PTXiSs Compressor

units

User documentation

Original manual
areacooling.com
v.22-01.01

Contents page

1. General Information ............................................................................................................................ 4

2. Safety ................................................................................................................................................... 5
2.1. Type code description .................................................................................................................. 6
3. Units specification ............................................................................................................................... 6
3.1. Components ................................................................................................................................. 6
4. Technical data...................................................................................................................................... 7
5. Units drawings ..................................................................................................................................... 8
5.1. PTXiAr-4.5 MHP|PTXiAr-7 MHP | PTXiAr-3 MP............................................................................ 8
5.1. PTXiAr-10 MHP ............................................................................................................................. 9
5.2. PTXiSs-15 MHP | PTXiSs-10 MP .................................................................................................. 10
5.3. PTXiSs-17D MHP | PTXiSs-21D MHP .......................................................................................... 11
5.4. PTXiSs-26D MHP | PTXiSs-29D MHP | PTXiSs-17D MP .............................................................. 12
6. Schematic diagrams........................................................................................................................... 13
6.1. PTXiAr-4.5/7 MHP....................................................................................................................... 13
6.2. PTXiSs-10 MHP ........................................................................................................................... 13
6.3. PTXiSs-15 MHP ........................................................................................................................... 14
6.4. PTXiSs-17D/21D MHP ................................................................................................................. 14
6.5. PTXiSs-26D/29D MHP ................................................................................................................. 15
6.6. PTXiAr-3 MP................................................................................................................................ 15
6.7. PTXiSs-10 MP .............................................................................................................................. 16
6.8. PTXiSs-17D MP ........................................................................................................................... 16
7. Condensing unit transport ................................................................................................................ 17
8. Checking the technical condition ...................................................................................................... 17
9. Installation ......................................................................................................................................... 18
9.1. General remarks ......................................................................................................................... 18
9.2. Location of the unit .................................................................................................................... 18
9.3. Requirements on the refrigeration system ................................................................................ 18
10. Preparation for starting the unit ..................................................................................................... 21
10.1. Tightness test and drying ......................................................................................................... 21
10.2. Refrigerant charging ................................................................................................................. 22
10.3. Power connection .................................................................................................................... 22
10.4. Control the order of connection of the power supply ............................................................. 22
10.5. External permission to start ..................................................................................................... 23
11. Starting the unit............................................................................................................................... 23
11.1. Unit turn on switch ................................................................................................................... 24
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11.2. Checking the correct operation of the unit .............................................................................. 24

12. Operation and maintenance of the unit ......................................................................................... 25
12.1. Requirements concerning operation of the unit...................................................................... 25
12.2. Oil level control ........................................................................................................................ 26
12.3. Cranckase heater ...................................................................................................................... 26
13. Servicing .......................................................................................................................................... 26
13.1. Servicing actions ....................................................................................................................... 27
13.2. Regular inspections of the installation ..................................................................................... 28
13.3. Typical problems ...................................................................................................................... 29
14. Decommissioning ............................................................................................................................ 31
15. Attachments .................................................................................................................................... 32
15.1. The commissioning report........................................................................................................ 33

AREA COOLING SOLUTIONS Sp. z o.o. reserves the right to make changes to its products and to data inside this documentation
without any prior notice. All rights reserved

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v.22-01.01

1. General Information
• Refrigeration PTXiSs units are designed for automatic operation in refrigerated storage
rooms, refrigeration cabinets, liquid coolers and other equipment the operating parameters
of which meet the requirements of unit's characteristics.

• Compressor units are designed to be used with HFC refrigerants. Refrigerants allowed for
specific units are listed in table at the end of this chapter. Filling or refilling these units with
any other refrigerant type can cause damage. The units must not operate in conditions
exceeding their working parameters. Doing otherwise can cause damage to the unit and will
void the warranty.

• In case of lack some elements, such us safety valves, in special versions of units, it may be
necessary to additionally equip the installation with them.

• Unit constitutes only a part of a refrigeration system and must be used only with its other
components.

• The evaporator capacity, expansion valve and other components must be selected
accordingly to the unit's capacity and the system must be designed to ensure appropriate oil
circulation (including its return to the compressor crankcase).

• Any inconsistencies in delivery must be reported before installing the equipment.

• Before installation and start-up of the unit familiarize yourself with this manual and follow
the information provided herein. The manufacturer shall not be responsible for damage or
improper operation of the unit resulting from failure to comply with the requirements
provided in this manual.

• The general instructions presented below contain certain subjects which must be taken into
consideration in order to install units in a correct and safe manner. The guidelines provided
are to be used as a checklist: each step must be completed before moving on to the next
one. Contact Area Cooling Solutions Technical Department to obtain more information.

• Instructions provided in technical and safety standards (for example EN-378, EN 60204, EN
60335), EU directives, national regulations should also be followed.

• During first start of the unit The Commissioning Report should be filled. Form can be found in
chapter 15. Attachments.

• Keep this instruction for whole period of use the condensing unit.

According to F-gas regulations it is necessary to minimalize and work against refrigerant

leakage. In case of a leakage it should be fixed without delay.

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Table of permitted refrigerants:

PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs
4.5 7 10 15 17D 21D 26D 29D 40D 3 10 17D
MHP MHP MHP MHP MHP MHP MHP MHP MHP MP MP MP

        

        

        

  
       

         

2. Safety
All work on refrigeration system shall be carried out only by personnel which has
been trained and instructed in all work. Personnel which installs, services, maintains,
repairs, checks for leaks, decommissions refrigeration systems shall have f-gas
certificate for proper category.

A compressor unit is a pressurized system and as such poses the risk of injuries.
Protective clothing and googles should be used. Connections must not be opened
before lowering the pressure in the system.

While working with refrigerants precautions shall be taken and personal protective
equipment, such us gloves, googles, shall be used.

During operation surface temperatures exceeding 60°C or below 0°C can be reached
which may cause burns and frostbites. Before working on the unit switch it off and
allow to cool down

Improper handling can cause electric shock.

Never use oxygen to carry out pressure tests of the refrigerating or the air
conditioning circuit. Oxygen can explode upon contact with oil and cause injuries.
When carrying out a pressure test with a pressurized gas such as nitrogen (N2), make
sure to use a regulator to control the pressure.

During installation and decommission precautions shall be taken. Safety and health
rules shall be obeyed. Special caution is required during work with electrical and
pressurized components.

Installation is filled with refrigerant and oil which in specific conditions, for example
while brazing or soldering, can cause fire, explosion or serious injuries and burns.

Instructions provided in technical standard EN-378-3 concerning safety measures,

first aid and procedures in case of danger shall be followed
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2.1. Type code description

P T X i S s 24 D MHP
• P - high • M - voltage • X - ester oil • I - inverter • S - Sanyo • s - scroll • cooling • Dual • MP - low
performance 1ph. (Panasonic) capacity compressor temperature
• T - voltage 3 • N - Bristol • MHP - mid
ph. and high
temperature

P T X i S s - 21 D MHP
Medium and high temperature

Dual compressor

Aproximated cooling capacity [KW]

Compressor type: s-scroll, p-piston, r - rotary

Compressor manufacturer: S-Panasonic, B-Bristol, E-embraco, A-Avic

Type of compressor regulation: i - inverter

Type of oil: X- ester oil

Power supply: T- 3-phase

Unit type: P- high performance

3. Units specification

3.1. Components

• Panasonic hermetic compressor with inverter or Panasonic tandem (compound of inverter +

constant speed compressors) unit with cranckase heater
• shut-off valve on suction and discharge of the compressor
• insulation on suction pipe,
• HP/LP pressure switch – compressor protection
• liquid receiver with shut-off valve on the outlet,
• electrical connection box
• vibration absorber at discharge line
• liquid line: filter drier, sight glass with moisture indicator, shut-off valve
• LP pressure switch – manual control,
• oil separator
• suction separator
• safety valve

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4. Technical data

PTXiAr PTXiAr PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiSs PTXiAr PTXiSs PTXiSs
Condensing Unit Type 4.5 7 10 15 17D 21D 26D 29D 3 10 17D
MHP MHP MHP MHP MHP MHP MHP MHP MP MP MP

Length A [mm] 1000 1000 1200 1200 1300 1300 1650 1650 1000 1300 1650

Dimensions Height B [mm] 705 772 775 775 874 874 975 975 705 705 975

Width C [mm] 530 507 561 530 662 662 649 649 530 530 649

Weight gross [kg] 140 140 140 140 200 200 200 200 140 180 200
C-SBS180H00B/ C-SBS180H00B/ C-SBVN373L0B/ C-SBVN373L0B/ C-SCVN603L0J/
Model C-7RVN113L0A C-7RVN153L0A C-SBS180H00B C-SBVN373L0B C-7RVN153L0A C-SCVN603L0J
C-SBN303H8G C-SBN453H8G C-SBN453H8G C-SCN603H8T C-SCN603L8H
3
Displacement [m /h] 1,25-7,5 1,7-10,4 5,8-17,4 7,7-24,6 5,8-17,4 / 11,6 5,8-17,4 / 14,7 7,7-24,6 / 14,7 7,7-24,6 / 23,6 1,7-10,4 10,0-37,6 10-37,6 / 23,8
Inv. /30-90 Inv. /30-90 Inv. /30-80 Inv. /30-80 Inv. /20-75
Frequency [Hz] Inv. /30-180 Inv. /30-180 Inv. /30-90 Inv. /30-80 Inv. /30-180 Inv. /20-75
400/3/50 400/3/50 400/3/50 400/3/50 400/3/50
MCC [A] 12 12 16 17,5 16/11,1 27/13,8 16/13,8 17,5/13,8 12 24,6 24,6/17,3
Compressor Current
LRA [A] - - - - - / 48 6,3 - / 66 - / 66 - - - / 80

Oil type FV68S FV68S FV68S FV68S FV68S FV68S FV68S FV68S FV68S FV32S FV32S

Oil compressor charge [dm3] 0,7 0,7 2 2 2/1,7 2,0/ 1,7 1,3 2,0/ 2,8 0,7 2,5 2,5/2,5

Heater [W] 40 40 70 90 2x70 2x70 40 2x90 40 2x90 2x90

Volume @10 m [dBa] 39 39 39,3 44 44 44 44 44 38 44 44

Suction [mm] 16 18 22 28 28 28 35 35 22 28 35

Connections Discharge [mm] 10 12 12 12 22 22 22 22 10 16 22

Liquid [mm] 10 10 12 12 22 22 22 22 10 12 22

3
Liquid receiver [dm ] 3,9 7,1 10 14 14 14 14 14 3,9 10 14

Voltage [V/ph/Hz] 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50 380-415/3/50
CU Power
supply Recommended minimum cross section of power supply cables 5x1,5mm2 5x2,5mm2 5x4mm2 5x4mm2 5x6mm2 5x6mm2 5x10mm2 5x10mm2 5x2,5mm2 5x4mm2 5x10mm2

Recommended minimum protection B16 C16/B25 C25/B32 C40 C40 C40 C50 C50 C16/B25 C32 C50

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5. Units drawings
5.1. PTXiAr-4.5 MHP|PTXiAr-7 MHP | PTXiAr-3 MP

A 1000 mm D 953 mm
B 775 mm E 419 mm
C 507 mm

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5.1. PTXiAr-10 MHP

A 1200 mm D 1153 mm
B 775 mm E 419 mm
C 561 mm

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5.2. PTXiSs-15 MHP | PTXiSs-10 MP

A 1200 mm D 1153 mm
B 775 mm E 419 mm
C 561 mm

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5.3. PTXiSs-17D MHP | PTXiSs-21D MHP

A 1300 mm D 1253 mm
B 875 mm E 544 mm
C 662 mm

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5.4. PTXiSs-26D MHP | PTXiSs-29D MHP | PTXiSs-17D MP

A 1650 mm D 1603 mm
B 975 mm E 649 mm
C 649 mm

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6. Schematic diagrams

6.1. PTXiAr-4.5/7 MHP

13 14 1. Schraeder valve/Zaworek serwisowy
12 2. Ball valve/Zawó kulowy
3. Suction pressure transmitter/Przetwornik ciśnienia ssania
4. Suction insulation/Izolacja na ssaniu
11 5. Schraeder valve body/Korpus zaworka serwisowego
6. Crankcase heater/ Grzałka karteru
15
7. Inverter/Falownik
8. Compressor/Sprężarka
1 9. Dual pressure switch LP/HP /Presostat podówjny LP/HP
10. Vibration absorber/Tłumik drgań
1 11. Oil separator/Odolejacz
12. Check valve/Zawór zwrotny
16
13. Liquid receiver/Zbiornik cieczy
14. Safety valve / Zawór bezpieczeństwa
10 15. Rotalock valve/Zawór rotalock
16. Filter drier/Filtr odwadniacz
9 17 17. Sight glass/Wziernik
PSHL
1

8
~
~
7 6
1
5 2
Liquid line outlet/Linia cieczowa wylot

4
suction line/ssanie
1 discharge line/tłoczenie
2
liquid line/lina cieczowa
Suction line inlet/Linia ssawna wlot oil line/linia olejowa
impulse line/linia impulsowa
1 1 1
PT 3
1

6.2. PTXiSs-10 MHP

2 1. Suction separator/Separator ssawny
14 15 16 2. Schraeder valve/Zaworek serwisowy
13 3. Suction pressure transmitter/Przetwornik ciśnienia ssania
5 4. Suction insulation/Izolacja na ssaniu
5. Rotalock valve/Zawór rotalock
12 6. Crankcase heater/ Grzałka karteru
7. Inverter/Falownik
5
8. Compressor/Sprężarka
9. Temperature sensor/ czujnik temperatury
10. Dual pressure switch LP/HP/Presostat podówjny LP/HP
11 11. Vibration absorber/Tłumik drgań
12. Oil separator/Odolejacz
13. Check valve/Zawór zwrotny
17
14. Ball valve/Zawó kulowy
1 15. Liquid receiver/Zbiornik cieczy
16. Safety valve / Zawór bezpieczeństwa
1 17. Filter drier/Filtr odwadniacz
10 9 18 18. Sight glass/Wziernik
PSHL
TI
1
01

~ 8
~
7 6
2
5 14
4 Liquid line outlet/Linia cieczowa wylot
suction line
1 dicharge line
Suction line inlet/Linia ssawna wlot liquid line
oil line
impulse line
2 2 2

PT 3
1

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6.3. PTXiSs-15 MHP

2
14 15 16 1. Suction separator/Separator ssawny
13
2. Schraeder valve/Zaworek serwisowy
3. Suction pressure transmitter/Przetwornik ciśnienia ssania
4. Suction insulation/Izolacja na ssaniu
12 5. Rotalock valve/Zawór rotalock
5 6. Crankcase heater/ Grzałka karteru
7. Inverter/Falownik
1
8. Compressor/Sprężarka
1 9. Temperature sensor/ czujnik temperatury
10. Dual pressure switch LP/HP/Presostat podówjny LP/HP
11. Vibration absorber/Tłumik drgań
17 12. Oil separator/Odolejacz
13. Check valve/Zawór zwrotny
11 14. Ball valve/Zawó kulowy
10 15. Liquid receiver/Zbiornik cieczy
16. Safety valve / Zawór bezpieczeństwa
PSHL
1
9 18 17. Filter drier/Filtr odwadniacz
TI

01
18. Sight glass/Wziernik
5

~ 8
~
7 2
6 14
5 Liquid line outlet/Linia cieczowa wylot
4
suction line
1 dicharge line
Suction line inlet/Linia ssawna wlot liquid line
oil line
impulse line
2 2 2

PT 3
1

6.4. PTXiSs-17D/21D MHP

2 1
7

1
1
1. Schraeder valve/Zaworek serwisowy
2. Ball valve/Zawór kulowy
3. Suction separator/ Separator cieczy
15 15 8 16 4. Pressure switch LP/Presostat LP
5. Suction pressure transmitter/Przetwornik ciśnienia ssania
14 14 6. Suction insulation/Izolacja na ssaniu
17 7. Vibration absorber / Tłumik drgań
8. Rotalock valve/ zawó kątowy
11 11 9 9. Crankcase heater / Grzałka karteru
TSHL TSHL
1 10. Compressor/Sprężarka
13 01 01
11. Termostat / Thermostat
PSH/PSL 12. Inverter/Falownik
8 8 13. Dual pressure switch LP/HP /Presostat podówjny LP/HP
01
18 14. Oil separator/Odolejacz
10 10 15. Check valve/Zawór zwrotny
~ 16. Safety valve/Zawór bezpieczeństwa
~ 17. Liquid receiver/Zbiornik cieczy
12 9 9
18. Filter drier/Filtr odwadniacz
19 19. Sight glass/Wziernik
8 8

1
2
6 6 Liquid line outlet/Linia cieczowa wylot
suction line
dicharge line
2 1 liquid line
3
7 6 oil line
1 1 1 1 impulse line
Suction line inlet/Linia ssawna wlot

5 4
PT PSL
1 1

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6.5. PTXiSs-26D/29D MHP

2 1
7

1
1
1. Schraeder valve/Zaworek serwisowy
2. Ball valve/Zawór kulowy
3. Suction separator/ Separator cieczy
15 15 8 16 4. Pressure switch LP/Presostat LP
5. Suction pressure transmitter/Przetwornik ciśnienia ssania
14 14 6. Suction insulation/Izolacja na ssaniu
17 7. Vibration absorber / Tłumik drgań
8. Rotalock valve/ zawó kątowy
11 11 9 9. Crankcase heater / Grzałka karteru
TSHL TSHL 10. Compressor/Sprężarka
13 01 01 11. Termostat / Thermostat
PSH/PSL 12. Inverter/Falownik
8 8 13. Dual pressure switch LP/HP /Presostat podówjny LP/HP
01
18 14. Oil separator/Odolejacz
10 10 15. Check valve/Zawór zwrotny
~ 16. Safety valve/Zawór bezpieczeństwa
~ 17. Liquid receiver/Zbiornik cieczy
12 9 9
19 18. Filter drier/Filtr odwadniacz
19 19. Sight glass/Wziernik
8 8

1
2
6 6 Liquid line outlet/Linia cieczowa wylot
suction line
dicharge line
2 1 liquid line
3
7 6 oil line
1 1 1 1 impulse line
Suction line inlet/Linia ssawna wlot
5 4
PT PSL
1 1

6.6. PTXiAr-3 MP
1. Schraeder valve/Zaworek serwisowy
15 2. Ball valve/Zawór kulowy
3. Suction pressure transmitter/Przetwornik ciśnienia ssania
13 4. Suction insulation/Izolacja na ssaniu
14 5. Schraeder valve body/Korpus zaworka serwisowego
6. Crankcase heater / grzałka karteru
12 7. Inverter/Falownik
8. Compressor/Sprężarka
16 9. Pressure switch LP/HP / Presostat LP/HP
10. Temperature sensor/ czujnik temperatury
11. Vibration absorber / Tłumik drgań
12. Oil separator/Odolejacz
11 13. Check valve/Zawór zwrotny
14. Liquid receiver/Zbiornik cieczy
15. Safety valve/ Zawór bezpieczeństwa
1 16. Rotalock valve/Zawór rotalock
1 17 17. Filter drier/Filtr odwadniacz
18. Solenoid valve NC/ Elektrozawór NC
TI 10 19. Sight glass/Wziernik
9 01
5
PSH/PSL
18
01 7 8 5
19
~
~
6

5 1
2
Liquid line outlet/Linia cieczowa wylot
4
1 suction line/ssanie
2 discharge line/tłoczenie
Suction line inlet/Linia ssawna wlot liquid line/lina cieczowa
1 1 1 oil line/linia olejowa
impulse line/linia impulsowa
3 PT
1

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6.7. PTXiSs-10 MP
1. Suction separator/Separator ssawny
6 17 2. Schraeder valve/Zaworek serwisowy
3. Schraeder valve body/Korpus zaworka serwisowego
15 4. Suction pressure transmitter/Przetwornik ciśnienia ssania
16 5. Suction insulation/Izolacja na ssaniu
6. Rotalock valve/Zawór rotalock
14 7. Crankcase heater / grzałka karteru
6 8. Inverter/Falownik
9. Compressor/Sprężarka
10. Pressure switch LP/HP / Presostat LP/HP
13 11. Solenoid valve NC/ Elektrozawór NC
12. Temperature sensor/ czujnik temperatury
2 13. Vibration absorber / Tłumik drgań
14. Oil separator/Odolejacz
3 15. Check valve/Zawór zwrotny
16. Liquid receiver/Zbiornik cieczy
TI 12 18 17. Safety valve/ Zawór bezpieczeństwa
11 01
18. Filter drier/Filtr odwadniacz
6 19. Sight glass/Wziernik
10 3 20. Ball valve/Zawór kulowy
11
PSH/PSL
9 3
01
~ 19
~
8 7
6
2
20
Liquid line outlet/Linia cieczowa wylot
5

1 suction line/ssanie
discharge line/tłoczenie
Suction line inlet/Linia ssawna wlot liquid line/lina cieczowa
oil line/linia olejowa
2 2 3 2 impulse line/linia impulsowa
PT
4 1

6.8. PTXiSs-17D MP
2 1
7
1. Schraeder valve/Zaworek serwisowy
1 2. Ball valve/Zawór kulowy
8 16 3. Suction separator/ Separator cieczy
1 4. Pressure switch LP/Presostat LP
1 5. Suction pressure transmitter/Przetwornik ciśnienia ssania
17 6. Suction insulation/Izolacja na ssaniu
7. Vibration absorber / Tłumik drgań
15 15 9 8. Rotalock valve/ zawó kątowy
19
9. Crankcase heater / Grzałka karteru
1
NC

14 14 10. Compressor/Sprężarka
11. Termostat / Thermostat
12. Inverter/Falownik
11 11
11 18 13. Dual pressure switch LP/HP /Presostat podówjny LP/HP
TSHL TSHL
19 14. Oil separator/Odolejacz
13 01 01
15. Check valve/Zawór zwrotny
PSH/PSL 16. Safety valve/Zawór bezpieczeństwa
8 8 NC
01 17. Liquid receiver/Zbiornik cieczy
20 18. Filter drier/Filtr odwadniacz
NC
10 10 19. Solenoid valve NC/ Elektrozawór NC
~ 19
20. Sight glass/Wziernik
~
12 9 9

8 8 1
2
Liquid line outlet/Linia cieczowa wylot

6 6 suction line/ssanie
discharge line/tłoczenie
liquid line/lina cieczowa
1 oil line/linia olejowa
3 2 impulse line/linia impulsowa
7 6
1 1 1 1 1
Suction line inlet/Linia ssawna wlot
5 4
PT PSL
1 1

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7. Condensing unit transport

Warning: Danger of injury!

Block stacking is not allowed.

During transport and storage, unit should be transported exclusively on a palette.

Lifting by means of sling belts attached to palette is permissible.
Lifting and moving the device should be performed using devices designed for this
(forklift, crane, etc.)
Machines used for lifting the unit must meet the requirements of Directive 2006/42/EC,
have adequate load capacity and be approved for use.

Never go under a suspended unit.

Unless the unit is transported manually, maintain safe distance from the transported unit
of at least 1.5 m.

Tilting the device is not allowed.

The unit must stand levelled.

Store the device in shaded area in temperatures between -35°C and +50°C.

The device with package shall not be subjected to rain, corrosion environment or direct
sunlight.

After unpacking, make a judgement whether the unit is undamaged and complete.
Noticed discrepancies should be reported to supplier.

During transport and storage, the unit should be protected against humidity and dust (e.g.
foil, carton)

Use of pipes, condenser collecting pipes or fittings to lift the unit is forbidden.

8. Checking the technical condition

Upon receiving the unit check:

- if it was not damaged during transport (every unit is packaged),

- its tightness (each unit is pre-filled with dry nitrogen at the pressure of 3–5 bar)

- its components for damage (pipes, pressure switch etc.),

- if the compressor is filled with the appropriate amount of oil; if the compressor has a sight glass,
check if it is filled to ¾ of its total volume,

- if the accessories are consistent with the order.

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9. Installation

9.1. General remarks

Incorporation the unit into any refrigeration system should be preceded by technical consultation
or drawing up a project with selection of other components of the system (evaporators,
automation) and determination of the appropriate location for the unit and pipes.

Have the unit installed by a qualified personnel familiar with cooling equipment.

9.2. Location of the unit

The unit can be installed outdoors under a roof or indoors. Install the unit on a solid and level surface
and be sure not to obstruct air circulation.

Ensure a foundation with horizontal surface – strong, stable and rigid enough to carry the entire unit
weight and eliminate vibration and interference.

The unit must be leveled. Incorrect assembly of the unit will result in the loss of warranty.

Location of the unit should ensure access for service and maintenance work.

The units should be installed so that they are not exposed to direct sunlight and must be located far
from any heat sources (heaters, central heating, furnaces).

9.3. Requirements on the refrigeration system

Condensing units are dried and pre-filled with oil and dry nitrogen gas at the factory. The unit's
connections are tight. Pay attention not to introduce dirt and moisture into the system. The
refrigeration system must be made of dry and clean components, according to the plan, technical
rules and relevant standards and regulations.

The unit is pre-filled with pressurised nitrogen. To release it, loosen the nuts
at valve service connections both at the suction and the discharge side.

In addition the refrigeration system should:

- protect the compressor against ingress of the liquid refrigerant both during operation and
shutdown. To do so, route the suction lines in an appropriate way (siphonage), use appropriate
automation components, evaporators etc.
- ensure the oil return to the compressor by properly arranging the refrigerant lines (maintain
recommended drops, use traps etc.)
- provide protection against excess energy losses by insulating both the suction and the liquid
refrigerant sides (depending on the piping arrangement),
- all connections must be tight – it is recommended to use soldered connections.

Refrigeration system containing F-gases should be marked accordingly.

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Oil traps

On the suction pipeline, downstream the location provided for installation of a thermostatic
expansion valve's sensor or an electronic expansion valve's temperature sensor, a shallow siphon
must be provided to collect oil and refrigerant. The siphon on the suction pipeline allows oil to flow
upwards to the maximum height of three meters.

0,5-1%
Unit

3m

0,5-1%

Evaporator

If there is a risk that a liquid refrigerant floods the compressor because the refrigerant does not
evaporate completely in the evaporator, use a siphon downstream the evaporator (the topmost
part of the siphon must be over the evaporator) and a liquid separator at the suction side.

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Location of the suction pipeline outlet from the evaporator depends on the difference of levels that
compressor and evaporator are situated in. The pipe must be led out in different ways if the
evaporator is located at the same or different level as the compressor This is particularly important
to ensure correct oil return from the evaporator, improve refrigerant evaporation and reduce the
risk of flooding the compressor with a liquid refrigerant.

If the evaporator is situated higher than the compressor (which is common in large installations), it
is recommended to pump down the refrigerant before stopping the compressor. If there is no pump
down option, suction line should ensure siphoning refrigerant in the evaporator. It will protect the
compressor from flooding during standstill. If the evaporator is situated below the compressor,
there should be oil locks on vertical lines.

Compressor below the evaporator Compressor above the evaporator

Double rises

In units working at changing loads and with adjustable capacity, a double riser on suction vertical
line should be used.

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A double riser gives the effect of a downsized riser at minimum load, while providing about the
same pressure drop as a full sized line at full load. The smaller riser is sized to insure oil return at the
minimum capacity step; the larger riser is sized so that the combined “flow areas” of both of these
risers are approximately equal to the main suction or discharge line.

10. Preparation for starting the unit

10.1. Tightness test and drying

After the installation is complete, carry out a tightness test of the system using nitrogen. The
tightness of the unit is tested at the factory.

The tightness test should be carried out according to EN-378-2.

Pressure of the nitrogen should be increased gradually according to safety rules.

Do not exceed the factory pressure setting of 30 bar for high pressure side (HP) and 15
bar for low pressure side (LP).

Do not carry out tightness tests by introducing chemical agents into the system. Doing so will void
the warranty.

To dry the system, generate vacuum inside and fill the system with nitrogen. Generate vacuum
twice: first when the condensing unit's valves are shut and then:
- reduce pressure to 1.3 mbar
- fill the system with nitrogen to the pressure of at least 10 bar,
- empty the system via service connection on the suction valve,
- generate vacuum when the unit's cut-off valves are opened until the pressure of 1.3 mbar is
reached,
- check the vacuum after 3 hours,
- if no leak is detected, fill the system with refrigerant.

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Do not start the compressor or power the contacts of the electric motor while there is
underpressure in the system. It may cause electric arc or irreversible damage to the
motor of the compressor.

10.2. Refrigerant charging

Before charging the refrigerant turn on the crankcase heater and check the oil level in the
compressor.

Liquid refrigerant should be charged into the liquid receiver.

After commissioning it may be necessary to add refrigerant. If so, do it on the suction side.

Zeotropic blends (R404A, R407C, R448A, R449A, R513A) should be charged only in a liquid form.

10.3. Power connection

The electrical system must be installed by a certified electrician.

The electrical system must meet the requirements of relevant safety regulations and
standards.

Connect the main power cord to the screw terminals marked -Xz on the electrical board of the unit.

The electrical connection of the unit should be made taking into account the recommendations for
the minimum cable cross-sections of specified unit included in the table in point No. 5.

Warning: The use of wires with too small cross-section may result in voltage drops, increased
current consumption and incorrect operation of short-circuit and overload protection. This can lead
to the destruction of the compressor, condenser fans and health or life threat.

Before starting the unit for the first time or after a longer standstill, make sure that the power
supply wires of the unit are not damaged and that the screw connections of the electrical
components have not been loosened! (The loosening of the joints could have been caused by
vibration during transport or prolonged work).
Additional information not included in this document is given in Appendix A "Electrical
documentation and quick start guide "

10.4. Control the order of connection of the power supply

Selected units are equipped with a phase presence and rotation control relay (marking
-R0). When the power supply is applied, the pilot light on the relay should remain on, otherwise
check the voltage present on each phase and the order of phase connection should be checked.

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Before start up checking connections in terminal block should be performed. Then whole circuit
breakers should be set in positions ON.

The light is flashing: INCORRECT function.

The light is fixed: CORRECT function.

This does not apply to 1-phase powered models and models with Bonfiglioli inverters without safety
mode.

10.5. External permission to start

The selected units are equipped with an option to connect external start permission of unit, as a
potential-free contact (eg. the contact of a standard relay). The connection location of the permit
can be identified by the jumper on the electrical panel connectors.
Note:
If the above described connection is open the unit will not start!

There is voltage on this terminals if unit is turned on!

11. Starting the unit

Start the procedure after charging the refrigerant, checkout of correctness of: connections,
refrigerant fill, leakage, electrical connections and power supply (phase control relay - if
present).

1) Make sure the S1 switch is in position "0".

2) Set the HP / LP protection switch according to the limits for the refrigerant used (factory settings
are for R449A).
Does not apply to mini pressure switches.

3) Set the LP pressure switch for safety mode - the setting should ensure proper installation
conditions in the case of operation without smooth regulation (no inverter).
Does not apply to units without safety mode.

4) Set the fan speed regulator according to the recommended limits for the refrigerant used.
5) Check if all cut-off valves are opened.

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6) Turn on the power supply of the unit.

7) Set the operating parameters on the inverter and / or the controller according to the limits for
the refrigerant used.
8) Wait until the compressor crankcase is warmed up (point no. 13.3).
9) Turn on start permission signal or install the bridge at the connection point (turn off the power
first).
10) Set the S1 switch to operating mode.

Additional information not included in this document is given in Appendix A "Electrical

documentation and quick start guide "

11.1. Unit turn on switch

The units have an on-board switch with the mark -S1 for switching off and on.

Selected models have a 3-position switch with the option of switching the unit in safety mode - the
work of the compressor bypassing the inverter.

The unit works only after selecting the operating mode with the -S1 switch.

Use the -S1 switch to select the unit operating mode:

1 - Inverter operation mode (default)

2 - Safety mode - if present

11.2. Checking the correct operation of the unit

After start-up the unit should operate without generating excessive vibrations, knocks and heat. The
evaporators should be covered with frost evenly.

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Check the pressure on the test pressure gauges. The difference between the condensing
temperature indicated by the pressure gauge and the ambient temperature should be within 0–
15 K.

The indicator should indicate a colour corresponding to dry refrigerant. The flow should be smooth
and non-turbulent. If the flow is turbulent and bubbles are visible, too low amount of refrigerant is
used.

The thermostatic valve must be adjusted correctly. Vapour from the evaporator should be
superheated by 4–8ºC. The thermostatic valve should be adjusted according to valve instruction
manual. Adjust the valve when the refrigeration system is operating.

Gas temperature at the compressor's discharge side must not exceed 115ºC

12. Operation and maintenance of the unit

12.1. Requirements concerning operation of the unit

According to F-gas regulations refrigerant systems may be subjected to obligatory

tightness tests and keeping records depending on the type of the refrigerant and its
charge.

To ensure appropriate compressor working conditions, its number of start/stop cycles must be
limited. For this reason the unit's capacity should be selected accordingly to the capacity
requirements. Use controllers to limit the number of compressor's working cycles.
The maximum allowed number of condenser unit start-ups is 8 per hour and the minimum
operating time is 3 minutes.These are limit values and must not be exceeded.
The recommended compressor rest period (time relay) is a minimum of 5 minutes.

To ensure a correct work of the unit during operation:

a) crankcase heater should be powered all the time or during compressor’s stops. Crankcase
heater should be turned on at least 24 hours before starting the compressor,
b) if knocking noise is heard or in case of improper operation, overheating or lack of cooling
effect disconnect the unit from the power supply, locate the faults and address them,
c) at least once per 14 days (or more frequently if necessary) defrost the evaporators in the
refrigerated storage room,
d) open the refrigerated storage room only when necessary and for the shortest time possible,
e) if the unit is not used for a long period (4–5 days), disconnect it from the power supply,
f) if the unit is not used for more than 6 days, remove the refrigerant from the system and
drain it to the unit's receiver; disconnect the unit from the power supply,
g) after the first 40 hours of operation check the oil quantity and refill it if necessary,

h) do not over adjust the automation system's settings. These operations can be carried out
only if necessary and after reading the relevant instruction manual,

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i) at least once in a two weeks visually check the unit, check the correctness of its operation,
settings and operation of the automation system,
j) check if the refrigerant is dry; if necessary replace the filter drier.

12.2. Oil level control

Using oil type other than the original one and replenishing the original oil with other oil type can
damage the compressor and void the warranty.

Using excessive amount of oil can damage the compressor.

The minimum and maximum oil levels are reached when the oil amount is 20% less/more than the
nominal oil level respectively. In compressors equipped with a sight glass it corresponds to 1/3
(minimum) and 2/3 (maximum) of the scale. Check the oil quantity and quality regularly regardless
of the compressor type.

To determine the oil amount in compressors and tandem units not equipped with sight glasses do
the following:
- periodically weight the unit by means of a precision balance,
- periodically drain the oil and replace it.

12.3. Cranckase heater

The heater can reach the temperature of 800C. Touching the heater can cause burns.
The oil temperature should be maintained at approximately +450 to 550C.

Lack of heater or its damage must be immediately reported to the supplier.

Failure to connect the electric heater to the power supply can damage the compressor. This will
void the warranty.

Oil crankcase heater must be connected to the power supply at least 24 hours before starting the
compressor after longer period of non-operation, as well as during normal operation of the system,
even if the compressor does not operate.

13. Servicing

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13.1. Servicing actions

The compressor unit must be regularly checked by authorized and qualified personnel.

Any modifications of the system introduced by third parties are the sole responsibility of the user
and will void the warranty.

1) Before attempting to carry out maintenance work, make sure that the equipment is not
operating and is disconnected from the power supply. Exercise caution when carrying out
maintenance of electrical connections.
2) Visually check if there is no visible damage which would render the system non-operational.
3) If the system was dried or is filled with nitrogen, dry and fill the system. Carry out these
operations according to the general rules.

4) Check if the pipes and connections are not broken and if there are no visible cracks and
other signs of mechanical damage. Make sure that transport or long period of non-
operation did not cause components to move in relation to each other which could damage
them.

5) Switch on the heaters 24 hours before the start-up. This is required before the first start-up
and after each prolonged period of non-operation if voltage was disconnected from the
terminals. Failure to do so may cause oil to foam and lead to compressor damage.

6) Before the start-up, particularly after installation or maintenance, make sure the
compressor cut-off valves at the suction and discharge sides are opened. Close the valves
only when necessary.

7) When emptying the system and compressors follow the general rules.

8) Do not leave air in the compressor before filling it with refrigerant. Dry the compressor
thoroughly.

9) The oil level in the compressor and the oil separator circuit must be correct. If significant oil
loss is noticed, replenish the oil by using the same oil type which was used originally or its
alternative

10) Set the pressure switches according to the refrigerant compatible with the compressor.
Settings of controls and pressure switches must not cause the compressor's operating range
to be exceeded.
11) Before starting the entire system check if the compressors are connected correctly. To do
so, measure the current drawn by the compressor during start-up. Measure the current
when the suction and discharge side valves are opened. The current at the start-up should
quickly increase to the maximum value and drop after reaching it. If this does not happen,
check for the cause of this problem and address it.

12) he refrigerant temperature at the discharge side should not exceed 1150C.
13) The crankcase temperature should be within +400C to +450C.
14) The vapour at the suction side should be superheated by 10–20 K. If these values are
exceeded, adjust the expansion valves or controllers.

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15) Adjust the fan speed by the regulator (if present).

13.2. Regular inspections of the installation

Once a month - Check the pressure at the discharge side

- Check the pressure at the suction side
- Check the temperature of sucked vapour
- Check the temperature of vapour at the discharge side
- Check the crankcase temperature
- Check the vapour superheating
- Check the oil level and refill it if necessary
- Check the current drawn by compressors' motors
- Check the cleanliness of the condenser
- Check the moisture level in the system
- Check the condition of flexible couplings
- Check the refrigerant leaks
- Check if the coolers are not blocked by ice
Once in 6 months - Certification of safety valves
- Checking the condition of evaporators' drip trays
- Checking the condition of pipelines of a condensate
- Checking the condition of condensers (particularly their cleanliness)
Once in 12 months - Clean the condenser
- Analyse the oil composition
- Clean the plate and shell and tube evaporators
- Check the operation of check and solenoid valves
- Check the pressure drop at the suction filter

In case any irregularities are noticed, take appropriate steps to address them. It is recommended
to prepare a form to be filled in during the periodic inspections, repairs, adjustment and
maintenance.

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13.3. Typical problems

No. Symptoms Possible causes

1 High pressure switch Presence of air or other gas in the system which does not liquefy
caused the Condenser not working properly due to dirt build-up, lack of water
compressor to switch flow, too high ambient temperature or insufficient flow of air (fans
off damaged)
Liquid filter clogged or sight glass damaged
Evaporator overloaded
Expansion or solenoid valve damaged (closed)
System is not dry
Low pressure
Refrigerant level too high
2 Low pressure switch Pressure too high
caused the Liquid filter clogged or sight glass damaged
compressor to trip System is not dry
Suction filter clogged
Evaporator load low (coolers clogged)
Expansion or solenoid valve damaged (closed)
3 Oil pressure switch Too low oil level in the compressor
caused the Presence of refrigerant in oil – the crankcase heater may not work
compressor to trip properly
Oil supply line damaged – oil filter clogged, oil separator or oil
separator valves damaged
4 Too much current Condenser not working properly due to dirt build-up, lack of water
drawn by the flow, too high ambient temperature or insufficient air flow (fans
compressor damaged)
Phase loss or voltage too low
Evaporator overloaded
5 High pressure at the Evaporator overloaded
suction side, vapour The compressor does not operate at full capacity
superheat level is Discharge side valve damaged
normal Suction valve damaged
6 High suction Evaporation pressure too high
pressure, vapour Refrigerant level too high
superheat level is Expansion valve damaged – the valve does not close
low
7 Low suction Liquid filter clogged or sight glass damaged
pressure, vapour Refrigerant level too low
superheat level is System is not dry
high Expansion or solenoid valve damaged (closed)
8 Low suction Suction filter clogged
pressure, vapour Evaporator load low (coolers clogged)
superheat level is
normal
9 Condensation Condenser not working properly due to dirt build-up,
pressure too high, lack of water flow,
refrigerant too high ambient temperature

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temperature at the or insufficient air flow (fans damaged)

discharge side high

10 Condensation Condenser not working properly due to dirt build-up,

pressure too high, lack of water flow,
refrigerant too high ambient temperature
temperature at the or insufficient air flow (fans damaged)
discharge side low System overfilled with refrigerant
System is not dry
Evaporator thermal load too high
11 Condensation System overfilled with refrigerant
pressure low, Liquid filter clogged or sight glass damaged
refrigerant Discharge side valve damaged
temperature at the Suction valve damaged
discharge side is high Suction filter clogged
Solenoid valve damaged
Refrigerant level too low
12 Condensation
pressure low, The compressor does not operate at full capacity
refrigerant Evaporator load low – coolers clogged, cooled medium inlet
temperature at the temperature too low
discharge side is
normal
13 Condensation System overfilled with refrigerant
pressure low, Expansion valve damaged – the valve is constantly opened
refrigerant
temperature at the
discharge side is low
14 RLA high System overfilled with refrigerant
Presence of air or other improper gas in the system
Condenser not working properly due to dirt build-up, lack of water
flow, too high ambient temperature or insufficient air flow (fans
damaged)
15 RLA low Filter drier clogged or sight glass damaged
The compressor does not operate at full capacity
Compressor discharge side valve damaged
Compressor suction valve damaged
Expansion or solenoid valve damaged (closed)
16 Refrigerant at the System overfilled with refrigerant
condenser too cold Presence of air or other improper gas in the system
Filter drier clogged or sight glass damaged
Expansion or solenoid valve damaged (closed)

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14. Decommissioning

In case of decommissioning the unit or its components exercise caution with electrical and
pressurized components

Before decommissioning disconnect supply voltage and extract the refrigerant according to rules
concerning handling refrigerants.

In case of changing single element close shut-off valves before and after it and extract the
refrigerant from that section.

Refrigerant recovered from the installation should be recycled, reclaimed or utilized.

Temperature of the oil extracted from compressor and oil separator can be above 60ºC. Exercise
caution.

Oil is pollutive waste and should be utilized.

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15. Attachments
• The commissioning report
• Appendix A - Electrical documentation and quick start quide

AREA COOLING SOLUTIONS Sp. z o.o. reserves the right to change its thresholds and ratings on the self-portrait without presentation. All
rights reserved

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15.1. The commissioning report

PROTOCOL OF UNIT START UP

SERIAL NUMBER UNIT TYPE DATE OF START UP REFRIGERANT QUANTITY [KG]

Unit of
Parameter measurement
Value
Pressure switch LP setting bar
Pressure switch HP setting bar
Voltage reading of phase L1- L2 of unit power supply V
Voltage reading of phase L2- L3 of unit power supply V
Voltage reading of phase L3- L1 of unit power supply V
Voltage reading of phase L1- N of unit power supply V
Voltage reading of phase L2- N of unit power supply V
Voltage reading of phase L3- N of unit power supply V
Reading of compressor amperage from inverter(PAR.211)in stable working conditions A
Reading of output voltage from inverter (PAR.212) V
Evaporation pressure in stable working conditions(steady load)/quantity of working units bar
Superheating on evaporator °C
Quantity of registered(weighed) refrigerant kg
Quantity of Cooling units/ evaporators szt.
Maximal Cooling load kW
Minimal Cooling load kW
Pressure of condensing measured with manometers bar
Suction temperature measured °C
F-Gas certification NUMER

Name of person performing start up Date Signature

Name of company installing the units

Facility address

THIS PROTOCOL SHOULD BE DELIVERED TO THE MANUFACTURER FROM PROCESSING

WITHIN 5 DAYS.

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Adresy

ul. Relaksowa 27

55-080 Nowa Wieś Wrocławska

Polska

Tel: +48 71 354 56 24

Fax: +48 71 354 56 22

[email protected]
[email protected]

Oddział Warszawa Oddział Katowice Oddział Gdynia

ul. Puławska 506/508, ul. Roździeńskiego 188 A, ul. Chwaszczyńska 70,

02-884 Warszawa, 40-203 Katowice, 81-571 Gdynia,

[email protected], [email protected], [email protected],

Tel. +48 22 463 43 20 Tel. +48 32 353 08 75 Tel. +48 58 778 90 43

www.area.pl www.areacooling.co.uk
www.areacooling.fr www.areacooling.de
www.area.es www.areacooling.dk
www.areacooling.ru

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