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Dc inverter vrf installation instructions and Tips

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Dekon one of the professional manufacture and supplier for DC inverter VRF system in China. Here is the Dc inverter vrf installation instructions and tips.

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Dc inverter vrf installation instructions and Tips

  1. 1. Installation instruction ON DC Inverter VRFDEK
  2. 2. Installation procedures Confirm project Check drawing Install indoor unit Install outdoor unitInstall drainage pipes Flushing Install ducts InsulationVacuum system Electrical wiring Commissioning Welding Pipes laying Pressure test Refrigerant charge Check and hand over
  3. 3. 1. Indoor unit installation 2. Outdoor unit installation 3. Piping installation 4. Electrical wiring 5. Commission 6. Main tools VRF system installation
  4. 4. Indoor unit installation VRF system installation
  5. 5. Indoor unit 1.Location Use plumb bob to determine the location of indoor unit. Plummet Plumb bob
  6. 6. Indoor unit 2.Hoisting Use level meter to keep the indoor unit horizontally . Reduce the running noise Avoid the condensate water spill from the water collector Level meter
  7. 7. Indoor unit 2.Hoisting Supports must be strong enough. The supports should be full thread booms, and their diameters should be ≥ 10mm. Full thread booms 4 Supports for indoor unit
  8. 8. Indoor unit 2.Hoisting Dual nuts should be adopted to fix the indoor unit under the ceiling. Dual nuts Single nut
  9. 9. Indoor unit 2.Hoisting Pack the indoor unit with plastic bag after hoisting to protect them from dust entering.
  10. 10. Outdoor unit installation VRF system installation
  11. 11. The outdoor unit should be placed neatly, and reserve enough space for maintenance. The outdoor unit should be installed in the place that is dry, well-ventilation and close to the indoor units . Outdoor unit 1.Location
  12. 12. ≥1000mm ≥1000mm 150-500mm ≥1000mm 150-500mm Installation space is shown as below: Outdoor unit 1.Location
  13. 13. If 2 rows of ODUs: Outdoor unit 1.Location We suggest: face to face  Easy maintenance  No air short-circuit
  14. 14. Good duct installation If the outdoor unit need to side out of the wind by ducting work , it is essential to remove out the wind grille. Outdoor unit 1.Location
  15. 15. All the outdoor units in one combination should be installed within 5 meters height difference. We recommend all the outdoor units installed on the same level if the project site conditions permit. Outdoor unit 1.Location
  16. 16. The foundation can be made of channel steel or concrete. Outdoor unit 2.Foundation making Reserve the space for discharging condensate water from outdoor units.
  17. 17. Rubber anti-vibration pads are necessary to avoid vibration. Rubber Pads Outdoor unit 2.Foundation making
  18. 18. Piping installation VRF system installation
  19. 19. Piping 0.Pipe storing  For storing the copper pipes: 1. If pipes will be used soon, nozzle should be sealed by plastic bag or tape. 2. If pipes will be stored for a long time, the pipes should be charged into 0.2~0.5MPa Nitrogen and the nozzle should be sealed by welding.
  20. 20. Piping 1.Procedures Piping check Pipes connection Flushing Drainage pipe installation Gas-tightness test Insulation Vacuum dry Additional refrigerant charge
  21. 21. Piping 2.Piping check  The permitted length and drop difference Permitted length Pipe Pipe length Pipe total length (Equivalent length) ≤20HP ≤800 m L1+L2+L3+…+ L8+L9 +A+B+C+…+I+J> 20HP ≤1000 m Max. pipe length(m ) Actual length ≤175m L1+L6+L7+L8+L9+J Equivalent length ≤190m Equivalent length from the first branch to the farthest indoor unit ≤40m L6+L7+L8+L9+J Drop height Drop height between indoor unit and outdoor unit ≤90m —— Drop height between indoor units ≤15m
  22. 22. Piping 2.Piping check LdLcLbLa LBLA L1 L6 L2 L7 L8 L9 f g h i j L3 L4 L5 a b c d e  The longest pipe length ≤ 190 m Ld+LA+LB+L1+L2+L3+L4+L5+e ≤ 190 m
  23. 23. Piping 2.Piping check LdLcLbLa LBLA L1 L6 L2 L7 L8 L9 f g h i j L3 L4 L5 a b c d e  The longest pipe length from 1st branch to farthest indoor unit ≤ 40 m L2+L3+L4+L5+e ≤ 40 m
  24. 24. Piping 2.Piping check LdLcLbLa LBLA L1 L6 L2 L7 L8 L9 f g h i j L3 L4 L5 a b c d e  Height difference between outdoor unit and indoor unit≤ 90 m  Height difference between indoor units ≤ 15 m ≤ 15m≤ 90m
  25. 25. Piping 2.Piping check  Select the correct branch joints according to the installation requirement.
  26. 26. Piping 3.Pipe hanging  The distance between the supports of the copper pipes.  When the liquid pipe and gas pipe are hung up together, it is determined by the diameter of liquid pipe. Diameter (mm) ≤ 20 20 ~ 40 ≥ 40 Distance (m) 1 1.5 2  Record the actual liquid pipe length for future reference when charging additional refrigerant.
  27. 27. Vertically Horizontally Horizontally Vertically Piping 3.Pipe connection The branch joint of outdoor side must be installed horizontally. The branch joint of indoor side can be installed horizontally or vertically.
  28. 28. Piping 3.Pipe connection  When install the branch joint horizontally A 15 ° 15 ° A direction Wrong Correct Horizontal Avoid refrigerant distribution unbalance.
  29. 29. Piping 3.Pipe connection  Keep enough distance: 1. Between two branch joints ≥1m 2. Between branch joints and indoor unit ≥0.5m 3. From the inlet or outlet of branch joint, there should be straight pipe with length at least 0.5m 0.5m
  30. 30. Piping 3.Pipe connection  Why? If the distance is not big enough, it maybe cause unwanted noise The distribution of the refrigerant is not well balanced in this case
  31. 31. Piping 3.Pipe connection Two branch joints are too close! There must be no sharp bend (90ºangle ) within 0.5m away from the branch joint.
  32. 32. Piping 3.Pipe connection Do not replace branch joint with T pipe or use the branch joint from other suppliers ->DEKON branch joint is necessary
  33. 33. Piping 3.Pipe connection  Requirement of welding:  When welding the copper pipe, nitrogen is necessary to protect the copper pipe. The pressure of the nitrogen is 0.02 MPa Charge the nitrogen to the copper pipe at the beginning of welding and only when the copper is fully cooled down, the nitrogen can be removed
  34. 34. Piping 3.Pipe connection 2Cu + O2 CuO High temp.  Why the Nitrogen is necessary?
  35. 35. Piping 3.Pipe connection  How to charge Nitrogen. Pressure regulating valve
  36. 36. Piping 3.Pipe connection  How to charge Nitrogen. N2 will leak from here!
  37. 37. Piping 4.Flushing  Purpose: eliminating dust, water vapor and oxides caused when welding.  Note: the solid can not be eliminated, so please store the pipes carefully to prevent the solid entering.  Method: 1. Flush the pipe with 0.5 MPa Nitrogen 2. Block all the nozzles of the pipes 3. Use your hand to block one of the nozzles 4. When the pressure is too high to block, then remove your hand 5. Repeat the step 3 and 4 to each nozzle 6. After flushing, seal all the nozzles Eliminate Oxid es Mois ture Dust
  38. 38. Piping 4.Flushing ② ⑥ ⑤ ④ ③ ①  Procedures From far to near (sequence: ①-②-③-④-⑤-⑥ )  Note 1. When flushing one pipe, the other pipes need to be sealed. 2. After flushing, remember to seal all the pipes.
  39. 39. Piping 5.Gas-tightness test Before test, gas/liquid stop valves of outdoor unit should be closed well Exhaust the air in the system by vacuum pump Charge Nitrogen slowly from both gas and liquid side at the same time  Purpose: check the gas leakage of the system  Procedures:  Caution: the gas used must be Nitrogen, but Nitrogen is forbidden to charge to the outdoor unit’s stop valve directly.
  40. 40. Piping 5.Gas-tightness test  Sequence of pressure test: Small leakage check: 4.0 MPa more than 24 hours 3rd stage Big leakage check: 1.5 MPa more than 3 minutes 2nd stage Large leakage check: 0.3 MPa more than 3 minutes 1st stage
  41. 41. Piping 6.Insulation Prevent condensate water adhere to the gas pipe Protect people from hurt of high temp. Avoid energy loss.  Purpose:  Caution: After finish the gastight test, we go on the insulation work of the refrigerant pipe.
  42. 42. Piping 6.Insulation Pipe diameter Thickness Φ6.4~15.9mm ≥15mm Φ15.9~38.1mm ≥20mm Φ38.1~54.1mm ≥25mm  Insulation material The insulation need to be thicker if the ambient is high temperature and humidity.
  43. 43.  The insulation of liquid pipe and gas pipe must be separate  The insulation work must be done to every part of the refrigerant pipes Piping 6.Insulation
  44. 44. Piping 6.Insulation Wrong Avoid the dust entering the pipe  Block the nozzle of the pipe when crossing the insulation material.
  45. 45. Piping 6.Insulation  The gap between two parts should be well insulated by additional insulation material. Insulation Copper pipe Wrong
  46. 46. Piping 7.Vacuum  Purpose:remove the air and water in the system.  Necessary tools:vacuum pump (displacement: 4L/s or more)  Vacuum degree: less than -755mmHg(-0.1MPa)  Caution: Do not open the valves of outdoor unit when vacuuming , and Vacuum dry from liquid side and gas side simultaneously With check valve
  47. 47. Piping 7.Vacuum Connect to vacuum pump When vacuum degree reach to -0.1MPa(-755mmHg) , continue vacuuming for another 1 hour Observe whether the pressure changes or not (more than 1 hour) Stop vacuuming Vacuum the system at least 2h Outdoor unit OFF OFF Gas side Liquid side  Vacuum steps:
  48. 48.  Additional refrigerant charging procedures:  Note: 1. Charging excessive refrigerant will cause liquid harmer. 2. Record the actual amount of additional refrigerant for further reference. Piping 8.Charge refrigerant Calculate necessary amount of additional refrigerant according to the diameter and length of liquid pipes1 Make sure the gastight test, vacuum dry, pipe installation has been finished 2 Charge additional refrigerant to the outdoor unit from gas side according to the calculation result in the 1st step 3 R410A UP
  49. 49.  Additional refrigerant charged volume:  Calculate the additional refrigerant according to the diameter and the length of all liquid pipes connecting to outdoor and indoor units. Piping 8.Charge refrigerant Liquid pipe Size R410A kg/m Φ 6.4 0.022 Φ 9.5 0.059 Φ 12.7 0.120 Φ 15.9 0.180 Φ 19.1 0.260 Φ 22.2 0.370 Φ 25.4 0.450
  50. 50. Piping 9.Drainage pipe Condensate water volume (L/h) = Indoor unit capacity (HP) × 2L/h Select the diameter according to the below table Condensate water volume : V (L/h) I.D (mm) Thickness (mm) V ≤ 14 Φ 25 3.0 14 < V ≤ 88 Φ 30 3.5 88 < V ≤ 175 Φ 40 4.0 175 < V ≤ 334 Φ 50 4.5 334 < V Φ 80 6.0  Selection steps:
  51. 51.  Caution:the lean of main drainage pipe must be bigger than 1%  Note 1. If the lean < 1%,then select drainage pipe with bigger diameter 2. The drainage pipe should be independent with other water pipe 3. Never put the drainage pipe together with dirty water pipe Piping 9.Drainage pipe Exhaust outlet Condensate pipe ≥ 1%
  52. 52.  Discharge drainage water naturally (without drainage pump):  If the pressure at the connection of the drain pipe is negative, it needs to be fixed a drainage trap.  A plug should be designed to make cleanning easily Piping 9.Drainage pipe 50mm 50mm plug Main drainage pipe
  53. 53. Piping 9.Drainage pipe Increase the height for easy discharge  Discharge with drainage pump: 1. 4-way cassette indoor unit has built-in with drainage pump, its pumping head is 1200mm at most 2. Drainage trap is not necessary when using the drainage pump
  54. 54. Piping 9.Drainage pipe  Note: with drainage pump Height can not beyond the pump head of drainage pump Well fixed for this part
  55. 55. Piping 9.Drainage pipe  Typical mistake: CorrectIncorrect Correct Drain pipe 3-way pipe Drain pipe 3-way pipe Drain pipe 3-way pipe Avoid horizontal confluence
  56. 56. Piping 9.Drainage pipe Correct wayExhaust outlet should not be upward
  57. 57. Piping 9.Drainage pipe The thickness of insulation material for condensing water pipe is 10mm. Thin insulation Section of the insulation is too tight
  58. 58. Piping 9.Drainage pipe  Water leakage test  Check leakage of water pipe After finished installation of drainage pipe, filled the pipe with water, waiting for 24 hours to check whether there’s any leakage.  Check leakage from the indoor unit Charge water from the check hole of indoor unit to check whether the water can be exhausted smoothly or not
  59. 59. Electrical wiring VRF system installation
  60. 60. Wiring 0.Procedures Address setting Power Supply (Strong power) Signal wire (Weak power)
  61. 61. Wiring 1.DIP switch setting  Outdoor address setting Setting address of outdoor unit through DIP switch SW01 1 2 Description OFF OFF Master unit OFF ON Slave 1 ON OFF Slave 2 ON ON Slave 3 SW01 14Hp Slave 2 16Hp Slave 1 18Hp Master
  62. 62. Wiring 1.DIP switch setting  Check the Condensing Fan type setting DIP switch “SW02” 1 2 Definition OFF OFF Dual DC Fan OFF ON DC fan left, AC fan right ON OFF AC fan right, DC fan left ON ON Dual AC Fan SW02
  63. 63. Wiring 1.DIP switch setting  Outdoor unit capacity setting Check the unit capacity setting match the nameplate through DIP switch“ SW03” SW03 1 2 3 Capacity OFF OFF OFF 8HP OFF OFF ON 10HP OFF ON OFF 12HP OFF ON ON 14HP ON OFF OFF 16HP ON OFF ON 18HP ON ON OFF 20HP
  64. 64. Wiring 1.DIP switch setting  Outdoor unit type setting SW04 1 2 3 Definition OFF OFF OFF DRV Ⅲ (Factory default)
  65. 65. Wiring 1.DIP switch setting  the quantity of outdoor and indoor unit lock setting Lock the quantity of outdoor and indoor unit through DIP switch “SW05” SW05 1 2 3 Definition OFF OFF OFF Unlock (Factory default) ON OFF ON Lock
  66. 66. Wiring 1.Address setting  Indoor address setting by Remote controller Indoor unit address NO. Methold Press [Sleep] button 8 times within 5 seconds to enter into the interface of remote parameter change; Select “parameter NO.” as “1” to enter the indoor unit addressing mode; set “Indoor unit address NO.” as required on site; press “sending button” to send order; When hearing buzzer once, it indicates successful setting
  67. 67. Wiring 2.Power supply Basic requirement All wires, and electric devices must be conformed to local standards All wiring work must be done by qualified person Voltage range: rated voltage ±10% Independent power supply Capacity of power device is bigger enough Well and reliable PE line
  68. 68. Power supply box Wiring 2.Power supply Creepage breaker /Manual switch 3-Phase 380/400/415V  Power supply for outdoor units
  69. 69. Wiring 2.Power supply  Power supply for indoor units Notice: All the indoor units which connected to one outdoor system must be connected to the same power supply
  70. 70. Wiring 2.Power supply Why should all the indoor units which combined in one system have same power supply? → System is normally running. → Some indoor units lose power (plug out or power supply failure) . → These indoor units stop, but built-in expansion valves still keep former opening degree, they can’t close. → The outdoor units and other indoor units are still running. → The liquid refrigerant flow into the stopped indoor units. → This unit’s evaporator will freeze, because their fans are stopped . → And the other indoor units can not get enough refrigerant distribution, so the cooling performance drop down. Even worse, the liquid refrigerant will directly suck back the compressor, which cause liquid hammer, damage the compressor.
  71. 71. Wiring 2.Power supply  Creepage breaker selection According to 1.5-2 times of the total rated current.  Manual switch selection As the power is supplied independently, selecting the manual switch and fuse capacity according to the total capacity. Total capacity of outdoor units (HP) Manual switch (A) Fuse (A) 10~14 100 75 15~18 100 100 19~28 150 150 29~36 200 200 37~47 300 250 48~50 300 300 52~64 400 400
  72. 72. Wiring 2.Power supply The spec. of the wire is selected according to the max. total current of outdoor units The spec. of the wire is selected according to the max. total current of indoor units L N Indoor unit Controller L1L2L3N
  73. 73. Wiring 3.Signal wire  Between outdoor units in one combination  Between outdoor unit and indoor unit A,BA,B Master unit Slave unitSlave unit A,B A,B
  74. 74. Wiring 3.Signal wire 1. Signal wire should be two core shielded twisted pair 2. Keep away from the strong power 3. Non-polar communication 4. Series connection  Key points
  75. 75. Wiring 3.Signal wire  Key points 5.Signal wire and refrigerant pipe should not be tied together.
  76. 76. Commission VRF system installation
  77. 77. Commission 1.Check before start Power wire / Signal wire Refrigerant pipe & insulation Gastight & vacuum dry 1. All the electric wiring is finished? 2. Wire specification are correct? 3. Power wire are well insulation? 4. Well connection? Additional refrigerant charge Check valves
  78. 78. Commission 1.Check before start 1. Pipes diameters are correct? 2. Pipes are well insulation? Power wire / Signal wire Refrigerant pipe & insulation Gastight & vacuum dry Additional refrigerant charge Check valves
  79. 79. Commission 1.Check before start 1. Gastight test has been passed? 2. Vacuum dry has been done? Power wire / Signal wire Refrigerant pipe & insulation Gastight & vacuum dry Additional refrigerant charge Check valves
  80. 80. Commission 1.Check before start Refrigerant has been charged correctly? Power wire / Signal wire Refrigerant pipe & insulation Gastight & vacuum dry Additional refrigerant charge Check valves
  81. 81. Commission 1.Check before start 1. Stop valves of outdoor unit are opened? 2. All the fans rotate normally? Power wire / Signal wire Refrigerant pipe & insulation Gastight & vacuum dry Additional refrigerant charge Check valves
  82. 82. Commission 2.Check Operation At least 6 hoursPreheat Error check Trial operation Operation test Hand to user
  83. 83. Commission 2.Check Operation Check if there’s any error code display on the IDU or ODU? Preheat Error check Trial operation Operation test Hand to user
  84. 84. Commission 2.Check Operation Turn-on all indoor units Preheat Error check Trial operation Operation test Hand to user
  85. 85. Commission 2.Check Operation 1. Check indoor units: Preheat Error check Trial operation Operation test Hand to user Setting 17℃ in cooling mode  High speed  Running more than 4 hours  Check Temp. -> Temp. difference between air intake and outlet of each indoor unit should be bigger than 8℃。
  86. 86. Commission 2.Check Operation 2. Check outdoor unit:  Discharge and suction temperature of compressors  Pressure of systems  Running current 3. Any abnormal noise, vibration 4. Record the operation parameter Preheat Error check Trial operation Operation test Hand over to user
  87. 87. Commission 2.Check Operation System pressure and temperature check R410A OD35/-,ID27/19 OD43/-,ID32/23 High pressure (MPa) 2.8~3.0 3.4~3.8 Low pressure (MPa) 0.85~1.0 1.0~1.45 Discharge temp.(℃) 70~80 / Suction temp.(℃) 11~14 / Indoor air outlet (℃) 12~15 degree (T1 is around 21~27) temp. difference between return and outlet (ΔT) 8~12
  88. 88. Commission 2.Check Operation Daily operation and maintenance explanation Preheat Error check Trial operation Operation test Hand to user
  89. 89. Main tools VRF system installation
  90. 90. Outlook Name Scope Copper pipe cutter R410A Copper pipe bender R22, R410A Main tools
  91. 91. Outlook Name Scope Flaring tool R22, R410A Expander R22, R410A Main tools
  92. 92. Outlook Name Scope Pressure gauge R410A Vacuum pump R410A Main tools 5/16″ Check valve
  93. 93. Outlook Name Anemometer acoustic meter Main tools
  94. 94. Outlook Name Infrared thermometer Clamp meter Main tools
  95. 95. Outlook Name Torque spanner Cutter Main tools
  96. 96. Outlook Name Electrodrill Manual hydraulic crimper Main tools
  97. 97. Thank you!

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