Dometic DuraSea DCA120D, Installation, Start-Up & Service Manual

Page 1: ...ometic Corporation Every precaution has been taken in the preparation of this manual to ensure its accuracy However Dometic Corporation assumes no responsibility for errors and omission Neither is any liability assumed for damages resulting from the use of this product and information contained herein RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE DuraSea Condenser Unit Installation Start Up Servi...

Page 2: ...e Suction Lines 10 Routing of Liquid Line 10 SERVICE VALVE OPERATION 10 REPLACEMENT RETROFIT 10 Existing evaporator coil 11 Acid Test 11 Installation 11 PRESSURE TEST AND LEAK CHECKING 11 EVACUATION 13 ELECTRICAL CONNECTIONS 13 Field Power Supply 13 Field Control Wiring 13 Thermostat 14 24VAC Controls 14 SYSTEM START UP 15 REFRIGERANT CHARGING GUIDELINES 15 PRELIMINARY REFRIGERANT CHARGE 15 SYSTEM...

Page 3: ...de air temperatures below 100 F 38 C At higher air temperatures the unit will operate but at a reduced capacity A high pressure shutdown may occur at outside ambient air temperatures near 130 F 54 C SAFETY INSTRUCTIONS RECOGNIZE SAFETY SYMBOLS WORDS AND LABELS The following symbols and labels are used throughout this manual to indicate immediate or potential safety hazards it is the owner s and in...

Page 4: ...on pink in color R 410A refrigerant cylinders have a dip tube which allows liquid to flow out of the cylinder in an upright position NOTE Recovery cylinder service pressure rating must be 400 psig 2758 kPa DOT RBA400 or DOT BW400 R 410A systems should be charged with liquid refrigerant Use a commercial type metering device in the manifold hose R 410A requires a different set of gauges than those u...

Page 5: ...s which may result in injury or death WARNING Electrical shock hazard Disconnect voltage at main panel or power source before opening any cover Failure to comply may result in injury or death To minimize the hazard of electrical shock and personal injury this component must be effectively grounded Refer to the installation guidelines for further information 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 D C ...

Page 6: ...ation of any codes or regulations CHECK UNIT ELECTRICAL CHARACTERISTICS Confirm before installation of unit that voltage amperage and circuit protection requirements listed on unit data plate agree with power supply provided PLACEMENT OF THE SYSTEM Selecting a good location for your air conditioner is the most important part of your preparations Be sure to consider the size of the area you are coo...

Page 7: ...her units and any other factors that may interfere with air circulation Where possible the top of the unit should be unobstructed however if vertical conditions require placement beneath an obstruction there should be a minimum of 30 inches 762 mm between the top of the unit and the obstruction s The specified dimensions meet requirements for air circulation only Consult all appropriate regulatory...

Page 8: ...rface or other sturdy platform Isolated from the structure to avoid transmission of vibrations DO Leave slack between structure and unit to absorb vibration When passing refrigerant tubes through the bulkhead seal the opening with RTV or a pliable silicon based caulk Ensure that the suction and liquid line tube diameters are appropriate for unit capacity Avoid unnecessary turns and bends by runnin...

Page 9: ...evaporator to the condensing unit You must use tubing with the proper diameter and wall thickness specified for R 410A pressures Refrigerant tubing is normally soft drawn and nitrogen purged All refrigerant lines should be capped to protect against moisture and dust infiltration Tubing should always be cut square keeping ends round and free from burrs Clean the tubing to prevent contamination Extr...

Page 10: ...ctrical Data Power Volts Hz Phase 208Ͳ230 60 3 460 60 3 Y 208Ͳ230 60 3 460 60 3 Y 208Ͳ230 60 3 460 60 3 Y 208Ͳ230 60 3 460 60 3 Y 208Ͳ230 60 3 460 60 3 Y 208Ͳ230 60 3 460 60 3 Y Min Circuit Ampacity 2 25 12 30 15 30 20 40 20 50 25 55 30 Max Breaker Protection 3 35 15 40 20 40 25 55 30 70 30 75 40 Min Max Volts 197 253 414 506 197 253 414 506 197 253 414 506 197 253 414 506 197 253 414 506 197 253 ...

Page 11: ...uce the minimum refrigerant velocity to ensure oil return at minimum load conditions Mounting the condensing unit above the evaporator coil will require oil traps at equal intervals along the suction line Install one oil trap for a height difference of 15 to 25 feet 4 5 to 7 6 m between indoor and outdoor units Install two oil traps for a difference of 26 to 50 feet 7 9 to 15 2 m three for 51 to 1...

Page 12: ... and cores and save for re installation Connect a source for nitrogen to one of these service fittings during tube brazing to prevent the formation of copper oxides inside the tubes at brazed joints When brazing the field tubing to base valves TXV valve or filter drier wrap the valves in wet rags to prevent overheating Use a brazing alloy of 5 minimum silver content Do not use flux Purge the refri...

Page 13: ...stall the new outdoor unit according to these installation instructions 5 Install a new field supplied liquid line filter drier at the indoor coil just upstream of the TXV or fix orifice metering device 6 If a suction line filter drier is also to be installed install suction line drier downstream of suction line service valve at condensing unit 7 Evacuate and charge the system according to the ins...

Page 14: ...pipe insulation encases a leaking fitting the escaping nitrogen can be forced down the insulation to a remote location giving a false indication of the leak location Apply a soap solution on all connections and joints Bubbles indicate leaks so mark these locations Clean off the soap solution when leak checking is complete If the leaks cannot be located with the previous methods an electronic leak ...

Page 15: ...ire based on MCA Minimum Circuit Amps on the unit data plate Connect wiring as per diagram located on unit Provide a ground fault and short circuit over current protection device fuse or breaker per NEC Article 440 or local codes Refer to unit informative data plate for MCB Maximum Circuit Breaker device size Use HACR type circuit breakers or time delay fuses to assure sufficient time delay to per...

Page 16: ...age insulated wire 35 C minimum For 50 to 75 ft 15 to 23 m use no 16 AWG insulated wire 35 C minimum For over 75 ft 23 m use no 14 AWG insulated wire 35 C minimum All wire sizes larger than no 18 AWG cannot be directly connected to the thermostat and will require a junction box and splice at the thermostat 24VAC CONTROLS Most commercial evaporator units include a transformer to provide 24VAC to pr...

Page 17: ...CHARGE DuraSea condensing units are pre charged with refrigerant as per unit data plate Pre charge amount is sufficient for condensing unit plus 15 foot of lineset Additional charge must be added for the evaporator and linesets longer than 15 feet 4 5 m The amount of refrigerant to be added can be estimated from Table 2 See example below 1 Purge gauge lines Connect service gauge to base valve serv...

Page 18: ...ompressor is operating in reverse it is noisier and its current draw is substantially reduced compared to rated values A phase monitor is recommended to indicate reverse power phasing The condenser fan should be blowing air toward fan grille To correct phase order 1 Turn off power to the unit tag disconnect 2 Reverse any two of the unit power leads 3 Reapply power verify correct compressor pressur...

Page 19: ...emperature sensing device on the liquid small line close to the liquid line service valve and insulate it so that outdoor ambient temperature does not affect the reading 5 Use a thermometer to measure the outdoor ambient temperature The outdoor temperature will determine the next step Outdoor Temp 65 F 18 C or Higher 1 Check subcooling and superheat Subcooling Saturated Liquid Temp Liquid Line Tem...

Page 20: ... in the 325 to 375 psig 2240 to 2585 kPa range see Figure 7 2 Charge the unit following the steps listed for Outdoor Temp 65 F 18 C or Higher on page 17 NOTE Accurate pressure gauge and temperature sensing devices are required System overcharge with refrigerant can lead to catastrophic failure Symptoms are high head high running current low superheat and high subcooling SYSTEM OPERATION The outdoo...

Page 21: ...Coil cleaning should be part of the unit s regularly scheduled maintenance procedures to ensure long life of the coil Failure to clean the coils may result in reduced durability in the environment Avoid the use of Coil brighteners High pressure washers Poor quality water for cleaning Use of non recommended coil cleaners is strongly discouraged since coil and unit durability could be affected ROUTI...

Page 22: ...initial refrigerant charge into the low side of the system and when checking and adjusting the system refrigerant charge When service activities are completed ensure the service caps are in place and secure check for leaks If the Schrader check valve must be removed and re installed tighten to 3 in lbs 34 N cm COMPRESSOR PROTECTION COMPRESSOR OVER TEMPERATURE PROTECTION IP A thermostat installed o...

Page 23: ...ctly 8 Compressor overtemperature switch open Check for open condition Allow time for reset Replace compressor if necessary 9 Loose electrical connections Tighten all connections 10 Compressor stuck See compressor service literature Contactor Closed 1 Compressor leads loose Check connections 2 Motor windings open See compressor service literature 3 Single phasing Check for blown fuse Check for loo...

Page 24: ...ower head defective Replace power head 5 Indoor coil partially iced Check low pressure setting 6 Indoor airflow restricted Remove obstruction Suction Pressure High 1 Heat load excessive Check for open doors or windows in vicinity of fan coil Unit operates too long or continuously 1 Low refrigerant charge Add refrigerant 2 Control contacts fused Replace control 3 Air in system Purge and evacuate sy...

Page 25: ...NDOOR UNIT HAS WATER BEEN PLACED IN DRAIN PAN TO CONFIRM PROPER DRAINAGE Y N ___________ ARE PROPER AIR FILTERS IN PLACE Y N ___________ HAS CORRECT FAN ROTATION BEEN CONFIRMED Y N ___________ PIPING ARE LIQUID LINE SOLENOID VALVES LOCATED AT THE INDOOR COILS AS REQUIRED Y N ___________ HAVE LEAK CHECKS BEEN MADE AT COMPRESSOR OUTDOOR AND INDOOR COILS TXVs Thermostatic Expansion Valves SOLENOID VA...

Page 26: ...AT TEMP ______________________ ENTERING OUTDOOR UNIT AIR TEMP ______________________ LEAVING OUTDOOR UNIT AIR TEMP _______________________ INDOOR UNIT ENTERING AIR DB dry bulb TEMP __________________ INDOOR UNIT ENTERING AIR WB wet bulb TEMP _________________ INDOOR UNIT LEAVING AIR DB TEMP _____________________ INDOOR UNIT LEAVING AIR WB TEMP _____________________ COMPRESSOR 1 AMPS L1 L2 L3 _____...

Page 27: ...NOTES ...

Page 28: ...s dometic com 24 7 TECH SUPPORT FOR UNITED STATES AND CANADA 8 00 AM to 5 00 PM Eastern Time 1 800 542 2477 After hours and weekends 1 888 440 4494 INTERNATIONAL SALES AND SERVICE Europe and the Middle East 44 0 870 330 6101 For all other areas visit our website to find your nearest distributor dometic com L 3153 06 01 2017 ...