chapter 5 - installation & commissioning service course.pdfinstallation – field piping •...

S-PZE01 ZEAS Service Course 9/23/2009

Pieter Goes - DENV Service Department 1

S-PZE01 ZEAS CCU Service Course

Chapter 5: Installation & Commissioning

223-Sep-09

Internal Use Only

Chapter 5: Installation & Commissioning• Part 1: Installation• Part 2: Commissioning

Nitrogen cylinder



Part 1: InstallationOutdoor Unit Oil TrapField Piping Field Piping ComponentsRefnet / Branches ST-ControllerField Wiring

5.1.1: Outdoor Unit



523-Sep-09

Internal Use Only

Installation – Outdoor Unit• Unpacking the unit:

When unpacking the unit, be sure all of following items are present.– Installation Manual– Operation Manual– Clamps– Accessory bag

Do not loose any of these items!

Position 1

Position 2

111

22 2

623-Sep-09

Internal Use Only

Installation – Outdoor Unit• Accessory bag:

The accessory bag contains a number of pipes that can be used to connect the unit to the field piping (easy installation). The content is as follows:

Note: some units have pipe connection of 25.4mm or 31.8mm. Adapters for 28.6mm and 34.9mm have to be purchased on site. The future Mass Production will contain the correct adapters.



723-Sep-09

Internal Use Only

Installation – Outdoor Unit• Installation space:

Leave enough operation and service space, as shown in following 3 patters

Single Unit Multiple Units

Pattern 1(wall heightlimited)

Pattern 2(wall heightlimited)

Pattern 3(wall heightNOT limited)

823-Sep-09

Internal Use Only

Installation – Outdoor Unit• Remark for patterns 1 and 2:

In case of pattern 1 and 2, the wall height on the front side is limited to 1500mmand the wall height on the suction side is limited to 500mm. The wall height on the side is not limited.Should the height exceed these values, you should add h1 and h2 as below:

22100

22300

21500

hY

hY

hX

+=

+=

+=

(in case of pattern 1)

(in case of pattern 2)



923-Sep-09

Internal Use Only

Installation – Outdoor Unit• Outdoor unit foundation

– Use suspension blocks or suspension frame to support the full length of the unit (the most heavy point is in the middle part) example plarock.

X O O O Not required for5 & 6hp unit

Not required for5 & 6hp unit

Available for5 & 6hp unit

1023-Sep-09

Internal Use Only

Installation – Outdoor Unit– Dimensions to make the suspension frame: • The base should be strong enough

to prevent vibration and noise

• The height of the frame should beat least 150mm above the floor

• Securely bolt the unit to the frame (use M12 foundation bolts)

• The bolts should be inserted at least 20mm

• Install anti-vibration rubber underthe full length of the unit



1123-Sep-09

Internal Use Only

Installation – Outdoor Unit– When using plarock

• Relatively cheap• Lightweight material• Strong structure

1223-Sep-09

Internal Use Only

Installation – Outdoor Unit• Outdoor unit installed inside

– Use drainpan (optional)– Make fan ducting (each fan separately)

• Standard the ESP of the outdoor fans is 30Pa, which can be seen as 3m of ducting

• The ESP value can be set to 78.6Pa by field setting (2-40-2)



1323-Sep-09

Internal Use Only

Installation – Outdoor Unit• Outdoor unit installed inside: attention points

When L ≥ 3m, the field setting for high ESP should be made

Louvered wall for suction air

Solid duct

Flexible connection

L

Drain Pan

1423-Sep-09

Internal Use Only

Installation – Outdoor Unit• Outdoor unit installed inside: attention points

Each fan should have separate ducting

Mistake:Field supplied outdoor ducting has no separation between fans.

Problem:Incorrect air flow. If only one fan operates air can be re-circulated.

Solution:Either use separate ducting for each fan or install divider plate.



1523-Sep-09

Internal Use Only

Installation – Outdoor Unit• Installation under eaves

Make sure that there is no air short circuit

Eaves are higher than 1 metre, good airflow

Eaves are lower than1 metre, good airflow

< 1m

> 1m

Eaves are 1 metre or less, short cycling can

occur

5.1.2 Field Piping



1723-Sep-09

Internal Use Only

Installation – Field Piping• 3 basic principles for field piping

Water/moisture

Dust/contaminants Leak

No leakage of refrigerantNo dust/contaminants inside

Do not let dust/contaminants inNo water/moisture inside

Do not let water/moisture in

TightCleanDry

Dust/contaminants

1823-Sep-09

Internal Use Only

Installation – Field Piping• Field piping installation precautions

– Keep pipes protected at all possible times during installation, or pinch/tape the pipe– Finish pipework ASAP

<Unprotected (uncovered) pipe ends> <Protected (covered) pipe ends>

<Unprotected pipe ends> <Protected pipe ends><Taping>A method by which the ends of the copper tubes are covered with vinyl tape

Pipe end

Wrap the copper tube with tape.

Cut flat

Fold down Wrap with tape again

<Pinching>A method by which the ends of the copper tubes are closed off and the gaps are brazed.

Copper tube

Braze

Brazing filler metal



1923-Sep-09

Internal Use Only

Installation – Field Piping• Brazing:

Oxygen Free Nitrogen MUST be used during all brazing processes (pressure regulated to 0.2bar = 0.02MPa)

N2 N2N2N2 N2

Taping

Tapered nozzle

Valve

Nitrogen gas regulator

Nitrogen cylinder

Taping Pressure hose

2023-Sep-09

Internal Use Only

Installation – Field Piping

Nitrogen replacementThe inner surface of the piping is clean.

The effects of nitrogen replacement

No nitrogen replacementThe inner surface of the pipe has blackened due to the oxide film.



2123-Sep-09

Internal Use Only

Installation – Field Piping• Consequenses of this carbon layer (brazing without N2)

– Clogging of expansion valve or capillary tube– Degradation of oil– Oxidation of compressor

Brazing is an exothermal reaction (energy comes free under the form of light and heat).

On the outer side of the pipe, the combustion is complete giving CO2 and H2O as products (enough oxygen present)

On the inner side of the pipe, the combustion is incomplete (not enough oxygen present to make complete combustion). This gives CO and C as side products (C is soot which can clog capillary tubes etc.)

When all the oxygen is replaced by nitrogen, there can be no reaction (nitrogen is an inert gas) no soot can be formed.

ECOOHOHC ++→+ 22283 345

EOHCOCOCOHC ++++↓→+ 22283 822272

2223-Sep-09

Internal Use Only

Installation – Field Piping• Piping insulation

Both liquid and gas line must be insulated! The liquid line can become very coldsee reference temperatures below.

– Liquid pipe minimum temperature: 0 ~ -10°C– Gas pipe minimum temperature: -26°C (MT Series)

-46°C (LT Series)

The thickness depends on the heat-through ratio.As a reference:- Gas pipe: 30mm- Liquid pipe: 10mm

Use sealant so no moisture can enter the insulation



2323-Sep-09

Internal Use Only

Installation – Field Piping• Outdoor unit field piping connections:

Model 5, 6hp 8, 10, 12hp 15, 20hpLiquid (mm) 9.5 9.5 12.7Gas (mm) 19.1 25.4 31.8

Locally purchased adapters willhave to be used (currently not in accessory bag)

2423-Sep-09

Internal Use Only

Installation – Field Piping• Connect the field piping to the unit (4 procedures)

– Procedure 1: Confirm if the shut-off valves are fully closed– Procedure 2: Connect a charge hose to the liquid and gas shut-off valves and

remove the gas from the pinched piping– Procedure 3: Cut off the small pinched pipe to check that teher is no oil inside

(danger for brazing!). If oil comes out, remove the large pinched pipe– Procedure 4: Sweat the brazing connection and remove the pinched pipe.



2523-Sep-09

Internal Use Only

Installation – Field Piping• Use the accessory pipes

– Connection to the front side

– Connection on the lateral side (through bottom plate)

5.1.3 Refnet / Branches



2723-Sep-09

Internal Use Only

Installation – Refnet / Branches• Liquid piping:

Install a Y-Joint (Refnet) or T-Joint and branch it horizontally, to create an even flowof liquid. A T-Joint is also allowed, because the flow of liquid is slow and under high pressure!

<Installation standards when installing Refnets in liquid line>Install the REFNET joint horizontally (±30°angle) or vertically (all positions allowed).

ＡＡHorizontal

A. Arrow view

<Horizontal pipe> <Vertical pipe>

2823-Sep-09

Internal Use Only

Installation – Refnet / Branches• Gas piping:

Install a Y-Joint (Refnet) or T-Joint and branch it vertically, so that the branchedpiping will be located above the main piping. This is to prevent oil from entering a cabinet which is thermostat OFF.

<Installation standards when installing Refnets in the gas line>

<Installation standards when installing T-Joints in the gas line>

Create a downwardslope



2923-Sep-09

Internal Use Only

Installation – Refnet / Branches• Distance between 2 branches in the liquid line

This is to have a laminar flow of liquid

At least 500

At least 500 At least 1,000

<Top view>

5.1.4 Field Wiring



3123-Sep-09

Internal Use Only

Wiring a ZEAS SystemPower Supply• Outdoor• ST Controller• Showcase IF

Communication• F1/F2 out• P1/P2 (relay signal)

(High voltage contact 230V to V free)

• C/C1 (Caution output)

• C/W1 (Warning output)

3223-Sep-09

Internal Use Only

Installation – Field Wiring• Power Supply and Maximum Fuse Ampère (MFA)

• The power supply cable characteristics (diameter, type) dependon the local legislation (different for country by country).

Model Power supply Fuse (A)LRMEQ5,6AY1 15LRLEQ5,6AY1 3 phase, N + E 15LRMEQ8,10,12AY1 380-415V 25LRLEQ8,10,12AY1 50Hz 25LRMEQ15,20AY1 40LRLEQ15,20AY1 40Showcase I/F single phase 10ST-Controller 230V 50Hz 10



3323-Sep-09

Internal Use Only

Installation – Field Wiring• Procedure how to connect power supply wiring on outdoor unit

3423-Sep-09

Internal Use Only

Installation – Field Wiring• Keep the power wiring (high voltage) and communication wiring

(low voltage) separated at least 5mm– Crimp style terminals are recommended.

– DO NOT put high voltage and low voltage (signal) wires in the same cable tray. This could cause interference on the communication line.

Low voltage (signal) High voltage

Crimp-style terminal



3523-Sep-09

Internal Use Only

Installation – Field Wiring• Keep the equipment enough away from equipment that creates

electrical noise (e.g. AM broadcasting equipment)

At least 1,500 mmMore than 100A

At least 1,000 mm100A

At least 500 mm50A

At least 300 mm

At least 50 mm

Less than 10A220V or more

Separation distance between power wiring for other equipment and control

wiring for Daikin air conditioners

Separation distance between power wiring and control wiring

for Daikin air conditioners

Power supply capacity for power wiring

At least 1,500 mmMore than 100A

At least 1,000 mm100A

At least 500 mm50A

At least 300 mm

At least 50 mm

Less than 10A220V or more

Separation distance between power wiring for other equipment and control

wiring for Daikin air conditioners

Separation distance between power wiring and control wiring

for Daikin air conditioners

Power supply capacity for power wiring

3623-Sep-09

Internal Use Only

Installation – Field Wiring

P2C C1 W1 P1

OutdoorF1 F2

1 2

Refrigerator RefrigeratorBlower coil

Relay Box Relay BoxRelay Box

ST Controller

F1F2

F1F2 Showcase IF

F1F2 Showcase IF

F1F2 Showcase IF

Control panel

Warning

Alarm

Operation switch



3723-Sep-09

Internal Use Only

Installation – Field Wiring• F1F2 Communication:

– Communication bus 16 V DC

– Type:• 2 core flexible (vinyl): NON-SHIELDED – IMPORTANT!• Sizes from 0,75 mm² - 1,25 mm²

– Maximum length of communication wiring = 1000 m

• F1/F2 Outdoor is used to connect Showcase I/F, ST-Controller & other Daikin equipment (ZEAS, CVP, VRV)

• F1F2 Indoor is not used for ZEAS

Conductor

Insulation

Sheath

<Cross-section of a communication cable>

3823-Sep-09

Internal Use Only


P2C C1 W1 P1

OutdoorF1 F2

1 2

Refrigerator RefrigeratorBlower Coil


ST Controller

F1F2

F1F2 Showcase IF

F1F2 Showcase IF

F1F2 Showcase IF

F1/F2 (outdoor)

Control panel

Warning

Alarm

Operation switch



3923-Sep-09

Internal Use Only

Installation – Field Wiring• Warning, Alarm and Operation Output (high voltage)

Connect Warning, Alarm and Operation Output wiring to terminal X2M and clamp it as follows

• Wiring specifications:– Wiring diameter: 0.75 ~ 1.25mm²– Maximum wiring length: 130m

• Capacity of contacts:– Total capacity Warning and Alarm Output: 0,5A or less at 220~240V– Capacity Operation Output: 0,5A or less at 220~240V

4023-Sep-09

Internal Use Only


P2C C1 W1 P1

OutdoorF1 F2

1 2



ST Controller

F1F2

F1F2 Showcase IF

F1F2 Showcase IF

F1F2 Showcase IF

F1/F (outdoor)

Control panel

Warning

Alarm

Operation switch

P1/P2 (operation)

C/C1 (warning)

C/W1 (alarm)



4123-Sep-09

Internal Use Only

Installation – Field Wiring• Principle of Operation Output (P1/P2)

The Relay Control Box contains a relay, which must be wired onsite in order to operate the Liquid Line Solenoid Valve in the desired conditions

P1P2 Relay Control Boxes

230VAC Refrigerator permission signal from outdoor unit

4223-Sep-09

Internal Use Only


Refrigerator Cabinet 1 Refrigerator Cabinet 2 Refrigerator Cabinet 3

SV

L

N

SV SV

P1

P2

Outdoor Unit PCB

L

N

L

N

Thermo onCabinet 1

Thermo onCabinet 3

Thermo onCabinet 2

230V AC Output

Relay control box 1 Relay control box 2 Relay control box 3

• P1P2 HIGH voltage (similar CVP principle)



4323-Sep-09

Internal Use Only


Refrigerator Cabinet 1 Refrigerator Cabinet 2 Refrigerator Cabinet 3

SV

L

N

SV SV

Outdoor Unit PCB

L

N

L

N

230V AC – 24V ACStep down Transformer

Relay control box 1 Relay control box 2 Relay control box 3

P1

P2

Thermo onCabinet 1

Thermo onCabinet 3

Thermo onCabinet 2

• P1P2 LOW voltage (similar CVP principle)

4423-Sep-09

Internal Use Only


Ry1

P1/P2 = permission for cooling (230V output)

Ry1 = 230V relayRy1-1 = Non voltage contact from contactor Ry1S1T = Cooling thermostat (cabinet)Y1S = Liquid solenoid valve

230V AC 230V AC

1 2P1 P2

Y1S

S1TRy1-1

230V

Wiring principle



4523-Sep-09

Internal Use Only

Installation – Field Wiring• Remote operation switch wiring

– For remote switch, use a non-voltage contact for microcurrent (not more than1mA, 12VDC)

– If the remote switch is used to start/stop the system, set the operating switch to “REMOTE”

• Wiring installationWire using the 1-2 contact on terminal X3M

Wiring specifications:

• Wiring diameter: 0.75 ~ 1.25mm²

• Maximum wiring length: 130m

4623-Sep-09

Internal Use Only


P2C C1 W1 P1

OutdoorF1 F2

1 2



ST Controller

F1F2

F1F2 Showcase IF

F1F2 Showcase IF

F1F2 Showcase IF

F1/F2 (outdoor)

Control panel

Warning

Alarm

Operation switch

P1/P2 (operation)

C/C1 (warning)

C/W1 (alarm)

1-2 (remote switch)



4723-Sep-09

Internal Use Only

Installation – Field Wiring• General remark for all wiring

– Use the washers for power wiring which are foreseen at the terminals

– Use tightening torque as in below table

5.1.5 Oil Trap



4923-Sep-09

Internal Use Only

Installation – Oil Trap• The outdoor unit has several ways of getting the oil back to the

compressors– By oil return cycle (2 ways) outdoor unit software– By oil separator outdoor unit hardware– By oil traps in gas line field piping (each 5 meter height difference)

<5m

5m

5m

5023-Sep-09

Internal Use Only

Installation – Oil Trap• Only when outdoor unit is situated HIGHER than the cabinets,

you will need to make an ‘OIL RECOVERY BEND’ for every 5 meters level difference in the GAS LINE.

• Remark 1: If the evaporator coil is in the top of the cabinet, the 5 metres should be measured from the top of the unit.

• Remark 2: The “oil recovery bend” should be constructed in such a way that there is a minimum of pressure drop.

The refrigerant velocity increases and takes the oil.OIL

To the outdoor unit



5.1.6 Field Piping Components

5223-Sep-09

Internal Use Only

Installation – Field Piping Components• Solenoid valves • Liquid line drier• Ball valves • Suction drier core• Sight glasses• Indoor filter• Expansion valve

Details: See Chapter 2 “System Build-Up”



5.1.7 ST-Controller

5423-Sep-09

Internal Use Only

Installation – ST-Controller• ST-Controller dimensions

Make some ventilation possible (heat generation 10W max)



Part 2: CommissioningFlushing Additional Refrigerant ChargePressure Test Test RunVacuum Drying ST-ControllerInstallation Check

5.2.1 Flushing



5723-Sep-09

Internal Use Only

Commissioning - Flushing• Use the flushing method. This has several benefits

– Removing dust, dirt, etc.– Check for cross piping

• The flushing method is done as follows1. Connect a bottle of oxygen free nitrogen

to the service port of the liquid service valve2. Regulate nitrogen into the pipe work at a constant 1 bar3. Make sure that the nitrogen is being released from

the intended liquid line going to the refrigeration cabinet(s)4. Place your hand over the open liquid line (using a cloth).

When the pressure increases remove your hand slowly“ensure gloves and safety glasses are worn”

5. Repeat step 3 a number of times for all cabinets6. Repeat the above procedure for the gas pipe line

5.2.2 Pressure Test



5923-Sep-09

Internal Use Only

Commissioning – Pressure Test• Always do the pressure testing with the field piping disconnected from the outdoor

unit. This is to prevent the possibility of the service valves letting by, and OFN getting into the outdoor unit.

• Pressure test at all marked points below: (design pressure cabinets) (38bar)• Close the stop valve on the liquid line for each cabinets (we will pressure test the

liquid line to 38bar). The gas line will be pressure tested at the design pressure of the cabinet.

1 2

SV SV SV

Liquid Line Gas Line

1 2

6023-Sep-09

Internal Use Only

Commissioning – Pressure Test• Pressure test different steps

10

0

20

30

40

3 min 3 min 24 hours

Step 1 Leak check after minimum 3 min. at 3 Bar

Step 2 Leak check after minimum 3 min. at 15 Bar

Step 3 Leak check after 24 h. at 38 Bar

Check ambient temperatureat begin and end of test!5K difference = 1 bar!



6123-Sep-09

Internal Use Only

Commissioning – Pressure Test• Leak test

When you are checking for leaks using bubble solution, be certain to use a recommended product from your Wholesaler, as using a watered down Fairy liquid solution can have the following effects or damage:

– Fairy liquid contains salt and this will have a capillary action and pull in moisture to your flare nut. This moisture will then get into the thread of the flare nut and when the pipe gets cold the moisture will freeze and expand causing the flare nut to crack.

– It also contains Ammonia, which if comes in contact your flared joint causes a corrosive action between the brass nut and the copper flare.

5.2.3 Vacuum Drying



6323-Sep-09

Internal Use Only

Commissioning – Vacuum Drying• Connect the vacuum pump to both liquid and gas service port

– Vacuum drying is an essential procedure, to ensure that the refrigerant pipe work isfree from moisture and foreign material, causing blockages which will cause problems with efficiency and the possibility of component failure.

– Evacuation must be carried out to using a high quality two stage vacuum pump (with non-return valve), good quality gauge manifold and hose set, and it is essential that a torr gauge is used to check the level of evacuation achieved.

6423-Sep-09

Internal Use Only

Commissioning – Vacuum Drying• Length of vacuuming

– Vacuum should take at least 2 hours down to -100.7kPa or below

– Then, leave the unit for at least 1 hour at the pressure of -100.7kPa or below and check that the vacuum gauge reading is not increasing. If the pressure rizes, there is residual water in the system or the system has a leakage.

– In case of rizing pressure, break the vacuum with Nitrogen and re-vacuumcompletely (Multiple evacuation).

Water boiling point Absolute pressure Gauge pressurekPa mmHgmmHg kPa℃



6523-Sep-09

Internal Use Only

Commissioning – Vacuum Drying• Using a Torr gauge

We advise to use a Torr gauge to check the state of vacuuming carefully. Be sure to vacuum deep enough to make sure that all moisture in the system can evaporate(depending on the outdoor temperature!).Below is a table that shows at which temperature moisture will boil off, against the level of vacuum in the system pipe work. So the colder the outdoor temperature, the lower level of Torr is required to be sure no moisture is present in the pipe work.

5.2.4 Installation Check



6723-Sep-09

Internal Use Only

Commissioning – Installation Check• Electrical work:

– Check if all the wiring is firmly connected– Check if te main power supply is good quality (stable condition etc.)

• Pipe work:– Make sure pipe size is correct– Make sure insulation work is done

5.2.5 Additional Refrigerant ChargeCalculationCharging



6923-Sep-09

Internal Use Only

Commissioning – Additional Refrigerant Charge

• Additional Refrigerant CalculationAll ZEAS units are pre-charged from factory following the table below

However, this is not enough. There must be an additional charge (sum of 4 items)

– Item 1: additional charge by piping length. This is called the “trim charge”. The trim charge is calculated as follows

total length of 15.9mm liquid pipe x 0.19 = “ ” kgtotal length of 12.7mm liquid pipe x 0.12 = “ ” kgtotal length of 9.5mm liquid pipe x 0.06 = “ ” kgtotal length of 6.4mm liquid pipe x 0.023 = “ ” kg +

= “ ” kg

Model 5, 6hp 8, 10, 12hp 15, 20hpFactory charge (kg R410A) 5.2 7.9 11.5

7023-Sep-09

Internal Use Only


• Additional Refrigerant Calculation– Item 2: Additional charge by showcase size. Because the heat exchanger from

one refrigerator has another volume than the heat exchanger volume of another, it is impossible to calculate it based on the liquid line length (difference case bycase). That is why we add a small charge for each refrigerator in the system.

*Note: 1. Case of showcase, the condition of capacity:

• Medium temperature application (MT): Te = -10°C

• Low temperature application (LT) Te = -35°C

2. In case of blower coil, the condition of capacity is given with Td = 10 K

Showcase capacity* Additional charge (kg)Q Showcase Blower

MT LT coil Q < 5kW 1.2 1.4 0.6

5kW ≤ Q < 10kW 2.3 3.2 1.210kW ≤ Q < 15kW 3.4 5.2 1.715kW ≤ Q < 20kW 4.6 2.320kW ≤ Q < 25kW 5.9 3.025kW ≤ Q < 30kW 7.0 3.530kW ≤ Q < 35kW 8.2 4.135kW ≤ Q < 40kW 9.7 4.9

40 ≤ Q 11.0 5.5



7123-Sep-09

Internal Use Only


• Additional Refrigerant Calculation– Item 3: Additional refrigerant charge depending on the outdoor unit model

(constant)

– Item 4: Additional charge by adjustment = finetuning charge. This is decided bythe reading of the sight glass. If the sight glass is full liquid or few bubbles are present, no finetune charge must be added. However, if the sightglass shows many bubbles, a maximum of 10% of item 2 can be added.

Item 4 ≤ 0.1 * Item 2

Model 5, 6hp 8, 10, 12hp 15, 20hpConstant charge (kg R410A) 1.0 3.0 3.5

7223-Sep-09

Internal Use Only


• Additional Refrigerant Calculation– Total additional charge = item 1 + item 2 + item 3 + item 4.– Round this value in units of 0.1kg.– Write it on the specified label (as below) and attach it to the unit.



7323-Sep-09

Internal Use Only


• Additional refrigerant charging procedure1. Check that the RUN SWITCH is OFF. The RUN SWITCH is located behind

the left-hand side inspection hole.2. Turn ON the main power supply the “Alive LED” on the Main PCB should

blink. When the power supply is turned on, H2P will blink for the first 5 seconds. After that, H2P will go OFF. H2P comes ON in case of an abnormality. The LED’s are located behind the right-hand side inspection hole

7423-Sep-09

Internal Use Only


• Additional refrigerant charging procedure3. Open the valve to charge refrigerant through the liquid line service port. Make

sure that only liquid R410A is charged. When the cylinder has no siphon, put the cylinder upside down during the charging process. Now we are chargingbased on the pressure difference between cylinder and vacuumed field piping. Use a scale to measure the amount of R410A that is charged.

4. When the calculated amount is charged, close the charging valve and disconnect the bottle. You can now proceed to step 6.

5. When the charging procedure slows down (pressures have equalized) and the full additional charge has not been added yet, the bottle must be disconnectedfrom the liquid line service port and connected to gas line service port.

6. Now open the liquid and gas stop valves, so the refrigerant comes free fromthe outdoor unit. Put the RUN SWITCH in the ON position. When you stillneed to fill refrigerant, it must be done through the gas line. Be very carefullthat no liquid enters the compressor, as we are charging liquid directlyinto the compressor suction line.



7523-Sep-09

Internal Use Only

• Apply screw lock agent (especially on the gas stop valve)!To prevent the brass nuts from cracking (freezing water inside the nut), the nuts must be sealed (example: green Locktite = soft type). Do not apply screw lock agent to the sealing part (rubber).

– Stop valve cover:

– Service port nut:


7623-Sep-09

Internal Use Only


• Tighten the stop valve shaft, stop valve cover and service port nuts firmly using a torquewrenchThis is to prevent any leaks that might happen during the years of operation (no onevalve is 100% closed)



5.2.6 Test Run

7823-Sep-09

Internal Use Only

Commissioning – Test Run• Check the sight glass condition

• Check that there is cold air coming from the indoor units.• Check that the indoor units perform defrosting.• When turning the power supply OFF, ALWAYS set first the

OPERATION SWITCH OFF before turning OFF the main power supply. Not doing so, you might damage crucial parts likecompressor etc.



7923-Sep-09

Internal Use Only

Commissioning – Test Run• Use the RAM Monitor to verify the system parameters. Most

important are:– Suction superheat: 10 ~ 20K– Discharge superheat: 20 ~ 40K

When these values are too high/low, it could be that the indoorunit expansion valves are not correctly regulated (open/closethem a little bit).

RAMMonitor

MAINPCB

More info on how to use RAM Monitor in Chapter 6 “Troubleshooting & Maintenance”

8023-Sep-09

Internal Use Only

Commissioning – Test Run• Should there be an error at the time of the test run (H2P lit), the

malfunction should be checked in the Monitoring Mode. See Chapter 6 “Troubleshooting & Maintenance” on how to use this function.

*1 Set the OPERATION SWITCH to OFF and the ON again. If the problem persists, refer to the Service Manual



5.2.7 ST-Controller

8223-Sep-09

Internal Use Only

Commissioning – ST-Controller• Get the Activation Key (same procedure as for iTouch

controller/iManager)

• MAC address

• Software ID

• User informationActivation key

ST-Controller



8323-Sep-09

Internal Use Only

Commissioning – ST-Controller

Go to the following webpage:http://global.daikin.com/activation/login.php

1. Surf to the registration website

8423-Sep-09

Internal Use Only

User name: EUActivatorNo password required

Commissioning – ST-Controller2. Login to the website



8523-Sep-09

Internal Use Only

There are three submenu’s:

Basic software: Choose this item when you want to get the activation key for the basic software (at startup of the controller)

Option software: Not used for ST-Controller

Reconfirm: Choose this item when you do not remember your activation key and you want tore-confirm it.

Commissioning – ST-Controller3. Choose “Basic Software”

8623-Sep-09

Internal Use Only

When choosing “basic software”you will be asked to fill in more information about the site.

This provides useful information to DIL for future improvements of the product.

Be sure to fill in your country correctly, because we might need this particular info in the database, for instance when an ESV has to be issued.

Commissioning – ST-Controller4. Fill in site information



8723-Sep-09

Internal Use Only

Confirm the information

Commissioning – ST-Controller5. Confirm the data

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Internal Use Only

Fill in all fields and press the “OK” button.

Fill in the following fields:

The MAC address: give in the MAC address (you can find it on a sticker on the back of the ST-Controller). Make sure you use capital letters and numbers and also fill in the dash “-” between every two letters or numbers. (e.g. 00-80-4F-81-00-9E)

The Software ID: give in the Software ID (you can find it on a sticker on the back of the ST-Controller and also on a piece of paper delivered with the controller). Be careful not to make input mistakes, e.g. difference between number 0 and capital letter O.

The Software Version: give in the software version.

No need to fill in

Commissioning – ST-Controller6. Fill in Mac Address, Software ID and Software Version



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Press the “OK”button

Commissioning – ST-Controller7. Re-confirm the key information

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1) Write down the Activation key and keep it in a safe place

2) Fill in the activation key in the License key input screen of your ST-Controller (go to settings system settings license key input)

3) Your ST-Controller is now activated

Commissioning – ST-Controller8. Fill in the Activation Key and make a copy of it on the License

Paper (that you get with the ST-Controller). Save this info!

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