FUSION Commercial Condensing Units€¦ · 27 3220 4286 5556 7032 8712 10598 12688 14984 2693 3149...

FUSION Commercial Condensing Units

Medium & Low Temperature Applications

ISSUE: 01.03.2016

COMMERCIAL CONDENSING UNITS TECHNICAL MANUAL

Issue: 01.03.2016

Contents

Nomenclature & Product Configuration 3

Specifications Unit Data 4

Performance Data: R404A 5-6

Performance Data: R407A 7

Performance Data: R407F 8

Performance Data: R134a 9

Performance Data: R407C 10

Health & Safety General Information 11

Installation Unit Location 12

Installation Clearances 12

Field Piping 13

Pressure Testing 14

Evacuation & Charging 14

Electrical 15

Commissioning Pre startup checks 16

Running the unit 16

Safety pressure switch settings 17

Fan speed controller settings 17

Drawings Unit dimensional drawings 18-20

Electrical wiring diagrams 21-24

Service & Maintenance 25-26

F-Gas Information 27

Technical Information Fan Speed Controller 28

Dual Pressure Switch 29

DC Fan & Controller 30-32

Certification Declaration of Conformity 33-36

Issue: 01.03.2016

Nomenclature

1: Single Phase 3: Three Phase Application: M: Medium Temperature L: Low Temperature

Nominal Capacity in Horse Power 0150: 1.5 HP

JEH2: J & E Hall International (Fusion)

Standard product configuration

Series 1

• Danfoss hermetic compressors (SC)

• Liquid receiver with fusible plug

• Fitted liquid line drier & sight glass

• Dual LP/HP Pressure control

• External service valves

• IP54 rated control panel

• Mains Isolator

• Fuse protection to fan & control circuit

• Alarm output available from HP switch

• Acoustic insulation to compressor compartment

• Operate with refrigerant R404A only

Series 2/3/4 (As above but additionally / alternatively)

• Maneurop hermetic compressors (MTZ/NTZ)

• Oil separator and discharge check valve on low temperature models

• Gomax flexible pressure hoses

• Combined mains isolator with short circuit / overload protection

• Compressor contactor

• Crankcase heater on compressor

• Pressure actuated fan speed controller

• Compressor jacket

• Multi – refrigerant (model dependent)

JEH2 0150 M 1

Issue: 01.03.2016

Specifications

Swept Volume

Oil Charge

NC a MCC b LRC c FLC Liquid Suction

(m³/h) (Litres) (Litres) (A) (A) (A) (A) (Litres) (Litres) (m³/h) (inch) (inch) (mm) (mm) (kgs) dB(A)JEH2-0050-M-1 SC10MLX 1.79 0.60 - 3.6 4.7 18.4 1 0.3 1.9 1.2 1910 1/4 3/8 869 x 430 x 489 545 x 400 46 29JEH2-0088-M-1 SC18MLX 3.08 0.60 - 4.3 6.6 23.4 1 0.3 1.9 1.2 1910 1/4 3/8 869 x 430 x 489 545 x 400 46 29JEH2-0150-M-1 MTZ18-5 5.26 0.95 - 6.6 10.0 40.0 1 0.6 1.5 4.6 3040 3/8 1/2 1104 x 478 x 650 703 x 448 82 37JEH2-0150-M-3 MTZ18-4 5.26 0.95 - 2.7 5.0 20.0 1 0.6 1.5 4.6 3040 3/8 1/2 1104 x 478 x 650 703 x 448 82 37JEH2-0225-M-1 MTZ28-5 8.36 0.95 - 11.0 20.0 51.0 1 0.6 3.1 4.6 2620 3/8 1/2 1104 x 478 x 650 703 x 448 89 36JEH2-0225-M-3 MTZ28-4 8.36 0.95 - 4.1 7.5 23.0 1 0.6 3.1 4.6 2620 3/8 1/2 1104 x 478 x 650 703 x 448 89 36JEH2-0300-M-1 MTZ36-5 10.52 0.95 - 15.3 22.0 60.0 1 0.6 3.1 4.6 2620 3/8 5/8 1104 x 478 x 650 703 x 448 89 37JEH2-0300-M-3 MTZ-36-4 10.52 0.95 - 5.0 9.0 30.0 1 0.6 3.1 4.6 2620 3/8 5/8 1104 x 478 x 650 703 x 448 89 37JEH2-0400-M-3 MTZ50-4 14.90 1.80 - 5.9 11.5 48.5 1 1.0 4.7 7.6 4250 1/2 7/8 1347 x 556 x 884 946 x 500 120 37JEH2-0500-M-3 MTZ64-4 18.94 1.80 - 7.8 14.0 64.0 1 1.0 4.7 7.6 4250 1/2 7/8 1347 x 556 x 884 946 x 500 120 40JEH2-0600-M-3 MTZ72-4 21.04 1.80 - 8.7 15.5 80.0 1 1.0 7.6 7.6 4150 1/2 7/8 1347 x 556 x 884 946 x 500 126 40JEH2-0675-M-3 MTZ80-4 23.63 1.80 - 10.3 18.0 80.0 1 1.0 7.6 7.6 4150 1/2 1 1/8 1352 x 556 x 884 946 x 500 126 42JEH2-0825-M-3 MTZ100-4 29.80 3.90 - 12.4 22.0 90.0 2 1.2 6.9 14.0 6770 1/2 1 1/8 1261 x 594 x 1435 812 x 560 205 42JEH2-1000-M-3 MTZ125-4 37.49 3.90 - 14.3 27.0 105.0 2 1.2 6.9 14.0 6770 1/2 1 1/8 1261 x 594 x 1435 812 x 560 205 42

JEH2-0075-L-1 1 SC18CLX.2 3.08 0.60 - A 3.7 5.9 23.5 1 0.3 1.9 1.2 1910 1/4 3/8 869 x 430 x 489 545 x 400 46 30JEH2-0175-L-1 NTZ48-5 8.40 0.95 0.50 4.5 11.0 37.0 1 0.6 1.5 4.6 3040 3/8 5/8 1104 x 478 x 650 703 x 448 86 35JEH2-0175-L-3 NTZ48-4 8.40 0.95 0.50 2.1 4.8 16.0 1 0.6 1.5 4.6 3040 3/8 5/8 1104 x 478 x 650 703 x 448 86 35JEH2-0225-L-1 NTZ68-5 11.80 0.95 0.50 9.2 17.0 53.0 1 0.6 3.1 4.6 2620 3/8 5/8 1104 x 478 x 650 703 x 448 92 38JEH2-0225-L-3 NTZ68-4 11.80 0.95 0.50 3.5 8.4 25.0 1 0.6 3.1 4.6 2620 3/8 5/8 1104 x 478 x 650 703 x 448 92 38JEH2-0350-L-3 NTZ96-4 16.70 1.80 0.60 3.3 10.1 32.0 1 1.0 4.7 7.6 4250 1/2 7/8 1347 x 556 x 884 946 x 500 125 38JEH2-0400-L-3 NTZ136-4 23.60 1.80 0.60 6.1 14.3 51.0 1 1.0 4.7 7.6 4250 1/2 1 1/8 1352 x 556 x 884 946 x 500 125 38JEH2-0725-L-3 NTZ215-4 37.50 3.90 0.60 7.5 22.3 74.0 2 1.2 6.9 14.0 6770 1/2 1 1/8 1261 x 594 x 1435 812 x 560 203 40JEH2-0825-L-3 NTZ271-4 47.30 3.90 0.60 9.7 27.0 96.0 2 1.2 6.9 14.0 6770 1/2 1 1/8 1261 x 594 x 1435 812 x 560 203 41

Unit ModelS

eri

es

CompressorOil

Sep. Charge

Oil Type

Unit Dry

Weight

SPL @

10m d

Compressor Fan Motors

Type No.

Coil Volume

Liquid Receiver

Airflow

Connections

Unit Dimensions (W x D x H)

Mounting Dimensions

(W x D)

Electrical Data

Me

diu

m T

em

pe

ratu

re

1 A

2

B

3

4

Low

Tem

pera

ture

2

C3

4

c LRC = Locked Rotor Currentd Sound Pressure Level @ 10m free field at (-10/+32°C) MT & (-25/+32°C) LT conditions. Alternative conditions may produce different results

Oil Type A = Polyolester Emkarate RL32HOil Type B = Maneurop Ester 160PZOil Type C = Maneurop Ester 160Z or 160SZa NC = Nominal Current @ condition -10°Cte / +32°Cta MT and -35°Cte / +32°Cta LT with R404A refrigerantb MCC = Maximum Continuous Current

Issue: 01.03.2016

Specifications

Performance Data: Medium Temperature (R404A)

Unit M odel HP TE TA

-30 -25 -20 -15 -10 -5 0 5 -30 -25 -20 -15 -10 -5 0 5

27 - - 694 851 1037 1254 1500 1777 - - 492 530 570 611 654 698

32 - - 532 686 871 1085 1330 1604 - - 509 548 590 633 679 726

38 - - 391 543 725 937 1179 1451 - - 526 569 614 661 710 761

27 - - 1057 1320 1619 1952 2321 2724 - - 781 847 918 993 1073 1157

32 - - 990 1214 1478 1782 2126 2510 - - 790 859 933 1011 1094 1180

38 - - 868 1065 1302 1579 1896 2252 - - 798 871 949 1031 1118 1209

27 649 961 1338 1780 2287 2859 3496 4198 853 945 1040 1137 1237 1339 1444 1550

32 558 837 1180 1589 2062 2601 3204 3878 856 959 1063 1169 1276 1385 1495 1607

38 431 679 987 1355 1783 2271 2819 3427 865 973 1084 1197 1313 1431 1552 1675

27 1172 1722 2341 3031 3790 4620 5519 6489 1189 1394 1597 1799 1999 2198 2395 2591

32 977 1491 2074 2728 3451 4245 5108 6042 1197 1409 1621 1831 2041 2249 2457 2663

38 819 1293 1826 2420 3073 3787 4560 5394 1199 1418 1637 1859 2081 2306 2531 2758

27 1681 2306 3036 3871 4811 5856 7006 8261 1689 1936 2193 2460 2737 3024 3321 3627

32 1524 2120 2815 3611 4506 5502 6597 7793 1716 1957 2213 2484 2770 3071 3387 3718

38 1281 1869 2546 3314 4171 5119 6156 7284 1787 2015 2262 2530 2817 3125 3452 3800

27 2313 3247 4366 5670 7159 8833 10692 12736 2307 2616 2927 3240 3555 3872 4191 4512

32 2061 2900 3924 5133 6527 8106 9870 11819 2373 2686 3004 3327 3655 3988 4326 4669

38 1719 2482 3409 4502 5759 7182 8769 10522 2408 2731 3064 3407 3760 4123 4496 4879

27 3220 4286 5556 7032 8712 10598 12688 14984 2693 3149 3610 4076 4547 5023 5504 5989

32 2885 3862 5043 6430 8021 9818 11819 14026 2818 3265 3722 4189 4666 5153 5650 6157

38 2393 3347 4466 5750 7199 8813 10592 12536 2847 3309 3786 4278 4785 5307 5844 6396

27 3326 4604 6076 7744 9606 11664 13916 16364 3053 3517 4001 4505 5029 5573 6137 6721

32 2979 4181 5568 7140 8897 10839 12966 15278 3147 3608 4093 4604 5139 5700 6285 6896

38 2471 3635 4943 6397 7995 9739 11627 13661 3222 3680 4173 4701 5264 5862 6495 7162

27 3656 5119 6756 8569 10556 12719 15056 17569 3242 3840 4447 5065 5692 6330 6977 7635

32 3172 4593 6164 7885 9756 11777 13948 16269 3279 3911 4548 5190 5837 6489 7146 7808

38 2694 4060 5546 7152 8878 10724 12690 14776 3453 4047 4666 5310 5979 6673 7392 8136

27 3832 5545 7467 9600 11942 14495 17257 20230 4227 4916 5601 6282 6959 7632 8301 8965

32 3322 4982 6816 8826 11010 13370 15904 18614 4340 5013 5696 6389 7092 7805 8528 9260

38 2809 4349 6043 7893 9897 12057 14371 16841 4504 5148 5817 6511 7230 7974 8743 9537

27 5786 7709 9811 12094 14556 17199 20021 23024 5365 6158 7000 7893 8835 9828 10870 11963

32 4952 6931 9020 11219 13528 15947 18476 21115 5504 6286 7127 8029 8990 10012 11093 12235

38 4351 6155 8073 10107 12255 14519 16897 - 5627 6424 7281 8198 9175 10212 11309 -

TE: Evaporating Temperature (ºC)TA: Ambient Temperature (ºC)Rating Condition: Suction Gas Superheat 10K, Sub cooling 0K

Ser

ies

4

JEH2-1000-M -3 R404A

Cooling Capacity (Watts)

Ser

ies

3

JEH2-0300-M -1&3 R404A

JEH2-0400-M -3 R404A

1.5

0.8

0.5JEH2-0050-M -1 R404A

JEH2-0225-M -1&3 R404A

R404A

Ser

ies

1S

erie

s 2

Data presented in accordance with BS EN 13215:2000

8.25

10

Absorbed Power (Watts)

JEH2-0500-M -3 R404A

JEH2-0825-M -3 R404A

JEH2-0150-M -1&3 R404A

JEH2-0600-M -3 R404A

JEH2-0675-M -3 R404A

6

6.75

5

JEH2-0088-M -1 R404A

2.25

3

4

Issue: 01.03.2016

Specifications

Performance Data: Low Temperature (R404A)


-45 -40 -35 -30 -25 -20 -45 -40 -35 -30 -25 -20

27 245 365 500 650 815 995 430 494 564 638 718 802

32 175 289 418 562 721 895 440 506 577 653 734 820

38 104 209 329 464 614 779 452 520 592 670 752 840

27 455 738 1051 1394 1767 2170 513 720 937 1164 1401 1648

32 363 643 947 1277 1631 2011 551 756 971 1196 1431 1676

38 - 492 800 1132 1490 1872 - 793 995 1212 1444 1691

27 829 1253 1718 2222 2767 3351 1147 1348 1579 1840 2131 2452

32 762 1139 1567 2044 2572 3149 1248 1443 1667 1922 2206 2521

38 - 1017 1410 1868 2391 2979 - 1449 1689 1955 2245 2561

27 996 1506 2141 2901 3786 4796 1298 1621 1953 2296 2648 3011

32 789 1252 1845 2567 3420 4402 1363 1687 2021 2365 2719 3083

38 - 1080 1603 2272 3085 4044 - 1779 2101 2438 2790 3157

27 1629 2354 3200 4165 5251 6456 2097 2554 3047 3574 4137 4734

32 1347 2020 2824 3757 4821 6014 2109 2567 3065 3603 4181 4799

38 - 1749 2495 3396 4452 5663 - 2578 3079 3625 4216 4852

27 2363 3485 4717 6059 7511 9073 2768 3454 4220 5066 5992 6998

32 2026 3070 4245 5549 6984 8548 2803 3497 4272 5126 6061 7075

38 - 2563 3716 5014 6457 8045 - 3551 4318 5169 6106 7127

27 3293 4813 6469 8259 10185 12245 3967 4796 5726 6755 7885 9114

32 2890 4276 5818 7514 9366 11372 4037 4868 5805 6846 7993 9244

38 - 3713 5111 6694 8462 10415 - 4931 5877 6932 8098 9373

0.75JEH2-0075-L-1 R404A

Cooling Capacity (Watts) Absorbed Power (Watts)R404A

Ser

ies

1

8.25

JEH2-0350-L-3 R404A

Ser

ies

2S

erie

s 3

Ser

ies

4

3.5

JEH2-0400-L-3 R404A

4

JEH2-0175-L-1&3 R404A

1.75

JEH2-0225-L-1&3 R404A

2.25

Data presented in accordance w ith BS EN 13215:2000

Rating Condition: Suction Gas Superheat 10K, Sub cooling 0K

JEH2-0725-L-3 R404A

7.25

JEH2-0825-L-3 R404A

TE: Evaporating Temperature (ºC)

TA: Ambient Temperature (ºC)

Important Note: For Low Temperature applications:

1. The use of an expansion valve with maximum operating pressure (MOP) or a crankcase pressure regulator which limits the suction pressure to a maximum of 4 bar relative (-5°C) is compulsory.

2. On some applications the use of a suction accumulator may be required.

Issue: 01.03.2016

Specifications

Performance Data: Medium Temperature (R407A)


-15 -10 -5 0 5 -15 -10 -5 0 5

JEH2-0150-M -1/3 R407A

1.5 32 1490 1960 2510 3130 3830 1040 1150 1260 1370 1480

JEH2-0225-M -1/3 R407A

2.25 32 2550 3280 4090 4990 5980 1640 1840 2040 2240 2450

JEH2-0300-M -1/3 R407A

3 32 3380 4280 5300 6440 7710 2220 2490 2780 3090 3420

JEH2-0400-M -3 R407A

4 32 4810 6200 7810 9640 11700 2970 3290 3620 3950 4300

JEH2-0500-M -3 R407A

5 32 6020 7620 9460 11540 13890 3740 4200 4670 5160 5660

JEH2-0600-M -3 R407A

6 32 6690 8450 10440 12660 15130 4110 4630 5170 5740 6340

JEH2-0675-M -3 R407A

6.75 32 7390 9270 11350 13620 - 4640 5250 5880 6530 -

JEH2-0825-M -3 R407A

8.25 32 - 10460 12880 15530 - - 6380 7080 7790 -

JEH2-1000-M -3 R407A

10 32 - 12850 15360 18040 - - 8090 9080 10130 -




Maximum cut-out setting of HP sw itch must not be greater than 25 bar


R407A Cooling Capacity (Watts) Absorbed Power (Watts)

Ser

ies

2S

erie

s 3

Ser

ies

4

Issue: 01.03.2016

Specifications

Performance Data: Medium Temperature (R407F)


-15 -10 -5 0 5 -15 -10 -5 0 5

JEH2-0150-M -1/3 R407F

1.5 32 1520 2120 2620 3270 3970 1120 1240 1370 1480 1610

JEH2-0225-M -1/3 R407F

2.25 32 2730 3540 4420 5380 6410 1710 1940 2160 2410 2670

JEH2-0300-M -1/3 R407F

3 32 3700 4710 5820 7000 8260 2200 2490 2780 3110 3460

JEH2-0400-M -3 R407F

4 32 5100 6590 8240 10060 12040 2840 3150 3470 3790 4150

JEH2-0500-M -3 R407F

5 32 6270 8040 10060 12210 14570 3620 4100 4610 5150 5730

JEH2-0600-M -3 R407F

6 32 6950 8840 10960 13290 15570 4030 4560 5130 5750 6460

JEH2-0675-M -3 R407F

6.75 32 8070 10100 12350 14690 17180 4770 5440 6150 6930 7780

JEH2-0825-M -3 R407F

8.25 32 - 11450 14090 16850 19710 - 6580 7400 8290 9260

JEH2-1000-M -3 R407F

10 32 - 14130 17170 20450 - - 8280 9480 10850 -




Maximum cut-out setting of HP sw itch must not be greater than 26 bar


Ser

ies

3S

erie

s 4

R407F Cooling Capacity (Watts) Absorbed Power (Watts)

Ser

ies

2

Issue: 01.03.2016

Specifications

Performance Data: Medium Temperature (R134a)


-15 -10 -5 0 5 10 15 -15 -10 -5 0 5 10 15

27 - - - - - - - - - - - - - -

32 - - - - - - - - - - - - - -

38 - - - - - - - - - - - - - -

27 - - - - - - - - - - - - - -

32 - - - - - - - - - - - - - -

38 - - - - - - - - - - - - - -

27 918 1347 1826 2355 2934 3563 4242 701 751 801 853 905 959 1013

32 842 1229 1671 2168 2720 3327 3989 721 775 831 889 949 1011 1075

38 761 1091 1481 1931 2441 3011 3641 738 800 864 932 1002 1076 1152

27 1547 2128 2823 3634 4559 5600 6755 949 1053 1163 1280 1403 1533 1670

32 1436 1958 2595 3347 4214 5196 6293 973 1082 1197 1320 1449 1586 1730

38 1310 1763 2330 3013 3810 4723 5750 1002 1113 1234 1365 1506 1657 1818

27 2426 3160 3998 4942 5990 7144 8402 1313 1456 1609 1772 1945 2128 2321

32 2279 2948 3721 4600 5583 6672 7865 1353 1510 1677 1854 2041 2238 2445

38 1941 2584 3332 4185 5143 6206 7374 1396 1570 1754 1948 2152 2366 2590

27 3198 4306 5624 7152 8890 10838 12996 1825 1991 2158 2324 2490 2655 2821

32 2917 3925 5143 6571 8209 10057 12115 1853 2044 2234 2424 2613 2802 2990

38 2593 3482 4582 5891 7411 9140 11080 1877 2097 2317 2535 2753 2969 3185

27 3930 5271 6833 8614 10616 12837 15279 2196 2426 2672 2932 3208 3498 3804

32 3593 4823 6273 7943 9833 11943 14273 2200 2473 2756 3049 3352 3665 3988

38 3195 4295 5614 7154 8913 10893 13092 2222 2531 2850 3179 3518 3867 4226

27 4594 6092 7814 9762 11934 14332 16954 2398 2658 2947 3267 3616 3996 4405

32 4309 5680 7272 9083 11115 13366 15838 2413 2717 3046 3400 3779 4183 4612

38 3811 5052 6507 8178 10063 12164 14479 2429 2765 3126 3512 3923 4359 4820

27 5027 6653 8519 10625 12971 15557 18383 2604 2878 3188 3532 3912 4326 4776

32 4667 6153 7879 9845 12051 14497 17183 2634 2945 3292 3673 4090 4541 5028

38 4355 5676 7242 9053 11109 13410 15956 2675 3030 3421 3846 4307 4802 5333

27 5800 7728 9922 12380 15104 18092 21346 3188 3549 3929 4330 4750 5191 5651

32 5322 7083 9110 11401 13958 16779 19866 3261 3662 4083 4524 4985 5466 5967

38 4796 6349 8172 10265 12628 15261 18164 3313 3775 4252 4744 5251 5773 6310

27 7256 9494 11993 14751 17770 21048 24587 3647 4152 4687 5252 5847 6472 7127

32 6615 8667 10980 13552 16385 19477 22830 3686 4237 4818 5429 6070 6741 7442

38 5875 7701 9792 12148 14769 17655 20806 3685 4304 4947 5616 6309 7028 7771

TE: Evaporating Temperature (ºC)TA: Ambient Temperature (ºC)Rating Condition: Suction Gas Superheat 10K, Sub cooling 0K

JEH2-0825-M -3 R134a

JEH2-0150-M -1&3 R134a

JEH2-0225-M -1&3 R134a

JEH2-0300-M -1&3 R134a

JEH2-0400-M -3 R134a

0.8

0.5JEH2-0050-M -1 R134a

Ser

ies

2S

erie

s 3

JEH2-1000-M -3 R134a

6

6.75

1.5

2.25

3

4

Data presented in accordance with BS EN 13215:2000

8.25

10

5

JEH2-0088-M -1 R134a

Cooling Capacity (Watts) Absorbed Power (Watts)

JEH2-0500-M -3 R134a

JEH2-0600-M -3 R134a

JEH2-0675-M -3 R134a

R134a

Ser

ies

1S

erie

s 4

Issue: 01.03.2016

Specifications

Performance Data: Medium Temperature (R407C)


-15 -10 -5 0 5 -15 -10 -5 0 5

27 - - - - - - - - - -

32 - - - - - - - - - -

38 - - - - - - - - - -

27 - - - - - - - - - -

32 - - - - - - - - - -

38 - - - - - - - - - -

27 1408 1969 2642 3415 4306 948 1041 1122 1196 1262

32 1285 1815 2448 3173 4006 960 1063 1155 1240 1317

38 1122 1614 2183 2870 3647 969 1087 1198 1295 1385

27 2390 3273 4310 5491 6830 1428 1616 1787 1945 2089

32 2222 3059 4037 5152 6424 1441 1648 1842 2023 2189

38 1997 2781 3680 4723 5779 1447 1679 1903 2113 2339

27 3387 4429 5630 6990 8528 1923 2178 2408 2616 2798

32 3237 4233 5376 6672 8115 1942 2218 2472 2703 2912

38 2987 3986 5033 6307 7691 1963 2263 2554 2801 3032

27 4383 5920 7741 9871 12347 2563 2847 3117 3369 3594

32 4062 5505 7233 9246 11559 2609 2915 3210 3493 3762

38 3625 4972 6517 8434 10582 2660 2991 3328 3645 3961

27 5401 7291 9524 12087 15086 3094 3524 3949 4371 4771

32 5021 6819 8937 11377 14178 3128 3576 4027 4478 4922

38 4534 6208 8099 10420 12961 3167 3642 4138 4624 5127

27 6100 8165 10567 13323 16446 3486 3983 4481 4976 5464

32 5701 7660 9940 12544 15511 3523 4041 4567 5099 5628

38 - 7032 9076 11518 14209 - 4109 4683 5259 5855

27 7120 9406 12040 15027 18402 4274 4814 5290 5805 6277

32 6766 8930 11422 14253 17438 4320 4906 5462 5997 6521

38 - 8254 10971 13184 16085 - 5014 5559 6245 6848

27 7714 10463 13676 17341 21501 5031 5680 6282 6858 7420

32 7286 9867 12862 16284 20144 5061 5764 6430 7073 7708

38 - 9090 11826 15057 18621 - 5851 6597 7306 8019

27 10528 13730 17374 21396 25812 6392 7297 8180 9073 9993

32 - 13038 16336 20027 24130 - 7393 8374 9368 10383

38 - 12040 15219 18736 22542 - 7495 8551 9620 10726



Rating Condition: Suction Gas Superheat 10K, Sub cooling 0KData presented in accordance w ith BS EN 13215:2000

8.25

10

JEH2-0500-M -3 R407C

5

0.5JEH2-0050-M -1 R407C

2.25

3

4

0.8

JEH2-0225-M -1&3 R407C

R407C

Ser

ies

1

Absorbed Power (Watts)

6

6.75

Ser

ies

2S

erie

s 3

JEH2-0300-M -1&3 R407C

JEH2-0400-M -3 R407C

Ser

ies

4

JEH2-1000-M -3 R407C

Cooling Capacity (Watts)

JEH2-0088-M -1 R407C

1.5

JEH2-0600-M -3 R407C

JEH2-0675-M -3 R407C

JEH2-0825-M -3 R407C

JEH2-0150-M -1&3 R407C

Issue: 01.03.2016

Health and Safety

General information Before Installation • Ensure the units received are the correct models for the intended application.

• Ensure the refrigerant; voltage and MWP are all suitable for the proposed application.

• Check there is no damage to the units. Any damage should be advised to the supplier immediately.

• Check that the proposed equipment locations are suitable and provide adequate support for the weight of the units.

During Installation and subsequent maintenance

• Installation and maintenance are to be performed only by qualified personnel who are familiar with local codes and regulations, and experienced with this type of equipment.

• If lifting equipment is required, ensure that it is suitable for purpose, certificated and that the operatives are qualified to use it.

• Safe working methods are identified and operatives have suitable Personal Protective Equipment (PPE).

• Ensure the working area has adequate ventilation during brazing procedures.

• The units contain moving machinery and electrical power hazards, which may cause severe injury or death. Disconnect and shut off power before installation or service of the equipment.

• Refrigerant release into the atmosphere is illegal. Proper evacuation, recovery, handling and leak testing procedures must be observed at all times.

• Units must be earthed and no maintenance work should be attempted prior to disconnecting the electrical supply.

• The electrical covers and fan guards must remain fitted at all times.

• Use of the units outside of the design conditions and the application for which the units were intended may be unsafe and be detrimental to the units, regardless of short or long term operation.

• The units are not designed to withstand loads or stresses from other equipment or personnel. Such extraneous loads or stress may cause failure/leak/injury.

• In some circumstances, a suction accumulator (not supplied) may be required. It offers protection against refrigerant flood back during operation and also against off-cycle migration by adding internal free volume to the low side of the system.

• Tests must be conducted to ensure the amount of off-cycle migration to the compressor does not exceed the compressor’s charge limit.

• Wherever possible the system should be installed to utilize a pump down configuration.

Important Note: Only qualified personnel, who are familiar with refrigeration systems and components including all controls, should perform the installation and start-up of the system. To avoid potential injury, use care when working around coil surfaces or sharp edges of metal cabinets. All piping and electrical wiring should be installed in accordance with all applicable codes, ordinances and local by-laws.

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Installation

Unit location • In order to achieve maximum cooling capacity, the installation location for the condensing unit should be carefully selected.

• Install the condensing unit in such a way so that hot air ejected by the condensing unit cannot be drawn in again (short circuit of hot discharge air). Allow sufficient space for maintenance around the unit.

• Ensure that there is no obstruction to air flow into or out of the unit. Remove obstacles which block air intake or discharge.

• The location must be well ventilated, so the unit can draw in and distribute plenty of air thus lowering the condensing temperature.

• To optimize the unit running conditions, the condenser coil must be cleaned at regular intervals.

• The unit must be level in all directions.

Installation clearances • The installation location should allow sufficient space for air flow and maintenance around the unit.

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Installation

Field piping

To ensure satisfactory operation and performance, the following points should be noted for field piping arrangements:

• Pipework routes must be as simple and as short as possible.

• Avoid low points on pipework where oil can accumulate.

• Suction gas velocity must be sufficient to ensure good oil return.

• Use only clean, dehydrated refrigeration grade copper tube with long radius bends.

• Avoid flare type connections and take great care when brazing. Use only silver alloy rods.

• Run braze without over filling to ensure there is no leakage into the tube.

• To prevent oxidation, blow oxygen free nitrogen through pipework when brazing.

• Install insulation on all suction lines and on all pipes penetrating walls or passing through hot areas.

• Adequately support all pipe work at a maximum of 2 metre intervals.

• Where the condensing unit is situated below the indoor unit (coldroom evaporator / display case), the height difference between the two units should be no more than 6 metres.

• In vertical pipework, the use of U-trap and double suction risers is often required. These suction risers must always be fitted with a U-trap at the bottom and a P-trap at the top and never be higher than 4m unless a second U-trap system is fitted.

• Additional oil may be required if piping length exceeds 20m or multiple oil traps are fitted. Check the oil level closely during commissioning and add oil as necessary. Add oil in small amounts. Do not overfill the compressor!

• When installing a single compressor condensing unit with multiple evaporators connected which operate independently, care should be taken to ensure that the evaporating pressure/temperature does not fall outside the compressor operating limit at minimum load. If there is a potential for this scenario, consider multiple evaporators fed by a single solenoid valve or separate condensing units.

• Suction pipework should slope gently back towards the unit to assist oil return to the compressor. A fall of approximately 2cm per metre of pipework is acceptable.

• Liquid lines should be sized to ensure a full supply of liquid refrigerant to the expansion device. Careful attention should be paid to sizing of liquid lines on large risers (maximum 6m).

• Maximum recommended pipe length is 25 metres.

Correct line sizing will minimize the pressure drop and maintain sufficient gas velocity for proper oil return.

Important Note: One of the main factors affecting equipment reliability and compressor service life is refrigeration circuit contamination. During installation, circuit contamination can be caused by: • Brazing & Welding Oxides

• Filings & Particles from de-burring pipework

• Brazing Flux

• Moisture & Air

Important Note: Pipe sizing should only be determined by qualified personnel. All local codes of practice must be observed in the installation of refrigerant piping.

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Installation

Pressure testing The condensing units are pressure tested in the factory prior to dispatch. All units come with a holding charge of oxygen free nitrogen.

Once the pipework installation is complete, it should be pressure tested prior to evacuation to test for leaks. A pressure leak test should be carried out using oxygen free nitrogen (OFN). NEVER USE OXYGEN FOR PRESSURE TESTING SYSTEMS. A calibrated nitrogen pressure regulator must always be used. Before starting any pressure testing, ensure the area surrounding the system is safe, inform relevant personnel and fit warning signs indicating high pressure testing. Also, use correct PPE as required. Always pressurize the system slowly, preferably in stages up to the maximum required pressure. Maximum test pressures applicable to the unit are as follows:

Series Test pressure

High side Low side 1 24 barg

(350 psig) 12 barg

(175 psig)

2, 3, 4 28 barg (405 psig)

19 barg (275 psig)

Listen for any possible leaks and check all joints with bubble spray. If any leaks are discovered, release pressure slowly from system until empty, repair leak and then restart pressure testing procedure. Never attempt to repair a leak on a pressurized system. A strength test should also be incorporated (to installed pipework only) according to local regulations. Once testing has been completed satisfactorily, release the pressure from the system gradually and safely to external atmosphere.

Evacuation & Charging Once pressure testing has been completed, the system can now be evacuated to remove air and any moisture from the piping. This can be done as follows:

• Ensure any nitrogen charge is safely released from the system.

• Connect a gauge manifold to the connections on the service valves on the condensing unit.

• Connect a vacuum pump and vacuum gauge to the system.

• Ensure all gauge manifold and service valves are open as required.

• Evacuate the system until vacuum is below 250 microns (0.25 torr). Note: A triple evacuation procedure is recommended for all new systems or where moisture is suspected. Once the system is isolated and the vacuum pump is switched off, any rise in pressure indicates that either there may be a leak in the system or moisture is still present. In this case, recheck the system for leaks, repair as necessary, and then restart the evacuation procedure. Once completed satisfactorily, the vacuum pump and vacuum gauge can be removed. At this point, the refrigerant charge can be added to the system as required. Refrigerants must be charged in the liquid phase. Charging of liquid into the suction side of the system should ONLY be done with a metering device. Use calibrated weighing scales to record the amount of refrigerant added to the system.

Important Note:

Moisture prevents proper functioning of the compressor and the refrigeration system. Ensure that a good quality vacuum pump is used to pull a minimum vacuum of 250 microns (0.25 torr).

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Installation

Electrical

Mains cable type and sizing must be selected for the particular application and the electrical installation should conform to the current local standards.

• Cables to the condensing unit should wherever possible be routed through the cable glands supplied on the rear of the units.

• Connect the mains supply to the units as per the wiring diagrams on pages 21 – 24. To gain access to the electrical box, turn the mains isolator switch on the end of the unit to the OFF position, remove the screws from the end cover panel and remove panel. The electrical box is located behind the panel. Remove the screws in the electrical box cover to access components.

Important Note: The mains electrical supply to the condensing unit must be via a suitable motor rated circuit breaker or fuse. A mains isolator is fitted to all condensing units therefore an additional isolator is not required unless site conditions or regulations dictate differently. J & E Hall Fusion condensing units require either a 230 volt / 1 phase / 50Hz supply or a 400 volt / 3 phase / 50Hz supply, both of which must include a Neutral and an Earth. These systems are not suitable for any other supply voltages (other than a deviation of +/- 10% of the above values) and are not suitable for 60Hz supplies.

Important Note: There must be no more than 12 compressor starts per hour. A higher number reduces the service life of the compressor and can cause carry-over of oil into the system. If necessary, use an anti-short-cycle timer in the control circuit. A minimum 2 minute runtime after each start of the compressor and a 3 minute idle time after each stop are recommended. Only during the pump down cycle may the compressor run for much shorter intervals.

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Commissioning

Pre startup checks

Before starting the condensing unit the following checks should be carried out as a minimum:

• Check electrical supply is correct and all connections are sound.

• All moving parts are free and guards fitted.

• Compressor oil level satisfactory.

• Initial settings for safety switches and fan speed control.

• Overload (where fitted) set correctly.

• All valves in correct operating position.

• Initial refrigerant charge.

• Crankcase heater energized for a minimum of 12 hours before compressor start-up.

• Gauge manifold connected to both low and high sides of system.

Running the unit

• Run the unit and check compressor and condenser fan operation.

• Check system pressures and temperatures, gas charge and running currents of motors to ensure correct operation.

• Check compressor suction superheat. This should be between 10K and 20K at normal operating conditions.

• Final adjustment of safety switches settings and fan speed control.

• Allow the system to run for 3 – 4 hours. Check compressor oil level and top up with the correct oil type as required (see page 4). Recheck the compressor oil level again after 24 hours operation.

• Carry out final leak test and ensure all panels/covers are fitted and screws tightened.

• Log all information along with the system model and serial numbers for future reference.

• Ensure that the customer / responsible person are provided with basic operating instructions and where electrical isolators are situated in case of emergency.

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Commissioning

Safety pressure switch settings The Saginomiya DNS HP/LP pressure switch fitted to JEH2 model condensing units with auto reset for low pressure and manual reset for high pressure is NOT factory preset. BOTH THE LP AND HP SWITCH SETTINGS MUST BE ADJUSTED TO SUIT THE APPLICATION BEFORE STARTING THE UNIT. Be sure that the high pressure setting does not exceed the receiver’s maximum service pressure.

High pressure safety The high pressure safety switch is required to stop the compressor should the discharge pressure exceed the values shown in the following table. The high pressure switch can be set to lower values depending on the application and ambient conditions.

Unit Type Series 1 Refrigerant R404A R404A/R407C R407A R407F R134a Cut Out (bar g) 24 28 25 26 16 Cut Out (psi g) 350 410 370 385 235

Series 2, 3, 4

Note: The HP switch settings for R407A & R407F are for MT application only.

Low pressure safety The low pressure safety switch protects the compressor against deep vacuum operation, a potential cause of failure due to internal arcing. The low pressure safety cut out should never be set below the settings as shown in the following table. For systems without pump-down the LP switch signal contact shall be used to energize a low pressure safety alarm.

Unit Type Refrigerant R134a R407C Application M* L* M* L* M* M* Cut Out (bar g) 2.0 0.1 1.0 0.1 0.6 1.4 Cut Out (psi g) 29 2 15 2 9 20

* M: Medium Temperature; L: Low Temperature

Series 1R404A R404A / R407A/F

Series 2, 3, 4

XGE Fan Speed Controller (Not DC Fan)

The fan speed controller is factory set to 19 bar for operation with R4XXX series refrigerants. This can be adjusted to suit site conditions / application or alternative refrigerants as described on page 28. The XGE controls are set to stop fan at Pmin. Recommended settings are as follows:

Refrigerant R404A / R407A/C/F R134aSetting (bar g) 19 11

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Drawings

Dimensional drawings: JEH2-0050-M-1, JEH2-0088-M-1, JEH2-0075-L-1

JEH2-0150-M-1/3, JEH2-0225-M-1/3, JEH2-0300-M-1/3, JEH2-0175-L-1/3, JEH2-0225-L-1/3

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Drawings

Dimensional drawings: JEH2-0400-M-3, JEH2-0500-M-3, JEH2-0600-M-3, JEH2-0350-L-3

JEH2-0675-M-3, JEH2-0400-L-3

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Drawings

Dimensional drawings: JEH2-0825-M-3, JEH2-1000-M-3, JEH2-0725-L-3, JEH2-0825-L-3

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Drawings

Electrical wiring diagrams: JEH2-0050-M-1, JEH2-0075-L-1

JEH2-0088-M-1

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Drawings Electrical wiring diagrams: JEH2-0150-M-1, JEH2-0175-L-1

JEH2-0225-M-1, JEH2-0300-M-1, JEH2-0225-L-1

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Drawings Electrical wiring diagrams: JEH2-0150-M-3, JEH2-0225-M-3, JEH2-0300-M-3, JEH2-0175-L-3, JEH2-0225-L-3

JEH2-0400-M-3, JEH2-0500-M-3, JEH2-0600-M-3, JEH2-0675-M-3, JEH2-0350-L-3, JEH2-0400-L-3

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Drawings Electrical wiring diagram: JEH2-0825-M-3, JEH2-1000-M-3, JEH2-0725-L-3, JEH2-0825-L-3

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Service & Maintenance

The condensing units are designed to give long life operation with minimum maintenance. However, they should be routinely checked and the following service schedule is recommended under normal circumstances: The removal of the top, side and front panels ensures that all parts are accessible.

1. Compressor – Inspect at regular intervals • Check for refrigerant leaks on all joints and fittings.

• Check mountings for tightness and wear.

• Check operation of crankcase heater.

• Check electrical connections.

• Ensure that no abnormal noise or vibration is detected during test run.

• Check the compressor oil levels and top up if required. The oil level should be ½ to ¾ way up the sight glass (where fitted).

2. Condenser Fan Motor & Blade – Clean and inspect at regular intervals

• Check for abnormal noise, vibration and fan imbalance.

• Ensure that the fan motor is clean and spins freely.

• Check that the condenser fan blade is clean and free from restriction and damage/imbalance.

• Note: The fan motor is pre-lubricated and factory sealed so no maintenance is necessary.

3. Condenser Coil – Clean and inspect at regular intervals. • Check and remove the dirt and debris between the fins using a soft brush, low pressure compressed air/inert gas or a low

pressure sprayer utilizing clean water. A suitable chemical coil cleaner may be used as required. Accumulations of dirt on the condenser face can be removed with a soft bristle hand brush. When using liquids, ensure electrical items are isolated and correctly protected.

• DO NOT USE HIGH PRESSURE JET WASHERS.

• Check and remove any obstacles which may hinder the airflow through the condenser coil.

Important Note:

Warning! – Disconnect the mains electrical supply before servicing or opening the unit.

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Service & Maintenance

4. Controls

• Check settings and operation of pressure switches.

• Check overload setting.

• Check fan speed control setting and operation.

5. Power Supply – Inspect at regular intervals. • Check the running current and voltage for the condensing unit.

• Check the electrical wiring and tighten the wires onto the terminal blocks if necessary.

6. Refrigerant Charge • Check the refrigerant charge by ensuring that the system is operating correctly, the pressures are as expected and that the

liquid line sight glass shows a full bore of liquid refrigerant.

• Carry out a full leak test.

7. Unit decommissioning and disposal • At the end of the unit’s useful life, a suitably qualified engineer should decommission it. The refrigerant and compressor oil

are classed as hazardous waste and as such must be reclaimed and disposed of in the correct manner, including completion of waste transfer paperwork. The unit components must be disposed of or recycled as appropriate in the correct manner.

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F-Gas Information From 1/1/2015, a new F-Gas Regulation (EC 517/2014) comes into force replacing the old Regulation (EC 842/2006. This will affect system labelling, information supplied within documentation and also the way in which thresholds for frequency of leak testing refrigeration systems are calculated. Please be aware of the following:

• The models of equipment covered in this Technical Manual rely on fluorinated greenhouse gases for their functioning.

• All unit models come from the factory pressurized with OFN (Oxygen Free Nitrogen) only.

• The GWP (Global Warming Potential) values of refrigerants which are specified for use along with the three new thresholds for leak testing requirements based on TCO₂Eq (Tonnes CO₂ Equivalent) are as follows:

Refrigerant Charge - kg

5T 50T 500T

Refrigerant GWP

CO₂Eq CO₂Eq CO₂Eq

R134a 1430

3.5 35 350

R404A 3922

1.3 12.7 127

R407A 2107

2.4 23.7 237

R407C 1774

2.8 28.2 282

R407F 1825

2.7 27.4 274

• Changes to leak testing requirements are as follows:

OLD LEGISLATION NEW LEGISLATION LEAK CHECKING FREQUENCY

3-30 kgs 5-50 TCO₂Eq Every 12 months but can be increased to 24 months if

fitted with a fixed leak detection system.

30-300 kgs 50-500 TCO₂Eq Every 6 months but can be increased to 12 months if

fitted with a fixed leak detection system.

300+ kgs 500+ TCO₂Eq Every 6 months - however automatic leak detection

system is mandatory which requires servicing every 12

months

To calculate TCO₂Eq value: Refrigerant charge (kgs) x Refrigerant GWP 1000 Please note: For systems with a charge below 3kg, the changes to the leak checking regime will not apply until 2017. Currently, there is no requirement for regular leak testing of systems with a total charge below 3kg. A refrigerant charge label is supplied with each unit (inside the electrical box) manufactured from January 2015. The total refrigerant charge for the system and the TCO₂Eq value must be entered on the label with indelible ink and must be adhered in the proximity of the product charging port. The label supplied will represent the refrigerants approved for use with that particular unit. Examples of the unit labels are as follows:

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Technical Information

XGE Fan Speed Controller (Not DC Fan)

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Dual Pressure Switch

Safety pressure switch settings The pressure switches fitted to condensing units with auto reset for low pressure and manual reset for high pressure are NOT factory preset.

Setting procedure for DNS Pressure switch

High Pressure side: Turning the adjusting screw (8) clockwise will increase the cut-out pressure setting. Turning the adjusting screw anti-clockwise will decrease the cut-out pressure setting. The differential setting is fixed so the cut-in will vary with the cut-out setting. Lock the spindle with locking plate after setting. Low pressure side: Range: Turning the range adjusting screw (2) clockwise will decrease the cut-in pressure setting. Turning the range adjusting screw anti-clockwise will increase the cut-in pressure setting. Differential: Turning the differential adjusting screw (3) clockwise will increase the differential pressure setting. Turning the differential adjusting screw anti-clockwise will decrease the differential pressure setting. Lock the spindle with locking plate after setting.

1. Micro Switch 2. Range Adjusting Screw 3. Differential Adjusting Screw 4. Low Pressure Scale plate

5. Low Pressure Range pointer 6. Differential pointer 7. Low Pressure Bellows cover 8. High Pressure range Adjusting Screw

9. High Pressure Scale plate 10. High Pressure Range pointer 11. High Pressure Bellow cover

Important Note: There must be no more than 12 compressor starts per hour. A higher number reduces the service life of the compressor and can cause carry-over of oil into the system. If necessary, use an anti-short-cycle timer in the control circuit. A minimum 2 minute runtime after each start of the compressor and a 3 minute idle time after each stop are recommended. Only during the pump down cycle may the compressor run for much shorter intervals.

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DC Fan & Controller The unit models below manufactured in 2015 are fitted with a DC condenser fan motor and controller:

Wiring diagram

Medium Temperature Low Temperature JEH2-0400-M-3 JEH2-0350-L-3 JEH2-0500-M-3 JEH2-0400-L-3 JEH2-0600-M-3 JEH2-0675-M-3

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Technical Information Fan drive controller setting (only applicable to DC fan)

Fan speed is regulated according to the signal received from the pressure transducer (S1NPH).

The default settings for R404A/R407A/R407F & R134a are loaded in different EEPROM’s as shown below.

*EEPROM labelled “04EA” consists of the program for R404A/R407A/R407F and is the default program installed in the fan speed

controller PCB.

* EEPROM labelled “042A” consists of the program for R134a and is the spare (included in the PCB electrical box).

Installation

It is important to eliminate or prevent annoying static charging which may cause failure of electronics. Below are a few options which

may be used when handling the fan speed controller during exchanging the EEPROM:

1) Always use anti-static wristband or anti-static gloves. If this is not available, then below option can be used.

2) Always grasp an unpainted metal part of the chassis with your bare hand before you touch anything inside the fan speed

controller. Do this even if you are wearing an anti-static wristband.

3) Always handle electronic components by a non-conducting (non-metallic) edge. Don't touch the pins or other connectors.

WARNING

• Ensure power supply is turned off with LED401 going off before changing the EEPROM.

• Failure to observe these instructions properly may result in property damage or personal injury, which may be serious

depending on the circumstances.

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Technical Information Fault signals:

The fan controller PCB will display a signal when a fault is detected.

LED701 flashes 0.5s on and 0.5s off and then stops 2s after 1 cycle, the signal is repeated until the fault is removed.

Dip switch K102: 1 indicates run single fan; ON indicates run two fans

The signal from the fan speed controller indicates faults as below:

No. Signal Fault

1 LED703 Steady light Over-Voltage (Over voltage protection: default DC 380V)

2 LED702 Steady light Over-Current (Overcurrent protection: default DC 1A)

3 LED701 Steady light Pressure transducer fault

4 LED701 Flash 13 times Read EEPROM data error

5 LED701 Flash 14 times Write EEPROM data error

6 LED701 Flash 15 times Fan A Hall Feedback error

7 LED701Flash 16 times* Fan B Hall Feedback error

* If there was more than one fault, the LED701 will display this signal.

EEPROM

FAULT LED’s

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Certification

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THIS PAGE IS LEFT BLANK INTENTIONALLY

J & E Hall Limited Hansard Gate West Meadows Derby, DE21 6JN England

Tel: + 44 (0) 1332 253400 Fax: + 44 (0) 1332 371061 Email: [email protected] www.jehall.com Issue: 01.03.2016

FUSION Commercial Condensing Units€¦ · 27 3220 4286 5556 7032 8712 10598 12688 14984 2693 3149...

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Transcript of FUSION Commercial Condensing Units€¦ · 27 3220 4286 5556 7032 8712 10598 12688 14984 2693 3149...