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r407c Guide PDF
r407c Guide PDF
air conditioning
John Roe
Managing Director
3D Air Sales Ltd
Distributors of air conditioning equipment manufactured
by MITSUBISHI HEAVY INDUSTRIES
Mr John Roe
Mr Brian Overall
C.Eng., B.Sc., M.C.I.B.S.E., M. Inst.R. C.Eng., M.I.Mech.E., M.C.I.B.S.E.,
D.M.S., A.W.P.
CONTENTS
SECTION 1
Page 2
SECTION 2
Page 3
New Regulations
Impact on Refrigeration and
Air Conditioning Users
SECTION 3
Page 4 - 7
SECTION 4
Page 8 - 9
SECTION 5
Page 10
SECTION 6
Page 11
Refrigerant Oils
SECTION 7
Page 12 - 16
SECTION 8
Page 17 - 19
SECTION 9
Page 20 - 22
SECTION 10
Page 23
Safety Precautions
SECTION 11
Page 24 - 25
Electrical Installation
SECTION 12
Page 26 - 28
Glossary of Terms
1.1
1.2
1.3
Estimated HCFC
Requirement,
ODP Tonnes
Amount Available
in Article 4,
ODP Tonnes
Revised Proposal
05/03/1999
ODP Tonnes (%)
1999
8079
8079
8079
2000
2001
2002
7869
7403
6387
8079
6678
6010
8079
6678
5676
2003
2004
2005
2006
3631
1985
1891
1797
2337
2003
2003
2003
3005
2003
2003
2003
2007
2008
2009
1703
220
220
2003
334
334
2003
1670
1670
2010
2011
2012
2013
220
220
220
220
334
334
334
334
0
0
0
0
2014
220
334
1.6
Section 2
2.0
2.1
2.2
1-1-2004
1-1-2008
2.3
2.4
CASSETTE systems
For commercial applications
3-pipe system:
KXR FDC280 with eight
cassette units connected, via
single and a 4-way
distribution controllers
4.0
Refrigerant R407C
4.1
4.2
4.3
4.4
4.5
4.6
Physical Characteristics
Type
R22
HCFC
Constituents
HFC's
R32, R125,R134a
% by Weight
23, 25 & 52
HCFC22
-43.6
-40.8
Molecular Weight
Flammability in Air Vol
ODP (R11=1)
GWP (CO2=1, 100 yrs)
Non Flammable
0.31
0.3
0.00
0.06
1600
1700
4.6
Bar
16.5
15.4
4.8
86.5
Non Flammable
Bar
Critical Temperature
86.2
Pressure Ratio
Refrigerant
R407C
HFC Blend
3.6
3.1
87.3
96.1
1.14
1.18
59.3
63
212
205.4
5.6
5.8
3456
3430.8
4.93
Figure 4.1
Graphical Comparison Saturation Pressure v
Temperature of R407C and R22
Table 4.1
Boiling
Point oC
Flammable
Effect on
Energy
Efficiency
Pressure
Effect on
Discharge
Temperature
R32
-52
Positive
High
Increase
R125
-51
Negative
High
Decrease
R134a
-27
Positive
Medium
Decrease
3
2.5
P (MPa)
HFC
Units
2
R-407C
R-22
1.5
1
0.5
4.7
0
-50
50
Temperature (C)
100
4.9
4.10
4.12
4.13
4.14
4.15
Figure 4.2
4.11
5.1
5.2
Table 5.1
Cycle Performance Properties
Units
R407C
R22
c
c
k
%
o
c
k
kW
2
38
10
75
7
10
12.5
2
38
10
75
7
10
12.5
Bar
Bar
15.645
5.4
4.81
5.04
12.64
12.5
2.507
0.07024
11.844
70.11
14.64
5.28
5.25
14.6
5.312
4.88
5.09
12.776
12.5
2.562
0.07288
12.204
73.70
12.0
0
0
o
o
kW
kW
kW
kg/s
m3/hr
o
c
o
c
k
k
5.3
5.4
10
Section 6
6.0
6.1
Refrigerant Oil
Mitsubishi Heavy Industries air conditioning systems
are designed on the basis that oil carried over by the
compressor is returned by the refrigerant flowing
around the system.
6.2
6.7
6.4
6.5
6.6
11
Refrigerant Cycle
To understand the mechanical vapour compression
refrigerant cycle, an understanding is required of
the individual processes that make up the cycle,
the relationship that exists between the several
processes, and the effect that changes in any one
process in the cycle have on all the other processes
in the cycle.
12
Figure 7.1
Basic Refrigeration Cycle
Compressor
Gas Suction Line
Superheated Vapour
High Pressure
Evaporator
changes state
of Refrigerant
Condenser
changes state
of Refrigerant
Heat
Absorbed
Heat
Rejected
Saturated Vapour
Liquid
High Pressure
Expansion Device
Liquid changes State
& Flashes to gas & liquid
Figure 7.3
Heat Pump Split System - Typical Layout of Refrigeration
Components - (MHI model FDTN208HEN)
13
Figure 7.4
VRF System - Simultaneous Heating and Cooling Typical Layout of Refrigeration Components
(MHI model FDC2001HKXR)
14
Figure 7.6
Typical Graphical Representation of Refrigerant
Cycle for a Pure Refrigerant R22
PRESSURE
Liquid
Refrigerant
Sub Cooling
Sensible Heat
Rejected at
Condenser
Superheat
Sensible Heat
Rejected at
Condenser
Expansion
t
Lines of Constan
Temperature
Figure 7.5
Pressure - Enthalpy diagram for a Pure Refrigerant R22
Latent Heat
Rejected at Condenser
Condensation
(Heat Rejection)
Superheated Vapour
Refrigerant
Evaporation
(Refrigeration Effect)
Work Done by
Compression
ENTHALPY
PRESSURE
Critical Point
Super Heated Vapour
Refrigerant
ne
pour Li
ed Va
Saturat
tQ
tan
id L
ns
iqu
dL
tur
ate
ant
Const e
Volum
Constant
Temperature
Sa
Co
ine
ua
lity
Lin
es
Lines of Constant
Temperature
Co
En nsta
tro nt
py
Liquid
Refrigerant
ENTHALPY
15
PRESSURE
Figure 7.7
Pressure - Enthalpy diagram for a Zeotrope
Refrigerant R047C
Critical Point
Super Heated Vapour
Refrigerant
stant
Lines of Con
Temperature
Co
n
Entr stant
opy
Liquid
Refrigerant
ant
Const e
Volum
BU
B
BL
DEW
LINE
EL
INE
Figure 7.9
Parallel Flow Through an Evaporator
Air off
Evaporator
Air on
Evaporator
25
ENTHALPY
TEMPERATURE (C)
Air
Superheat
Sensible Heat
Rejected at
Refrigerant
Superheat
5
Coil Temperature (R22)
0
LENGTH OF HEAT EXCHANGER
Condenser
Figure 7.10
Counterflow Process Through an Evaporator
Condensation
(Heat Rejection)
Expansion
Air on
Evaporator
Glide
t
Lines of Constan
Temperature
Evaporation
(Refrigeration Effect)
Air off
Evaporator
Work Done by
Compression
25
ENTHALPY
Air
Flo
wt
hro
Ev
ap
ora
15
Temperature
Drop of Air
20
TEMPERATURE (C)
PRESSURE
Superheated Vapour
Refrigerant
Latent Heat
Rejected at Condenser
ug
tor
10
Figure 7.8
Typical Graphical Representation of Refrigerant
Cycle for a Zeotrope Referant R047C
Sub Cooling
Sensible Heat
Rejected at
Condenser
hro
ora
15
Liquid
Refrigerant
Flo
wt
Ev
ap
Temperature
Drop of Air
20
ug
tor
Refrigerant
Outlet
Temperature
10
Refrigerant
Superheat
Coil Te
5
Refrigerant
Glide
mpera
ture (R
407C)
Refrigerant
Inlet
Temperature
0
LENGTH OF HEAT EXCHANGER
16
Section 8
8.0
8.1
Overview
A VRF system or split system does not normally have
indoor isolation valves, sight glasses or refrigerant
level indicators. Therefore it is essential that the
system be installed clean, dry and totally leak free,
as well as being charged with refrigerant accurately
to the manufacturers stated quantity.
8.2
Skill Requirements
All interconnecting pipework between the system
components should be installed, pressure tested
with oxygen free nitrogen, and commissioned by
a specialist refrigeration contractor, who shall provide
for each operative certificates of competence
regarding the brazing of copper pipework and
the safe handling of refrigerants.
8.3
Copper Pipework
All copper pipework and associated copper materials
must conform to the requirements of BS2871.
Part 2 being of suitable quality for refrigerants.
Quality
Size
Coils
Straight Lengths
Soft Tempered
Half Hard tempered
1/8 to 7/8
3/8 to 2 1/8
Pipework Support
Copper pipework shall either run in cable trays
or run individually. Whatever method is used the
pipework will be fixed or supported at the
maximum centres stated in the following table.
21/0.813
20/0.914
20/0.914
19/1.016
18/1.2
67.79
56.58
44.67
41.23
49.98
66.14
55.2
43.58
40.23
48.76
56.22
46.92
37.04
34.19
41.45
7/8
19/1.016
18/1.2
35.08
49.98
34.22
48.76
29.09
41.45
1.1/8
18/1.2
16/1.6
14/2.0
12/3.0
32.67
44.14
44.14
74.23
31.87
43.07
43.07
72.42
27.09
36.61
36.61
61.56
/2
/8
/4
/8
0.8
1.0
1.2
1.2
1.5
1.5
Vertical
1.0
1.2
1.5
1.5
1.5
1.8
Table 8.1
Maximum Allowable Pressures
3/8
1/2
5/8
3/4
/8
Gauge S.W.G/
Thickness mm
/4
Horizontal
Maximum Centre
Between Supports (M)
Outside
Diameter
(inch) OD
/4
/8
/2
/8
/4
/8
1 1/8
1 3/8
Horizontal
0.8
1.0
1.2
1.2
1.5
1.5
1.5
1.8
Vertical
1.0
1.2
1.5
1.5
1.8
1.8
1.8
2.4
17
Pressure Testing
The indoor units are charged with nitrogen during
manufacture and capped. Prior to installation
the caps are removed, and an aural inspection
should be done by listening as the caps are
removed. If the indoor units have lost nitrogen
gas, and there is no aural indication when the
caps are removed, this indicates a possible leak,
18
Operation
Pressure
Time
Flush System
3.0 Bar
2-3 mins
1st Pressurisation
Test
15.0 Bar
10 mins
2nd Pressurisation
Test
28.0 Bar
24 hours
Results
To indicate major leaks
If 1.0% deviation, check for
leaks at all joints
No deviation in pressure. If
deviation check for joint
porosity and small flare joint
leaks
8.7
Vacuum Drying
After satisfactory completion of the pressure
testing, the system (excluding the outdoor unit)
will be put under vacuum. This will remove moisture
from the system (by vaporisation) and furthermore
should the system fail to hold a vacuum it will
demonstrate that there is a small leak in the system.
8.8
8.9
8.10
Insulation
All pipework shall be insulated with preformed
armaflex or similar, Class "O" fire rated and
vapour sealed.
The insulation shall be installed as each section
of the pipework is completed and each section
of insulation shall be glued together.
At each joint in the pipework, the insulation shall
be neatly drawn back and secured to allow
inspection of the joint during pressure/vacuum
tests and system charging. Upon completion the
insulation shall be released, jointed and vapour
sealed.
When the installation is complete, identification
bands/tags complete with outdoor unit, internal
systems and indoor unit reference, shall be fitted
at a maximum of 4 metre centres.
The insulation thickness shall be as follows:
Refrigeration Pipe Size
inch O/D
1
13
Condense Drainage
The condensate pipework material shall either
be heavy duty PVC to BS3505 Class E or copper
to Table Y BS2871 Part 1.
PVC pipework joints shall be made with couplers
and solvent cement.
Copper pipework shall have soldered joints.
The condensate drainage pipework shall be
installed with a minimum gradient of 1;100.
To prevent the pipework 'sagging', the
support centres will be as follows:
Pipework Diameter
Maximum Distance
Between Supports mm
Up to 20mm O/D
1.5
Up to 32mm O/D
1.5
Insulation Thickness
mm
/4"
8.11
19
9.1
9.2
9.3
9.4
9.5
9.6
9.7
9.8
20
9.9
Equipment
(dedicated to R407C)
Notes
Vacuum Pump
Charging Cylinder
Refrigerant Cylinder
Leak Detector
Electronic Scales
9.10
21
Service manifold
Refrigerant
cylinder
To air conditioning unit
service valve connections
Internal syphon
tube
Electronic
scales
Gauges
Vapour mix
Maximum
filllevel
High Pressure
Gauge
Compound or
Low Pressure Gauge
Liquid
refrigerant
Minimum level of
refrigerant
10% by weight
22
Section 10
10.0
Safety Precautions
10.1
10.2
10.3
10.4
10.5
10.6
10.12
10.13
10.7
10.8
10.9
10.10
10.11
23
Practical
Quantity
Limits kg/m2
Ignition
0
C
GWP
ODP
A1
R22
0.14
635
1700
0.055
A1
R407C
0.35
704
1610
Group
Electrical Installation
11.1
11.2
24
2)
3)
4)
415V/3ph/50Hz
Outdoor
Unit
220V/1ph/50Hz
Indoor
Units
3 Core Remote
Control connection
Remote
Controller
415V/3ph/50Hz
Outdoor
Unit
220V/1ph/50Hz
5A
Spur
4 Way Distribution
Controller
1 Way Distribution
Controller
1 Way Distribution
Controller
1 Way Distribution
Controller
3 Core Wiring to
Relay Kit
Provided by others
Relay Kit
Provided
Mains
Power 2
Core to
Controller
2m long
provided
3 Core Wiring
2m Long
Provided
3 Core
Wiring
2m Long
Provided
220V/1ph/50Hz
5A
Spur
Indoor
Units
3 Core Remote
Control connection
Remote
Controller
25
auxiliaries such as pumps and fans and can also take into
account part load inefficiencies.
CRITICAL PRESSURE The saturation pressure equivalent
to the Critical Temperature.
CRITICAL TEMPERATURE The temperature above which
gas cannot be liquefied, irrespective of pressure.
Conventional refrigeration cycles can only operate
efficiently using fluids well below critical temperature.
DEW POINT The temperature at which a vapour will
condense or, where associated with glide, the higher or
highest boiling point of the mixture. The vapour
temperature without superheat.
EVAPORATOR A heat exchanger on the 'cold side' of a
refrigeration system in which refrigerant evaporates whilst
a substance is being cooled.
EVAPORATING TEMPERATURE The temperature at which
refrigerant boils from a liquid to a vapour.
EXPANSION DEVICE A valve, orifice, or capillary tube
connecting the condenser and evaporator, designed to
create a pressure drop between these two heat exchangers.
26
27
28
3D Air Conditioning
(Scotland) Limited
McGregor House,South Bank Business
Park, Kirkintilloch, Glasgow G66 1XF
Tel: 0141 777 5007
Fax: 0141 777 5009
Email: 3dairscot@edet.wiz.net.uk