How To Properly Install The Fnv Air-cooled Condenser?

How to Properly Install the Fnv Air-cooled Condenser?

Pre-Installation Preparation

Before construction begins, confirm the following foundational conditions to avoid subsequent rework:

Site Planning:

The installation location must be “unobstructed and well-ventilated”—sufficient space must be reserved above and around the unit (top clearance ≥1.5m, side clearance from obstacles ≥1m) to prevent hot air recirculation (if airflow is obstructed, condensing temperature may rise by 5-10°C, reducing cooling efficiency by 15%-20%).

Avoid installation in dusty, heavily oil-contaminated, corrosive gas environments (e.g., chemical workshops), or high-temperature areas (e.g., near boilers). If unavoidable, install additional dust screens, rain covers, or anti-corrosion coatings.

Load-bearing Inspection:

The mounting surface (roof, platform, or bracket) must meet the equipment's weight requirements (refer to the product manual; e.g., FNV-200 model weighs approx. 300-500kg). Concrete foundations must achieve C30 strength. Steel brackets require rustproofing treatment (apply rust-proof primer + topcoat) and pass load-bearing calculations (to prevent long-term operational deformation).

Tool and Material Preparation:

Tools: Torque wrench (for copper pipe connections), spirit level (for equipment leveling), vacuum pump (for system evacuation), nitrogen cylinder (for pipe pressure testing), multimeter (for motor wiring inspection).

Materials: Refrigeration copper tubing (must match refrigerant type, e.g., oxygen-free copper tubing for R410A), insulation wool (≥15mm thickness to prevent cold loss), sealant (for sealing casing gaps), vibration dampers (installed under equipment to reduce operational noise).

Core Installation Steps

(1) Equipment Positioning and Securing

Use a forklift or crane to smoothly transport the condenser to the installation location (take care to protect the coils and fan, avoiding collisions that could cause deformation);

Place vibration damping pads (minimum 2-3 per side, thickness 5-10mm, nitrile rubber material). Calibrate equipment level using a spirit level (deviation ≤1° to prevent condensate pooling or fan imbalance);

Secure the unit to the foundation or support frame using expansion bolts (bolt size ≥ M12; tighten to specified torque as per manual, e.g., 25-30 N·m), ensuring no looseness (no noticeable vibration during operation).

(2) Piping Connections (Critical: Sealing and Cleanliness)

Copper Tubing Connections:

Cut copper tubing to match system diameter (ensure clean cuts; use deburring tools to remove internal burrs and prevent contaminants entering the system);

Employ either “flared connections” or “brazing connections”: Flaring requires a dedicated flaring tool (60° flaring angle matching valve connections). Brazing requires phosphor bronze brazing rod (temperature 700-800°C). Nitrogen gas (pressure 0.02-0.05MPa) must be used during brazing to prevent oxidation and scale formation on copper tube inner walls (scale clogs filters and impairs cooling).

After connection, apply soapy water to the joint and check for leaks (no bubbles indicates pass). Never use open flames for leak detection (to avoid damaging insulation or creating safety hazards).

Condensate Drain Pipe Connection (if equipped with drainage):

Connect the condensate outlet at the bottom of the condenser to a DN20-DN32 PVC or stainless steel pipe. Ensure the pipe slope is ≥3‰ (to guarantee smooth condensate drainage and prevent ice buildup damaging the coil).

Install a water seal at the pipe end (to prevent external air ingress into the system). In northern regions, apply heat tracing (wrap with heating tape + insulation wool) to prevent freezing and cracking during winter.

(3) Electrical Wiring (Critical: Safety and Compatibility)

Verify power supply voltage matches motor rated voltage (e.g., 220V/380V; distinguish single-phase/three-phase motors). Before wiring, test motor insulation resistance with a multimeter (≥2MΩ; if below 0.5MΩ, dry treatment required to prevent short circuits).

Wire according to the electrical schematic (fan motor, pressure controller, temperature sensor, etc.). Clearly distinguish phase, neutral, and ground wires (ground wire must be reliably grounded with resistance ≤4Ω). Secure wire terminals with crimp connectors to prevent loosening and overheating.

Install a waterproof junction box (for outdoor installations). Protect wires by routing them through galvanized conduit (to prevent aging from sun exposure and rain), leaving sufficient excess length (to prevent wire breakage due to equipment vibration).

(4) System Pressure Testing and Vacuuming

Nitrogen Pressure Test: Charge the system with nitrogen (pressure 2.8MPa, matching the product's airtightness test pressure). Maintain pressure for 24 hours; a pressure drop ≤0.02MPa is acceptable (if excessive pressure drop occurs, inspect for leaks at connections).

Vacuum extraction: Use a vacuum pump (ultimate vacuum ≤5 Pa) to evacuate the system for ≥2 hours. After valve closure, hold for 1 hour; no vacuum recovery indicates pass (prevents residual air/moisture causing reduced cooling capacity or ice blockage).

After vacuum qualification, charge the refrigerant quantitatively according to type (refer to manual; e.g., FNV-150 model requires approx. 5-8kg of R404A). During charging, slowly add refrigerant from the low-pressure side to prevent liquid slugging of the compressor.

Post-Installation Inspection and Commissioning

Visual Inspection: Ensure no deformation of the casing, no peeling of the coating, no damage to the fan blades, and no signs of leakage on the coil.

Commissioning:

Connect the power supply and manually start the fan motor (verify rotation direction: clockwise indicates forward rotation; reverse rotation requires phase wire reversal).

After normal operation, check condensing pressure (R134a system: approx. 0.8-1.2 MPa; R404A system: approx. 1.2-1.6 MPa. If pressure is excessively high, inspect for ventilation obstructions or fan malfunction);

Check motor operating current (must be within ±10% of rated current; e.g., for a 380V motor with 10A rated current, operating current should be 9-11A. Overcurrent requires investigation of voltage or motor faults);

Verify condensate drainage is unobstructed with no water accumulation or dripping.