippled aluminium condenser fins with full fin collars.


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The condenser fans are helical type with wing-profile blades for achieving better performance. Each fan is protected by a guard. The motors are IP54. Fans thermal overloads are supplied as standard.

2.6. Liquid Receiver

Liquid refrigerant (condensate) from the condenser drains down into the liquid receiver.

The liquid receiver acts as a reservoir for surplus refrigerant, and is sized to hold the majority of the system charge when it is necessary to pump-down prior to opening up part of the system.

A dual relief valve protects the liquid receiver against excess pressure.

• For details of the relief valve, refer to publication 4-64 in Section 4.

2.7. Economiser (if applicable)

The system is supplied with direct expansion plate heat exchanger.

Economiser works as a subcooler. Liquid is being expanded in evaporator by electronic expansion valve, after evaporation process refrigerant flows through a non-return valve and filter strainer to economiser port located on the side of the compressor.

2.8. Capacity Control and Volume Ratio

ICU series compressors are provided with Variable Speed Drive control as standard. VSD allows compressor to operate from 12.5 Hz to 60 Hz.

Unit minimum capacity as percentage of full load capacity

Suction gauge (C) -35 -25 -15 -5 +5

HS3118.1 - HA052 to HS3122.1 - HA064 25.0% 25.0% 25.0% 25.0% 25.0%

HS3118.2 - HA064 to HS3122.2 - HA151 12.5% 12.5% 12.5% 12.5% 12.5%

HS3118.1 - HA052 E to HS3122.1 - HA064 E 17.5% 18.5% 19.5% 20.5% 21.5%

HS3118.2 - HA064 E to HS3122.2 - HA151 E 8.5% 9.0% 9.5% 10.0% 10.5%

Table 1 ICU’s minimum capacity load

Note: The smallest evaporator in the system must have higher or equal capacity load than the minimum capacity load of the unit (refer to Table 1).

Since the HS compressor utilises fixed intake and discharge ports

instead of valves, the overall compression ratio is determined by the configuration of these ports. The degree of compression is governed by the ratio between the flute volumes when it is sealed off by the star tooth at the beginning of the compression process, to that immediately before the discharge port is uncovered. This is known as the built-in volume ratio (VR) and is an important characteristic of all fixed-port compressors.

In order to achieve maximum efficiency, the pressure within the flute volume at the end of the compression process should equal the pressure in the discharge line at the instant the flute volume opens to discharge. Should these conditions not prevail, either overcompression or undercompression will occur, both of which result in internal losses. Although in no way detrimental to the compressor, inefficient compression will increase power consumption.


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In the Industrial condensing Units there are two types of VR:

• 4.9 for low temperature units, using HSL 3100 compressors with range of temperatures varying from -40ºC to -25ºC

• 3.0 for high temperature units, using HSM 3100 compressors with range of temperatures varying from -24ºC to 0ºC

Note: For both of VR there is need to use adjustable MOP metering devices in the process side.

2.9. MicroTech II C Plus Controller

MicroTech II C Plus controller is installed as standard; it can be used to modify unit set-points and check control parameters. A built-in display shows machine's operating status, programmable values, set-points, like temperatures and pressures of refrigerant and air. Device controls maximise the unit’s energy efficiency and the reliability. A sophisticated software with predictive logic, select the most energy efficient combination of compressors and condenser fans to keep stable operating conditions and maximise energy efficiency. The compressors are automatically rotated to ensure equal operating hours.

MicroTech II C Plus protects critical components in response to external signals from its system sensors measuring: motor temperatures, refrigerant gas and oil pressures, correct phase sequence.

For further information refer to the Controller Operating Manual.


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3. Integration into the Refrigeration Circuit

The compressor is an oil injected screw type. For HS L/M 3100 series compressors, the system contains an oil separator of sufficient capacity. The system is designed to return any oil carried over into the system from the separator, back to the compressor.

The suction return to the compressor must be dry gas in order to achieve full performance. Liquid return will be detrimental to performance although unlike reciprocating compressor is not harmful to the compressor in small quantities. However large quantities of liquid or oil returned to the compressor via the suction line can form an incompressible fluid in the rotor flutes with resultant damage to the compressor. Thus the system must be designed to prevent such occurrences.

3.1. Applications

• Cold stores

• Blast chillers

• Blast freezers

• Food processing

• Food distributions centres

• Supermarkets

Fig 2 Typical cold store complex with Daikin industrial condensing units


Issue 1.2 : 05/08 Page 13 of 38

3.2. Suction Line

The suction line should be designed to allow any build up of liquid to drain back to the evaporator. Refrigerant gas velocities should be sufficient to ensure recirculating oil is returned to the compressor.

3.3. Liquid Separation in the Suction Line

If liquid is present in the suction line due to excessive carry over from the evaporator and velocities are low, separation of the liquid can occur. If U-bends are present in the suction line liquid can collect in these traps. If the flow rate is suddenly increased (due to sudden increase in compressor load) then this liquid can be carried through to the compressor as a slug. It is these large erratic slugs of liquid that are detrimental to the compressor rather than constant small amounts of liquid return.

3.4. Electrical connections

The ICU has 3 electrical connections:

• Remote on/off

• External alarm link – for user alarm system

• Unit’s remote alarm signal link for tripping

Compressor motor and discharge high temperature thermistors are fitted as standard.

3.5. Safety Requirements for Compressor Protection

There are a number of system pressures and temperatures which must be monitored to protect the compressor and obtain an overall view of performance.


Page 14 of 38 Issue 1.2 : 05/08

4. Installation Guide

The following section has been prepared as a response to the many questions regularly asked about installing and applying our equipment. Much of the following information also appears in the instruction manuals

for the HS compressor and the Pack, but experience has shown

that installers and users, perhaps unfamiliar with this equipment, require this information before the unit is shipped.

4.1. Shipment

Before dispatch from the factory, all connections on the compressor package unit are either blanked or valved off before charging with dry nitrogen or refrigerant to a pressure of approximately 1 bar g. The evacuation process removes air and moisture, while the ‘holding charge’ maintains the system in this condition until it is time to install the unit.

CAUTION Stop valves and blanked pipe line connections must not be opened or tampered-with, otherwise the factory installed holding charge of nitrogen (and lubricating oil, if supplied) may be lost.

Packaged units and other items of plant which will eventually come into contact with refrigerant should arrive on site clean, dry and tightly sealed. If components do not arrive in this condition, the installer must notify

Daikin Europe NV, and provide full details of the problem.

4.2. Post - Delivery Inspection

Upon receipt of plant components it is important to make an immediate inspection of the equipment in the presence of the carrier’s representative, in case of damage which may have occurred during transit. If any damage is found, a notation should be made on the delivery receipt before signing, and a claim filed against the delivering carrier. It is the carrier’s responsibility to pay for any shipping damages. Check the contents of the shipment against the items listed on the advice note. Any

shortages must be reported to Daikin Europe NV, without delay.

When checking the compressor package unit, make sure the holding charge has been retained during transit from the factory. If pressure gauges register zero there is a leak which must be traced and repaired, that part of the system leak tested, evacuated and a fresh holding charge inserted.

4.3. Lifting and Moving System Components

System components are stringently tested before leaving the factory where every precaution is taken to ensure that equipment is dispatched to the customer in perfect condition. It is very important that installation personnel adopt the same standards of care when unpacking and handling. Care must be taken when off-loading and positioning the compressor package unit and other large system components. Chains, cables or other moving equipment must be positioned so as to avoid damage to the component being handled; the use of load spreaders or a lifting frame is recommended where appropriate. Do not attach hoists or slings to the pipework. Shock-loads or other rough handling should be avoided as this treatment may result in damage to equipment, or misalignment of the various subassemblies.

4.4. Storage and Preservation

If the plant is not to be installed immediately but held in store, the following points must be observed:


Issue 1.2 : 05/08 Page 15 of 38

4.4.1. Store Location

Plant should preferably be stored indoors in an unoccupied area which should be clean and vermin-free, with a warm, dry environment, well ventilated to discourage condensation. If the equipment is stored outside, protection from the elements must be provided which also keeps condensation to a minimum. The compressor and other packaged components must be positioned on a level floor with reasonable access around all four sides to enable periodic inspections to be made. The underlying floor must be capable of safely supporting the weight of the equipment. Items of equipment fitted with rolling element bearings, for example, the compressor, drive motors and pumps, should be stored away from sources of vibration or isolated using anti-vibration packing; this will prevent fretting corrosion (Brinelling) of the bearings. Provision must be made for access to drive motors and pumps to enable the shafts to be rotated at weekly intervals. Programmed integrated circuits (memory chips) are sensitive to low temperatures. Equipment containing these devices, for example, the MicroTech II controller, should not be exposed to ambient temperatures below -10 °C.

The store area must be secure against unauthorised access. This is important to prevent vandalism or accidental damage and serious or fatal injury caused, for example, by the escape of refrigerant or oil.

4.4.2. Protection During Storage

Cover the ventilation grills of electric motors and electrical control panels to prevent condensation and discourage dirt, dust and small creatures from entering; make sure these covers are removed at the end of the storage period. External unpainted metal surfaces, for example, the drive motor shaft extension or the exposed portion of a valve spindle, should be protected by coating with Shell Enis Fluid MD or a thin film of grease. Every six months check the protective coating and reapply as necessary. Carry out any additional special instructions for the long term storage of the following plant components:

• HS compressor; carry out the procedure described

under Placing the Compressor into Store in the compressor instruction manual.

• Compressor drive motor; refer to the manufacturer’s Instructions.

4.4.3. Storage Inspection Routine

At least once a week:

• Inspect the plant for signs of damage or deterioration.

• Check that the compressor package unit has retained its holding charge of nitrogen or refrigerant. Pressure gauges, where fitted, will show if there has been a decrease in pressure. Check any other packaged items which contain a holding charge.

Remember that significant changes in ambient temperature will cause the pressure of the holding charge to fluctuate. This should be taken into account if, because of a drop in pressure, a leak is suspected.

• Rotate drive motors and pumps by several turns. Shafts must be left in a different position each time they are rotated.


Page 16 of 38 Issue 1.2 : 05/08

4.4.4. Taking the Plant out of Storage

Clean off the grease from bare metal surfaces or, if Shell Enis Fluid MD was used, use white spirit or similar solvent to remove the protective film. Carry out the procedure described under taking the Compressor out of

Storage in the HS compressor instruction manual. Carry out any

additional special instructions for taking the plant components described in 4.4.2. out of storage.

4.5. Siting the Plant

When siting the plant, consideration should be given to the following:

a) Certain parts of the plant generate heat during operation, for example, the compressor package unit and electrical panels. These items of plant must be installed in a location which is well ventilated to ensure adequate dissipation of heat.

b) All parts of the plant should be positioned or protected to minimise the risk of impact damage, for example, by fork lift trucks.

c) Adequate working space should be provided on all sides and above plant components to allow for operation and maintenance, for example:

• access to instrumentation;

• access to stop valves, particularly isolating valves;

• changing filters, cleaning strainers;

• lubrication: grease nipples, oil filling connection;

• service pipe connections, for example, vent and drain lines;

Refer to the certified general arrangement drawing to establish the access required, pipe connections and sizes.

d) If the plant is accessible to unauthorised persons, steps must be taken to prevent access. This is to prevent vandalism or accidental damage, and serious or fatal injury, for example, from live terminals within electrical panels, or escape of refrigerant or oil.

ICU’s are air-cooled, hence it is important to observe the minimum distances which guarantee the best ventilation of the condenser coils. Limitations of space reducing the air flow could cause significant reductions in cooling capacity and an increase in electricity consumption.

To determinate unit placement, careful consideration must be given to assure a sufficient air flow across the condenser heat transfer surface. Two conditions must be avoided to achieve the best performance: warm air recirculation and coil starvation.

Both these conditions cause an increase of condensing pressures what results in reductions in unit efficiency and capacity. ICU performance is less affected in poor air flow situations because of its special condensing coil geometry.

Moreover the microprocessor has the ability to calculate the operating environment of the condensing unit and the capacity to optimize its performance staying on-line during abnormal conditions.

Each side of the unit must be accessible after installation for periodic service. Fig 3a shows you a minimum recommended clearance requirements.


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Vertical condenser air discharge must be unobstructed because the unit would have its capacity and efficiency significantly reduced.

If the units are positioned in places surrounded by walls or obstacles of the same height as the units, the units should be at least 2500 mm from obstacles (Fig 3b). In the event the obstacles are higher than the units, the units should be at least 3000 mm from the obstacle (Fig 3d). Units installed closer than the minimum recommended distance to a wall or other vertical riser may experience a combination of coil starvation and warm air recirculation, thus causing reduction in unit capacity and efficiency reductions. Once again, the microprocessor will allow the unit to stay on line, producing the maximum available capacity, even at less than recommended lateral clearances.

When two or more units are positioned side by side it is recommended that the condenser coils are at least 3600 mm distance from one another (Fig 3c); strong wind could be the cause of air warm recirculation.

a)

b)

c)

d)

Fig 3 Space requirements


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4.5.1. Installing Packaged Components

The following paragraphs refer to the compressor but also apply, in general terms, to other packaged components installed on a baseframe.

4.5.1.1 Foundations

Firm, robust foundations are essential to support the weight of the compressor package unit. Early consideration should be given to the design of adequate foundations in order to achieve these aims; in addition, the amount of extra work required at a later date will be minimised. If the unit is intended for use with an existing installation, inspect the foundations and make any reinforcements which may be necessary.

A concrete foundation is generally considered most suitable, alternatively, installation on a steel floor will be adequate provided the surrounding structure has been sturdily constructed; a flimsy girder framework, for example, would not be suitable. Wooden floors are also satisfactory if they are laid over a concrete or steel base.

The concept of the screw compressor reduces noise and keeps vibration levels to a minimum. This means that anti-vibration mountings can be dispensed with in the majority of cases. However, if the unit is to be installed on a steel foundation, it may be worth considering fitting antivibration mountings in order to keep noise and vibration transmission to the surroundings as low as possible. Vibration isolators should be fitted in accordance with manufacturer’s instructions.

Concrete foundations should be generously dimensioned and adequately reinforced. Where conditions permit, a concrete plinth is recommended so as to raise the equipment above the surrounding floor level and provide adequate drainage. If underlying floor conditions are unfavourable, or in the event of an insufficiently rigid floor, seek the advice of an Architect or Civil Engineer concerning the design of a suitable foundation.

The cavities required for foundation bolts are normally pre-cast into a concrete base; leave a rough finish to the walls of the cavities so as to provide a good key for the grout mixture. Cavities may also be formed with a pneumatic drill after the base has been cast.

4.5.1.2 Installation Onto Prepared Foundations

The following paragraphs refer to installations made on concrete as this is probably the most common foundation material; however, these notes are equally applicable to an installation made on a steel floor.

The foundation immediately beneath the package unit mounting positions must be made smooth and even to accept packing pieces large enough to extend over the whole area of each mounting pad. Proceed by grouting in the foundation bolts level with the surface of the foundations. Before applying the grout mixture, make sure the cavities in the foundation are dirt and dust-free. To encourage a superior bond between the grout and foundation, apply a cement wash to the inside of the cavities approximately 30 minutes before grouting. Always use a fresh grout mixture, a proportion of one part sand to one part cement is recommended. Allow the grout to set hard.

Lower the package unit into position on the prepared foundation. The unit baseframe should be levelled by adjusting as required at each mounting position, checking at each stage with a long-base spirit level. When the package unit is square and level, insert metal packers of the required thickness under the mounting positions. As far as possible, the number of packing pieces at each position should be kept to a minimum. Secure the unit in position.


Issue 1.2 : 05/08 Page 19 of 38

4.6. Connecting System Components

After installing the packaged subassemblies onto prepared foundations, they must be coupled together to form a complete refrigeration system. When fabricating interconnecting pipework and making connections, every precaution must be taken to prevent dust, dirt or moisture entering the system. Packaged items of the plant and other major system components, which have been evacuated and are supplied complete with a holding charge, should remain in this clean, moisture-free condition until immediately before they are coupled to the rest of the system. Refer to Part E: Evacuation and Dehydration of The Operating Manual.

NOTE: for trouble-free operation of the plant, complete cleanliness and dryness of the refrigeration system is of the utmost importance.

4.6.1. Pressure Equipment Directive (PED)

This directive applies to pressure equipment (refrigeration plant) and assemblies within the European Economic Area (EEC). PED – 97/23/EC becomes mandatory on 29/05/2002.

CAUTION Industrial Condensing Units are designed and manufactured to comply with the PED. It is essential that all other system components and assemblies subject to pressure (piping, vessels, stop valves, relief valves etc.,) comply with the regulations.

The scope of the new regulations is described in the publication Pressure Equipment, Guidance Notes on the UK Regulations, available from the Department of Trade and Industry.

4.6.2. Refrigeration Pipework

When fabricating interconnecting pipework and making connections, every precaution must be taken to prevent dust, dirt or moisture entering the system. Packaged items of plant and other major system components which have been evacuated and are supplied complete with a holding charge, should remain in this clean, moisture-free condition until immediately before they are coupled to the rest of the system.

NOTE: for trouble-free operation of the plant, complete cleanliness and dryness of the refrigeration system is of the utmost importance.

4.6.2.1 General

Refrigerant pipe lines must be installed according to normal refrigeration engineering practice. Note in particular the following points:

• Sufficient clearance must be provided for routine maintenance: tracing and repairing leaks, checking pipe insulation and vapour seals.

• Piping must be suitably supported according to its size and weight to avoid excessive strain on brazed, welded or flanged connections, valves, etc. The distance between supports depends on the size and service weight of the pipeline. Within the EEC, the recommended maximum spacing for single pipe supports is detailed in BS EN 378 Part 2: 2000, Tables 3 and 4.

• Long runs of piping must have provision for expansion and contraction.


Page 20 of 38 Issue 1.2 : 05/08

• Precautions must be taken to avoid excessive vibration or pulsation (liquid-hammer). Particular attention must be paid to prevent direct transmission of noise and vibration to or through the supporting structure.

• Pipe connections which are not used during normal operation must be fitted with blank flanges. For example, where branch connections are provided for future extensions to be made to the system.

4.6.2.2 Cutting, Joining and Bending Operations

Only refrigeration grade tubing should be used in the system. When in store, tubing must be properly sealed to prevent ingress of dirt and moisture.

After each length of tube has been cut to length, it must be cleaned immediately before it is installed into the system. Large sizes of tube can be cleaned by pulling through with clean rag. Smaller sizes of pipe, up to approximately 40 mm bore, should be blown through with dry nitrogen.

When joining pipes by brazing or welding, oxide scale will form on the interior surfaces in the vicinity of the joint. If the scale is allowed to remain, it will eventually begin to flake off the pipe walls and cause a dirt problem in the system, especially during the early life of the plant. Strainers will need cleaning more frequently than the recommended intervals and the commissioning period may need to be extended.

This problem may be overcome to a large extent by circulating dry nitrogen through the pipe during welding and brazing operations; however, it is also advisable to dislodge any scale which may have formed, by hammering each section of pipe, then pulling through with a stiff wire brush. Any pipework which is curved by heating and then bending must be given the same treatment.

4.6.2.3 Pressure Testing

Interconnecting refrigerant pipework fabricated on site must be subjected to a strength and leak test according with BS EN 378: 2008.

4.6.2.4 Storage

Piping and other components which have been prepared for installation and are not for immediate use must be capped and sealed tightly; otherwise they are likely to contain moisture when they are installed. When an unsealed component is taken from a cold to a warm atmosphere, moisture may condense on both the inner and outer surfaces. It follows, therefore, that a component which is cold should never be opened up when the ambient temperature is higher than the component. Also, sufficient time must be allowed for the temperature of the component to equalise with that of the surroundings before it is opened up. This precaution also applies to parts of the system which have been working at low temperatures and are being dismantled for servicing.

During erection, system components or lengths of prepared piping MUST NOT be left unblanked longer than is necessary to enable them to be installed into the system. This is particularly important in cases where items of plant are not protected from the weather. Even when pipes or components are undercover, on no account must they be left with the ends of pipes, etc. open to atmosphere. This precaution also applies to such periods as meal times.


Issue 1.2 : 05/08 Page 21 of 38

4.6.2.5 Installation

As each run of pipe is installed, tests should be made for pipework stresses. Remove flange connecting bolts to see if the bolts bind in their holes such that the flanges spring out of line when the bolts are removed. If this should occur, pipe hangers or support blocks must be adjusted to correct the alignment.

Steel pipes and components must be protected against corrosion by applying a suitable rustproof coating. Rustproofing must be applied before any insulation. Insulation must be effectively vapour sealed to prevent condensation forming.

4.6.2.6 Stop Valves

In the case of valves supplied with their branches prepared for butt welding or brazing into line, it is essential to avoid overheating the gland nut or seat insert, or contaminating the system with scale or weld. This can be prevented by removing the bonnet assembly before the welding or brazing operation takes place.

Check that valves are orientated correctly to permit access.

Those valves which are intended to be fitted with a cap over the bonnet (rather than a handwheel), check that the cap is firmly in position to prevent tampering, loss of refrigerant or the entry of air and moisture.

Normally closed stop valves which open to the atmosphere, for example, purge, drain and charging valves, must be fitted with blank caps to prevent refrigerant leakage. Capping the valve also protects the internals from corrosion.

4.6.2.7 Relief Valves

Relief valves must be vented to atmosphere, via a pipe, to the open air. Terminate the pipe at a point where there is no foreseeable hazard to the plant or to personnel, and no risk of refrigerant entering buildings nearby.

WARNING Refrigerant must never be discharged into the plant room or other enclosed space.

The vent line should be at least the same bore as the outlet from the relief valve (no smaller), contain no valves and a minimum number of bends. Turn-down the end of the vent pipe to prevent rainwater from entering the line. The discharge vent line, from the pressure relief valve to atmosphere, should be clearly marked so that its purpose can be identified.

4.7. Electrical Connections

Electrical wiring must be sized and installed to such a standard as to meet the requirements of the national and local codes pertaining to the area in which the installation is to take place. The supply power, voltage, frequency and phase must agree with the values stated on the motor casing. Check that incoming mains supply cables, motor fuses, circuit breakers and overloads are correctly sized.

Before any electrical connections are made to the plant, these installation and commissioning instructions should be studied, together with electrical wiring diagrams. Particular care should be taken to ensure correct terminal connection and rotation of the compressor and auxiliaries.

Gland plates are provided in electrical control cabinets for supply and control cables. Cabling must be inspected to the nearest point on the main run.


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Electrical checks should be made as follows:

• accessibility for operation and future maintenance;

• cable clipping;

• earthing continuity;

• electrical insulation resistance;

• glands and grommets;

• mounting and fastening;

• protection;

• wiring terminations;

To avoid problems of electrical interference, all low voltage wiring (transducers, data communications and 24 V dc) must be adequately separated from higher voltage ac wiring (110 V, 240 V, 415 V or higher). A separation of 150 mm is desirable but not always achievable within control panels. Low voltage and higher voltage cables should cross at right-angles.

External electrical connections required are detailed on the wiring

diagrams. Depending on the extent of Daikin Europe NV supply,

some of these connections may be made at the factory.

4.8. Lubricating Oil Charge

Lubricating oil should be charged into the oil separator/reservoir after the pipework completed, pressure tested and evacuated.

NOTE: the reservoir oil heaters MUST NOT be energised without first of all checking that the reservoir has been charged with oil. Failure to observe this warning may result in the heaters burning-out.

If the oil separator/reservoir is supplied without an oil charge, the easiest way to fill the reservoir is to suck in the oil with the reservoir under vacuum.


Issue 1.2 : 05/08 Page 23 of 38

Appendix 1 Industrial Condensing Unit Data

• Industrial Condensing Unit Nomenclature

• Standard unit performance data for R404A (high temperature units).

• Standard unit performance data for R404A (low temperature units).

• Economised unit performance data for R404A (high temperature units).

• Economised unit performance data for R404A (low temperature units).

• Technical specification for R404A.

• Dimensions and weight


Page 24 of 38 Issue 1.2 : 05/08

Industrial Condensing Unit Nomenclature


Issue 1.2 : 05/08 Page 25 of 38

Standard unit performance data for R404A

10 K Useful superheat

5 K Subcooling

Cooling Capacity Q (kW) Power Consumption P (kW) TE

Suction Gauge °C Suction Gauge °C Unit Model Efficiency Air on

-24 -20 -15 -10 -5 0 -24 -20 -15 -10 -5 0

32 60 75 92 113 135 160 38 41 44 47 50 54

35 56 70 87 106 127 152 39 43 46 49 53 57 HSM 3118.1-HA052 High

38 53 66 82 100 120 143 41 44 47 51 55 59

32 71 88 108 132 158 186 46 50 54 58 63 68

35 67 83 102 125 149 176 48 52 56 61 66 71 HSM 3120.1-HA052 Standard

38 62 78 96 117 140 165 50 54 59 64 69 75

32 75 94 116 142 171 203 45 49 52 55 59 63

35 70 88 109 134 162 193 46 50 54 57 61 66 HSM 3120.1-HA064 High

38 65 82 103 127 153 183 48 52 56 60 64 69

32 80 99 121 147 175 205 54 59 63 69 75 81

35 75 93 115 139 164 193 56 61 65 72 78 85 HSM 3121.1-HA052 Standard

38 70 87 107 129 153 58 63 69 76 82

32 85 105 130 159 192 227 52 57 61 64 69 74

35 79 99 123 151 182 216 54 59 63 67 72 77 HSM 3121.1-HA064 High

38 74 93 116 142 172 204 56 61 65 70 76 81

32 89 110 135 162 192 224 62 68 74 81 88 96

35 84 104 127 152 180 65 71 77 85 93 HSM 3122.1-HA052 Standard

38 78 96 117 141 68 74 81 90

32 96 119 146 178 214 253 60 65 70 75 80 87

35 90 112 138 169 202 239 62 68 73 78 84 91 HSM 3122.1-HA064 High

38 84 105 130 158 190 226 65 70 76 82 89 95

32 115 142 175 212 252 297 77 84 91 98 106 115

35 108 134 165 199 238 281 80 87 94 102 112 121 HSM 3118.2-HA064 Standard

38 100 125 154 187 226 84 91 99 108 118

32 120 149 185 225 270 320 75 82 88 94 100 108

35 112 140 174 212 255 303 78 85 91 98 105 113 HSM 3118.2-SE128 High

38 105 132 163 199 240 287 81 88 95 102 111 119

32 138 170 209 253 300 351 94 103 111 120 131 142

35 129 160 197 237 282 331 97 106 115 126 138 149 HSM 3120.2-SE115 Standard

38 120 150 183 221 263 102 111 121 133 145

32 145 179 221 270 323 382 91 100 107 114 123 133

35 135 168 209 255 306 362 95 103 111 119 129 139 HSM 3120.2-SE145 High

38 126 158 196 239 287 341 99 107 115 125 136 146

32 154 190 233 279 329 382 109 120 130 143 157 170

35 144 179 218 260 306 114 125 136 150 164 HSM 3121.2-SE115 Standard

38 134 166 201 238 120 131 144 159

32 163 201 248 301 360 423 106 116 125 135 146 158

35 152 190 234 285 339 399 110 120 130 141 153 165 HSM 3121.2-SE145 High

38 142 178 219 266 317 374 115 125 136 148 161 173

32 182 225 276 334 396 464 123 135 146 158 172 186

35 171 212 260 314 373 438 128 140 152 165 180 195 HSM 3122.2-SE145 Standard

38 159 198 243 292 349 134 146 159 174 190

32 189 234 288 351 420 495 121 132 142 152 163 176

35 177 220 272 331 397 469 125 137 147 159 172 185 HSM 3122.2-HA151 High

38 165 207 256 311 373 442 131 142 154 166 181 194

Table 2 Standard High Temperature Units


Page 26 of 38 Issue 1.2 : 05/08

Standard unit performance data for R404A


5 K Subcooling

Cooling Capacity Q (kW) Power Consumption P

(kW) TE

Suction Gauge °C Suction Gauge °C Unit Model Efficiency

Air on

-40 -35 -30 -25 -40 -35 -30 -25

32 28 37 48 60 28 31 34 38

35 26 35 45 56 30 32 35 39 HSL 3118.1-HA052 High

38 24 32 42 53 32 34 37 41

32 34 44 57 71 35 37 41 46

35 31 42 53 67 37 39 43 48 HSL 3120.1-HA052 Standard

38 28 38 49 62 39 42 46 50

32 35 46 59 75 34 37 40 45

35 32 43 56 70 36 38 42 46 HSL 3120.1-HA064 High

38 30 40 52 65 38 40 44 48

32 38 51 64 80 41 44 48 54

35 35 47 60 75 43 46 50 56 HSL 3121.1-HA052 Standard

38 32 43 55 70 46 49 53 58

32 40 53 67 85 39 43 47 52

35 37 49 63 79 42 44 49 54 HSL 3121.1-HA064 High

38 34 46 59 74 44 47 51 56

32 43 57 72 89 47 51 56 62

35 39 53 67 84 50 53 59 65 HSL 3122.1-HA052 Standard

38 36 48 62 78 53 57 62 68

32 45 59 76 96 45 49 54 60

35 42 56 71 90 48 51 56 62 HSL 3122.1-HA064 High

38 38 51 66 84 51 54 59 65

32 55 72 92 115 58 62 69 77

35 50 67 86 108 61 66 72 80 HSL 3118.2-HA064 Standard

38 46 62 79 100 65 70 77 84

32 56 74 95 120 57 61 68 75

35 52 70 89 112 60 64 70 78 HSL 3118.2-SE128 High

38 48 64 83 105 64 68 74 81

32 66 87 111 138 71 76 84 94

35 61 81 103 129 75 80 88 97 HSL 3120.2-SE115 Standard

38 55 74 95 120 79 85 93 102

32 68 89 115 145 69 74 82 91

35 63 84 108 135 73 78 86 95 HSL 3120.2-SE145 High

38 58 78 100 126 77 83 90 99

32 74 99 125 154 83 89 98 109

35 68 91 116 144 87 94 103 114 HSL 3121.2-SE115 Standard

38 62 83 106 134 93 100 110 120

32 77 102 130 163 80 87 96 106

35 71 96 122 152 85 91 100 110 HSL 3121.2-SE145 High

38 65 88 112 142 90 96 105 115

32 87 115 147 182 93 100 111 123

35 80 107 136 171 99 106 116 128 HSL 3122.2-SE145 Standard

38 73 98 126 159 105 112 123 134

32 89 118 151 189 91 99 109 121

35 82 110 141 177 97 103 114 125 HSL 3122.2-HA151 High

38 76 102 131 165 103 110 120 131

Table 3 Standard Low Temperature Units


Issue 1.2 : 05/08 Page 27 of 38

Economised unit performance data for R404A


5 K Subcooling

Cooling Capacity Q (kW) Power Consumption P (kW) TE

Suction Gauge °C Suction Gauge °C Unit Model Efficiency Air on

-24 -20 -15 -10 -5 0 -24 -20 -15 -10 -5 0

32 76 92 112 133 157 183 41 44 47 50 54 58

35 73 88 107 128 151 175 42 46 49 53 57 61 HSM 3118.1-HA052E High

38 70 85 102 122 143 162 44 48 52 56 60 64

32 91 109 132 157 184 213 50 54 59 63 68 73

35 86 104 126 150 176 198 52 57 61 66 72 77 HSM 3120.1-HA052E High

38 82 100 120 143 165 54 59 64 70 76

32 95 115 140 167 196 226 48 52 56 59 62 66

35 90 110 134 160 189 222 50 54 58 62 65 70 HSM 3120.1-HA064E Extra High

38 86 105 127 153 182 212 52 56 61 65 69 74

32 102 123 148 175 205 231 58 64 69 75 82 87

35 98 118 141 167 193 61 66 72 79 86 HSM 3121.1-HA052E High

38 93 112 135 159 63 69 76 84

32 108 131 158 189 222 258 56 61 65 69 73 78


38 98 119 144 173 204 233 60 66 71 76 82 87

32 115 138 165 194 224 68 75 82 89 97

35 110 132 157 185 71 78 85 94 HSM 3122.1-HA052E High

38 104 125 149 74 81 89

32 121 147 178 212 248 289 65 71 76 81 86 93


38 111 135 162 193 226 253 70 77 83 89 97 102

32 147 178 214 253 296 337 84 92 99 107 116 125

35 141 170 204 242 280 307 87 95 103 112 122 129 HSM 3118.2-HA064E High

38 134 162 194 229 91 99 108 119

32 152 185 224 267 313 365 81 89 95 101 108 115

35 145 177 214 256 301 350 84 92 99 106 114 122 HSM 3118.2-SE128E Extra High

38 139 169 204 244 286 323 88 96 103 111 120 127

32 176 212 254 301 352 392 102 112 121 132 144 154

35 168 202 243 288 331 106 116 127 139 152 HSM 3120.2-SE115E High

38 160 192 231 110 121 133

32 183 222 269 320 376 438 99 108 116 123 132 142

35 175 212 256 306 361 415 102 112 121 130 140 150 HSM 3120.2-SE145E Extra High

38 167 202 244 292 342 379 106 116 126 137 148 156

32 198 238 284 334 382 120 132 144 158 173

35 190 227 271 318 124 137 151 167 HSM 3121.2-SE115E High

38 179 215 130 143

32 210 255 308 367 431 501 114 124 133 143 153 165


38 192 233 281 335 389 430 123 134 146 158 171 180

32 230 276 330 388 447 136 150 163 178 195

35 220 264 314 370 142 156 171 187 HSM 3122.2-SE128E High

38 208 249 298 148 162 178

32 240 291 351 417 489 568 131 143 154 165 177 190


38 220 266 320 380 441 142 155 168 182 197

Table 4 Economised High Temperature Units


Page 28 of 38 Issue 1.2 : 05/08

Economised unit performance data for R404A


5 K Subcooling

Cooling Capacity Q (kW)

Power Consumption P (kW) TE

Suction Gauge °C Suction Gauge °C Unit Model Efficiency

Air on

-40 -35 -30 -25 -40 -35 -30 -25

32 40 50 62 76 31 34 37 41

35 38 48 60 73 33 35 39 42 HSL 3118.1-HA052E High

38 35 46 57 70 36 37 40 44

32 47 60 74 91 38 41 45 50

35 45 58 71 86 41 43 47 52 HSL 3120.1-HA052E High

38 42 55 68 82 44 46 49 54

32 49 61 77 95 37 40 44 48

35 46 59 74 90 39 42 46 50 HSL 3120.1-HA064E Extra High

38 44 57 71 86 42 44 48 52

32 54 69 84 102 45 48 53 58

35 51 66 81 98 48 51 55 61 HSL 3121.1-HA052E High

38 48 62 77 93 51 53 58 63

32 56 70 88 108 43 46 51 56


38 50 65 80 98 49 51 55 60

32 61 77 95 115 53 57 62 68

35 57 74 91 110 56 59 64 71 HSL 3122.1-HA052E High

38 54 69 86 104 59 62 67 74

32 63 80 99 121 50 54 59 65


38 56 73 91 111 57 60 64 70

32 77 98 121 147 64 69 76 84

35 73 94 116 141 69 73 79 87 HSL 3118.2-HA064E High

38 69 89 110 134 73 76 83 91

32 79 100 124 152 62 67 74 81

35 75 97 119 145 67 71 77 84 HSL 3118.2-SE128E Extra High

38 71 92 114 139 71 74 80 88

32 93 118 146 176 78 84 93 102

35 88 113 139 168 84 89 96 106 HSL 3120.2-SE115E High

38 82 107 132 160 89 93 101 110

32 96 121 150 183 75 82 90 99

35 91 117 144 175 81 86 93 102 HSL 3120.2-SE145E Extra High

38 85 111 137 167 87 90 97 106

32 105 135 165 198 92 99 109 120

35 99 128 157 190 99 104 113 124 HSL 3121.2-SE115E High

38 93 120 148 179 104 109 118 130

32 110 139 173 210 87 94 104 114


38 98 128 158 192 100 104 113 123

32 121 155 190 230 105 113 124 136

35 115 148 181 220 113 119 129 142 HSL 3122.2-SE128E High

38 107 139 171 208 119 124 135 148

32 126 159 197 240 100 109 119 131


38 112 145 180 220 115 120 129 142

Table 5 Economised Low Temperature Units


Issue 1.2 : 05/08 Page 29 of 38

Technical specification for R404A

Compressor Condenser Connections

Nom. motor

No fans x power

Fan diameter

Speed Air

flow Suction Liquid Unit Model

Model

kW (hp)

Qty

kW mm rpm m3/s in in

HS3118.1 - HA052 (E) HSL/M3118 60

(80) 1 running 1 standby

4 x 1.80 800 900 23.9 3 1/8" OD 1 3/8" OD

HS3120.1 - HA052 (E) HSL/M3120 60


4 x 1.80 800 900 23.9 3 1/8" OD 1 3/8" OD

HS3120.1 - HA064 (E) HSL/M3120 60


6 x 1.80 800 900 35.9 3 1/8" OD 1 3/8" OD

HS3121.1 - HA052 (E) HSL/M3121 82


4 x 1.80 800 900 23.9 3 1/8" OD 1 5/8" OD

HS3121.1 - HA064 (E) HSL/M3121 82


6 x 1.80 800 900 35.9 3 1/8" OD 1 5/8" OD

HS3122.1 - HA052 (E) HSL/M3122 82


4 x 1.80 800 900 23.9 3 1/8" OD 1 5/8" OD

HS3122.1 - HA064 (E) HSL/M3122 82


6 x 1.80 800 900 35.9 3 1/8" OD 1 5/8" OD

HS3118.2 - HA064 (E) HSL/M3118 60

(80) 2 6 x 1.80 800 900 35.9 5" NB 1 5/8" OD

HS3118.2 - SE128 (E) HSL/M3118 60

(80) 2 8 x 1.73 800 900 44.9 5" NB 1 5/8" OD

HS3120.2 - SE115 (E) HSL/M3120 60

(80) 2 6 x 1.73 800 900 32.3 5" NB 1 5/8" OD

HS3120.2 - SE145 (E) HSL/M3120 60

(80) 2 8 x 1.73 800 900 43.0 5" NB 2 1/8" OD

HS3121.2 - SE115 (E) HSL/M3121 82

(110) 2 6 x 1.73 800 900 32.3 5" NB 1 5/8" OD

HS3121.2 - SE145 HSL/M3121 82

(110) 2 8 x 1.73 800 900 43.0 5" NB 2 1/8" OD

HS3121.2 - HA133 E HSL/M3121 82

(110) 2 10 x 1.73 800 900 56.2 5" NB 2 1/8" OD

HS3122.2 - SE128 E HSL/M3122 82

(110) 2 8 x 1.73 800 900 44.9 5" NB 2 1/8" OD

HS3122.2 - SE145 HSL/M3122 82

(110) 2 8 x 1.73 800 900 43.0 5" NB 2 1/8" OD

HS3122.2 - HA151 (E) HSL/M3122 82

(110) 2 10 x 1.73 800 900 53.8 5" NB 2 1/8" OD

Table 6 Economised Low Temperature Units

Oil Charge

4 fan unit 6 fan unit 6 fan unit 8 fan unit 10 fan unit

1 compressor running

1 standby

1 compressor running

1 standby

2 compressors running



50 L 50 L 80 L 95 L 95 L

Table 7 Oil charge


Page 30 of 38 Issue 1.2 : 05/08

Dimensions and Weight

Length Width Height Weight Unit Model

mm mm mm kg

HS3118.1 - HA052 (E) 2240 2235 2340 2405

HS3120.1 - HA052 (E) 2240 2235 2340 2405

HS3120.1 - HA064 (E) 3140 2235 2340 2859

HS3121.1 - HA052 (E) 2240 2235 2340 2405

HS3121.1 - HA064 (E) 3140 2235 2340 2859

HS3122.1 - HA052 (E) 2240 2235 2340 2405

HS3122.1 - HA064 (E) 3140 2235 2340 2859

HS3118.2 - HA064 (E) 3140 2235 2340 2859

HS3118.2 - SE128 (E) 4040 2235 2340 4102

HS3120.2 - SE115 (E) 3140 2235 2340 3680

HS3120.2 - SE145 (E) 4040 2235 2340 4216

HS3121.2 - SE115 (E) 3140 2235 2340 3680

HS3121.2 - SE145 4040 2235 2340 4211

HS3121.2 - HA133 E 4940 2235 2340 4372

HS3122.2 - SE128 E 4040 2235 2340 4102

HS3122.2 - SE145 4040 2235 2340 4211

HS3122.2 - HA151 (E) 4940 2235 2340 4496

Table 8 Dimensions and Weight

Liquid receiver capacity

4 fan unit 6 fan unit 6 fan unit 8 fan unit 10 fan unit

1 running 1 standby

1 running 1 standby

2 running 2 running 2 running

132 L 251 L 251 L 370 L 489 L

Table 9 Liquid receiver capacity


Issue 1.2 : 05/08 Page 31 of 38

General Arrangement

Fig 4 General arrangement


Page 32 of 38 Issue 1.2 : 05/08

Appendix 2 System Schematic Flow Diagram

• Flow and instrumentation diagram.

• Flow and instrumentation diagram of the economiser option.

• Flow and instrumentation diagram of the liquid injection option.


Issue 1.2 : 05/08 Page 33 of 38

Flow and Instrumentation Diagram

Note: It is illegal to “purge” HFC refrigerants to atmosphere. Purge valves must be connected to reclaim unit.

Fig 5 Flow and instrumentation diagram


Page 34 of 38 Issue 1.2 : 05/08


Note: Drawing shows economiser line for 2 compressors running. Unit with 1 run and 1 standby compressor has only one economiser.

Fig 6 Flow and instrumentation diagram of the economiser circuit (optional)


Issue 1.2 : 05/08 Page 35 of 38


Fig 7 Flow and instrumentation diagram of the liquid injection (optional)


Page 36 of 38 Issue 1.2 : 05/08

Appendix 3 ICU Performance Data

For detailed selection use the HS compressor selection software, available

on CD.

Continuous research and development may necessitate changes to specifications and data in this Application Manual and the Compressor Selection Software.

Subcooling & Superheat Correction Factors

The performance data is based on 10.0 oC suction superheat and 5.0

oC

liquid subcooling.

The suction superheat is assumed to be usefully obtained. Such superheat can be obtained in the evaporator or in a liquid to suction heat exchanger or similar vessel in the refrigeration circuit producing a beneficial effect.

The approximate effect of an increase in useful suction superheat is an increase in capacity of 0.17 % for every additional 1.0

oC superheat.

Non usefully obtained superheat (such that might be picked up in the suction line due to heat exchange with the environment) will have a detrimental effect on performance.

The approximate effect is a loss in performance of approximately 0.7 % for each additional 1.0

oC of non useful suction superheat.

It is important to ensure adequate suction superheat. Insufficient superheat can result in liquid carry over into the compressor, reducing performance and also resulting in inadequate discharge superheat for satisfactory oil separation.

Additional subcooling will have a beneficial effect on the system performance.

The approximate effect of an increase in liquid subcooling is an increase in capacity of 1.1 % for every additional 1.0

oC subcooling.

If the useful superheat is obtained in a suction to liquid heat exchanger then only the effect of the increase in suction superheat should be taken in to account. Otherwise the effect on performance will be added twice. Using the increase in suction superheat also includes the effect of the change in specific volume at the compressor suction.

hs l/m 3100 series semi-hermetic single screw air cooled ... · semi-hermetic single screw air...

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