Installation manual mini


Published on

1 Like
  • Be the first to comment

No Downloads
Total views
On SlideShare
From Embeds
Number of Embeds
Embeds 0
No embeds

No notes for slide

Installation manual mini

  1. 1. ENGLISH ITALIANO ESPAÑOL FRANCAIS DEUTSCH PORTUGUESEINSTALLATION MANUALAIR CONDITIONER• Please read this installation manual completely before installing the product.• Installation work must be performed in accordance with the national wiring standards by authorized personnel only.• Please retain this installation manual for future reference after reading it thoroughly.TYPE : SystemP/NO : MFL62603701
  2. 2. ARUN/ARUV Series Outdoor Unit Installation ManualTABLE OF CONTENTSSafety Precautions .......................................................................................................3Installation Process .....................................................................................................7Outdoor Units Information ..........................................................................................8Before installation ......................................................................................................10Select the Best Location............................................................................................11Installation Space.......................................................................................................12Installation ..................................................................................................................16Refrigerant piping ......................................................................................................20Electrical Wiring .........................................................................................................40Test Run ......................................................................................................................58Caution For Refrigerant Leak....................................................................................70Installation guide at the seaside ...............................................................................722 Outdoor Unit
  3. 3. Safety Precautions Safety Precautions ENGLISHTo prevent injury to the user or other people and property damage, the following instructions mustbe followed.■ Incorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications. This symbol indicates the possibility of death or serious injury. This symbol indicates the possibility of injury or damage to properties only.■ Meanings of symbols used in this manual are as shown below. Be sure not to do. Be sure to follow the instruction.■ Installation Have all electric work done by a licensed Ask the dealer or an authorized technician to electrician according to "Electric Facility install the air conditioner. Engineering Standard" and "Interior Wire Regulations" and the instructions given in this manual and always use a special circuit.• If the power source capacity is inadequate or • Improper installation by the user may result in electric work is performed improperly, electric water leakage, electric shock, or fire. shock or fire may result. Always ground the product. Always intstall a dedicated circuit and breaker.• There is risk of fire or electric shock. • Improper wiring or installation may cause fire or electric shock. For re-installation of the installed product, Do not install, remove, or re-install the unit always contact a dealer or an Authorized by yourself (customer). Service Center.• There is risk of fire, electric shock, explosion, or • There is risk of fire, electric shock, explosion, or injury. injury. Do not store or use flammable gas or Use the correctly rated breaker or fuse. combustibles near the air conditioner.• There is risk of fire or failure of product. • There is risk of fire or electric shock. Prepare for strong wind or earthquake and Do not install the product on a defective install the unit at the specified place. installation stand.• Improper installation may cause the unit to • It may cause injury, accident, or damage to the topple and result in injury. product. Installation Manual 3
  4. 4. Safety Precautions When installing and moving the air Do not reconstruct to change the settings of conditioner to another site, do not charge it the protection devices. with a different refrigerant from the refrigerant specified on the unit.• If a different refrigerant or air is mixed with the • If the pressure switch, thermal switch, or other original refrigerant, the refrigerant cycle may protection device is shorted and operated malfunction and the unit may be damaged. forcibly, or parts other than those specified by LGE are used, fire or explosion may result. Ventilate before operating air conditioner Securely install the cover of control box and when gas leaked out. the panel.• It may cause explosion, fire, and burn. • If the cover and panel are not installed securely, dust or water may enter the outdoor unit and fire or electric shock may result. If the air conditioner is installed in a small room, measures must be taken to prevent the refrigerant concentration from exceeding the safety limit when the refrigerant leaks.• Consult the dealer regarding the appropriate measures to prevent the safety limit from being exceeded. Should the refrigerant leak and cause the safety limit to be exceeded, harzards due to lack of oxygen in the room could result.■ Operation Do not damage or use an unspecified power Use a dedicated outlet for this appliance. cord.• There is risk of fire, electric shock, explosion, or • There is risk of fire or electrical shock. injury. Be cautious that water could not enter the Do not touch the power switch with wet product. hands.• There is risk of fire, electric shock, or product • There is risk of fire, electric shock, explosion, or damage. injury. When the product is soaked (flooded or Be cautious not to touch the sharp edges submerged), contact an Authorized Service when installing. Center.• There is risk of fire or electric shock. • It may cause injury. Take care to ensure that nobody could step Do not open the inlet grille of the product on or fall onto the outdoor unit. during operation. (Do not touch the electrostatic filter, if the unit is so equipped.)• This could result in personal injury and product • There is risk of physical injury, electric shock, or damage. product failure.4 Outdoor Unit
  5. 5. Safety Precautions ENGLISH■ Installation Always check for gas (refrigerant) leakage Do not install the product where the noise or after installation or repair of product. hot air from the outdoor unit could damage the neighborhoods.• Low refrigerant levels may cause failure of • It may cause a problem for your neighbors. product. Keep level even when installing the product. Do not install the unit where combustible gas may leak.• To avoid vibration or water leakage. • If the gas leaks and accumulates around the unit, an explosion may result. Use power lines of sufficient current Do not use the product for special purposes, carrying capacity and rating. such as preserving foods, works of art, etc. It is a consumer air conditioner, not a precision refrigeration system.• Cables that are too small may leak, generate • There is risk of damage or loss of property. heat, and cause a fire. Keep the unit away from children. The heat When installting the unit in a hospital, exchanger is very sharp. communication station, or similar place, provide sufficient protection against noise.• It can cause the injury, such as cutting the finger. • The inverter equipment, private power generator, Also the damaged fin may result in degradation high-frequency medical equipment, or radio of capacity. communication equipment may cause the air conditioner to operate erroneously, or fail to operate. On the other hand, the air conditioner may affect such equipment by creating noise that disturbs medical treatment or image broadcasting. Do not install the product where it is exposed to sea wind (salt spray) directly.• It may cause corrosion on the product. Corrosion, particularly on the condenser and evaporator fins, could cause product malfunction or inefficient operation.■ Operation Do not use the air conditioner in special Do not block the inlet or outlet. environments.• Oil, steam, sulfuric smoke, etc. can significantly • It may cause failure of appliance or accident. reduce the performance of the air conditioner or damage its parts. Make the connections securely so that the Be sure the installation area does not outside force of the cable may not be applied deteriorate with age. to the terminals.• Inadequate connection and fastening may • If the base collapses, the air conditioner could generate heat and cause a fire. fall with it, causing property damage, product failure, or personal injury. Installation Manual 5
  6. 6. Safety Precautions Install and insulate the drain hose to ensure that water is drained away properly based on the installation manual.• A bad connection may cause water leakage. Be very careful about product transportation.• Only one person should not carry the product if it weighs more than 20 kg.• Some products use PP bands for packaging. Do not use any PP bands for a means of transportation. It is dangerous.• Do not touch the heat exchanger fins. Doing so may cut your fingers.• When transporting the outdoor unit, suspending it at the specified positions on the unit base. Also support the outdoor unit at four points so that it cannot slip sideways. Safely dispose of the packing materials. Turn on the power at least 6 hours before starting operation.• Packing materials, such as nails and other metal or • Starting operation immediately after turning on wooden parts, may cause stabs or other injuries. the main power switch can result in severe• Tear apart and throw away plastic packaging bags damage to internal parts. Keep the power switch so that children may not play with them. If children turned on during the operational season. play with a plastic bag which was not torn apart, they face the risk of suffocation. Do not touch any of the refrigerant piping Do not operate the air conditioner with the during and after operation. panels or guards removed.• It can cause a burn or frostbite. • Rotating, hot, or high-voltage parts can cause injuries. Do not directly turn off the main power Auto-addressing should be done in condition of switch after stopping operation. connecting the power of all indoor and outdoour• Wait at least 5 minutes before turning off the units. Auto-addressing should also be done in main power switch. Otherwise it may result in case of changing the indoor unit PCB. water leakage or other problems. Use a firm stool or ladder when cleaning or Do not insert hands or other objects through maintaining the air conditioner. the air inlet or outlet while the air conditioner is plugged in.• Be careful and avoid personal injury. • There are sharp and moving parts that could cause personal injury.6 Outdoor Unit
  7. 7. Installation Process Installation Process ENGLISH Determination of division work Indicate clearly who is to be responsible for switch settings Make relationship between outdoor, indoor, remote controller, and option connections clear." Preparation of contract drawings (Prepare control circuit diagram) Take account of gradient " The foundation must be level even Sleeve and insert work Outdoor unit foundation work of drain piping Check model name to make " Avoid short circuits and ensure " Installation of indoor unit Installation of outdoor unit sure the fitting is made correctly sufficient space is allowed for service Special attention to dryness, " Refrigerant piping work cleanness and tightness Drain pipe work Adjust to downward gradient Duct work Make sure airflow is sufficient Heat insulation work Make sure no gaps are left where " the insulating materials are joined Electrical work Multiple core cable must not be used."(connection circuits and drive circuits) (suitable cable should be selected) Airtight test" In the final check for 24hours at 3.8 MPa(38.7 kgf/cm2) there must be no drop in pressure. " Vacuum drying The vacuum pump used must have a capacity of reaching at least 5 torr, more than 1 hour Additional charge of refrigerant Recharge correctly as calculated in this manual. and record the amount of added refrigerant Fit facing panels Make sure there are no gaps left between the facing materials used on the ceiling Refer to automatic addressing flowchart"Automatic addressing of indoor unit Preheat the crank case with the electrical heater for more than 6 hours." (In case of outdoor temperature below 10℃) Test run adjustment Run each indoor unit in turn to make sure the pipe work has been fitted correctlyTransfer to customer with explanation Explain the use of the system as clearly as possible to your customer and make sure all relevant " documentation is in order • The above list indicates the order in which the individual work operations are normally carried out but this order may be varied where local conditions warrants such change. • The wall thickness of the piping should comply with the relevant local and national regulations for the designed pressure 3.8MPa. • Since R410A is a mixed refrigerant, the required additional refrigerant must be charged in its liquid state.(If the refrigerant is charged in its gaseous state, its composition changes and the system will not work properly.) Installation Manual 7
  8. 8. Outdoor Units Information Outdoor Units Information Outdoor Model Chassis External Apperance Phase PFC Fan Heat Pump Cooling Only 1Ø PFC ARUN50GS2A ARUV60GS2A ARUN60GS2A ARUN40LS2A ARUV40LS2A U3 2 FAN PFC ARUN50LS2A ARUV50LS2A 3Ø ARUN60LS2A ARUV60LS2A ARUN40LS2B ARUV40LS2B Active Filter ARUN50LS2B ARUV50LS2B ARUN60LS2B ARUV60LS2B U4 1 FAN 1Ø PFC ARUN40GS2A ARUV50GS2A ARUV40GS2A CAUTION Ratio of the connectable Indoor Units to the Outdoor: Within 50 ~ 130% Ratio of running Indoor Units to the Outdoor: Within 10 ~ 100% A combination operation over 100% cause to reduce each indoor unit capacity. Power Supply : 1Ø, 220~240V, 50Hz / 1Ø, 220V, 60Hz■ Heat Pump ModelChassis U4 U3 U3System(HP) 4 5 6Model ARUN40GS2A ARUN50GS2A ARUN60GS2ARefrigerant Product charge kg 1.8 3.0 3.0 CF(Correction Factor) kg 0 0 0Max. Connectable No. of Indoor Units 6 8 9Net Weight(Gross Weight) kg 77 106 106Dimensions (WxHxD) mm 950×834×330 950×1380×330 950×1380×330 inch 37.4×32.8×13.0 37.4×54.3×13.0 37.4×54.3×13.0Connecting Pipes Liquid Pipes mm 9.52 9.52 9.52 inch 3/8 3/8 3/8 Gas Pipes mm 15.88 15.88 19.05 inch 5/8 5/8 3/4 Connection Type FLARE BRAZING BRAZING8 Outdoor Unit
  9. 9. Outdoor Units Information■ Cooling Only Model ENGLISHChassis U4 U4 U3System(HP) 4 5 6Model ARUV40GS2A ARUV50GS2A ARUN60GS2ARefrigerant Product charge kg 1.95 1.95 3.0 CF(Correction Factor) kg 0 0 0Max. Connectable No. of Indoor Units 6 8 9Net Weight(Gross Weight) kg 78 78 106Dimensions (WxHxD) mm 950×834×330 950×834×330 950×1380×330 inch 37.4×32.8×13.0 37.4×32.8×13.0 37.4×54.3×13.0Connecting Pipes Liquid Pipes mm 9.52 9.52 9.52 inch 3/8 3/8 3/8 Gas Pipes mm 15.88 15.88 19.05 inch 5/8 5/8 3/4 Connection Type FLARE FLARE BRAZING Power Supply : 3Ø, 380~415V, 50Hz/ 3Ø, 380V, 60Hz *A:PFC model, B:Active Filter modelChassis U3 U3 U3System(HP) 4 5 6Model ARUN40LS2* ARUN50LS2* ARUN60LS2* ARUV40LS2* ARUV50LS2* ARUV60LS2* Product charge kg 3.0 3.0 3.0Refrigerant CF(Correction Factor) kg -0.5 0 0Max. Connectable No. of Indoor Units 6 8 9Net Weight kg 107 107 107 mm 950 x 1,380 x 330 950 x 1,380 x 330 950 x 1,380 x 330Dimensions (WxHxD) inch 37.4 x 54.3 x 13.0 37.4 x 54.3 x 13.0 37.4 x 54.3 x 13.0 mm Ø9.52 Ø9.52 Ø9.52 Liquid Pipes inch 3/8 3/8 3/8Connecting Pipes mm Ø15.88 Ø15.88 Ø19.05 Gas Pipes inch 5/8 5/8 3/4 Connectable Indoor Unit should be connected with "2 series" indoor unit only. Ex) ARNU07GSEA2 Installation Manual 9
  10. 10. Before Installation Before Installation Environment-friendly Alternative Refrigerant R410A• The refrigerant R410A has the property of higher operating pressure in comparison with R22. Therefore, all materials have the characteristics of higher resisting pressure than R22 ones and this characteristic should be also considered during the installation. R410A is an azeotrope of R32 and R125 mixed at 50:50, so the ozone depletion potential (ODP) of R410A is 0. These days the developed countries have approved it as the environment-friendly refrigerant and encouraged to use it widely to prevent environment pollution. CAUTION: • The wall thickness of the piping should comply with the relevant local and national regulations for the designed pressure 3.8MPa • Since R410A is a mixed refrigerant, the required additional refrigerant must be charged in its liquid state. • If the refrigerant is charged in its gaseous state, its composition changes and the system will not work properly. • Do not place the refrigerant container under the direct rays of the sun to prevent it from exploding. • For high-pressure refrigerant, any unapproved pipe must not be used. • Do not heat pipes more than necessary to prevent them from softening. • Be careful not to install wrongly to minimize economic loss because it is expensive in comparison with R22. Transporting the Unit• When carrying the suspended, unit pass the ropes between legs of base panel under the unit.• Always lift the unit with ropes attached at four points so that impact is not applied to the unit.• Attach the ropes to the unit at an angle of 40° or less.• Use only accessories and parts which are of the designated specification when installing. Air outlet grille Intake hole Corner Sub line Handle Always hold the unit by the corners, as holding A 40° or less it by the side intake holes on the casing may WARNING cause them to deform.* Product appearance may be different depending on model. CAUTION: Be very careful while carrying the product. - Do not have only one person carry product if it is more than 20 kg. - PP bands are used to pack some products. Do not use them as a mean for transportation because they are dangerous. - Do not touch heat exchanger fins with your bare hands. Otherwise you may get a cut in your hands. - Tear plastic packaging bag and scrap it so that children cannot play with it Otherwise plastic packaging bag may suffocate children to death. - When carrying in Outdoor Unit, be sure to support it at four points. Carrying in and lifting with 3-point support may make Outdoor Unit unstable, resulting in a fall.10 Outdoor Unit
  11. 11. Select the Best Location Select the Best Location ENGLISH1. Select space for installing outdoor unit, which will meet the following conditions: • No direct thermal radiation from other heat sources • No possibility of annoying neighbors by noise from unit • No exposition to strong wind • With strength which bears weight of unit • Note that drain flows out of unit when heating • With space for air passage and service work shown next • Because of the possibility of fire, do not install unit to the space where generation, inflow, stagnation, and leakage of combustible gas is expected. • Avoid unit installation in a place where acidic solution and spray (sulfur) are often used. • Do not use unit under any special environment where oil, steam and sulfuric gas exist. • It is recommended to fence round the outdoor unit in order to prevent any person or animal from accessing the outdoor unit. • If installation site is area of heavy snowfall, then the following directions should be observed. - Make the foundation as high as possible. - Fit a snow protection hood.2. Select installation location considering following conditions to avoid bad condition when additionally performing defrost operation. • Install the outdoor unit at a place well ventilated and having a lot of sunshine in case of installing the product at a place with a high humidity in winter (near beach, coast, lake, etc). (Ex) Rooftop where sunshine always shines. • Performance of heating will be reduced and preheat time of the indoor unit may be lengthened in case of installing the outdoor unit in winter at following location: - Shade position with a narrow space - Location with much moisture in neighboring floor. - Location with much humidity around. - Location where ventilation is good. It is recommended to install the outdoor unit at a place with a lot of sunshine as possible as. - Location where water gathers since the floor is not even.3. When installing the outdoor unit in a place that is constantly exposed to a strong wind like a coast or on a high story of a building, secure a normal fan operation by using a duct or a wind shield. • Install the unit so that its discharge port faces to the wall of the building. Keep a distance 500mm or more between the unit and the wall surface. • Supposing the wind direction during the operation season of the air conditioner, install the unit so that the discharge port is set at right angle to the wind direction. Strong wind Strong wind Blown air 500 Air inlet grille Turn the air outlet side toward the buildings wall, Set the outlet side at a right angle fence or windbreak screen. to the direction of the wind. Installation Manual 11
  12. 12. Installation Space Installation Space• The following values are the least space for installation. If any service area is needed for service according to field circumstance, obtain enough service space.• The unit of values is mm.■ In case of obstacles on the suction side 1. Stand alone installation 10 mo 0 or r re 0o 10 0o r 10 ore mo 0 or 10 ore m re m les s ss r o r le 0o 00 50 5 1000 or more 1000 or more 15 r mo0 or 0o re 10 ore 15 0o r m mo0 or 15 ore re m [Unit:mm] 2. Collective installation ss r le 0o 1000 or 50 more 10 10 0 0 mo 0 or mo 0 or re 10 re 10 mo 0 or mo 0 or re re r 20 0o r 20 0o mo 0 or 30 ore mo 0 or 30 ore m re m re [Unit:mm]12 Outdoor Unit
  13. 13. Installation Space■ In case of obstacles on the discharge side ENGLISH 1. Stand alone installation s les 0 or 50 1000 or more re re r mo r mo 0o 0o 50 50 s les 0 or 2. Collective installation 50 1000 or more 10 10 mo 0 or mo 0 or re re re ore r mo o rm 00o 10 00 10 [Unit:mm]■ In case of obstacles on the suction and the discharge side ➲ Obstacle height of discharge side is higher than the unit ss 1. Stand alone installation o r le 500 L>H L>H 1000 or more HL L H r r 0o 0o 25 ore 10 ore or m 00 r m 10 ore [Unit:mm] 0o e m 50 mor Installation Manual 13
  14. 14. Installation Space 2. Collective installation s les 0 or 50 1000 or L>H L>H more HL 10 L 0o 10 rm 0o ore rm r ore r 0o 0o 30 ore 30 ore m m ore or orm 00 50 10 more 12 [Unit:mm] ➲ Obstacle height of discharge side is lower than the unit 1. Stand alone installation ss r le 0o 50 1000 or more L≤H L≤H H H L L r 0o r 30 ore 0o or m 10 ore 00 r m 10 ore 0o m 50 ore m 2. Collective installation s les 0 or 1000 or more 50 L≤H L≤H H H L L 10 10 0o 0o rm rm ore ore r or 0o 00 30 r more or 3 more 0o 00 150 ore 15 more [Unit:mm] m14 Outdoor Unit
  15. 15. Installation Space Collective / Continuous Installation for roof top use ENGLISHSpace required for collective installation and continuous installation: When installing several units, leave spacebetween each block as shown below considering passage for air and people. 1. One row of stand alone installation or 100 ore r m 0o 200 ore m or 200 ore r m 0o 100more [Unit:mm] 2. Rows of collective installation (2 or more) • L should be smaller than H L≤H 10 mo 0 or L re or 300ore r m 0o 300more H or r 600ore 0o m 150 ore [Unit:mm] mSeasonal wind and cautions in winter • Sufficient measures are required in a snow area or severe cold area in winter so that product can be operated well. • Get ready for seasonal wind or snow in winter even in other areas. • Install a suction and discharge duct not to let in snow or rain. • Install the outdoor unit not to come in contact with snow directly. If snow piles up and freezes on the air suction hole, the system may malfunction. If it is installed at snowy area, attach the hood to the system. • Install the outdoor unit at the higher installation console by 50cm than the average snowfall (annual average snowfall) if it is installed at the area with much snowfall. 1. The height of H frame must be more than 2 times the snowfall and its width shall not exceed the width of the product. (If width of the frame is wider than that of the product, snow may accumulate) 2. Dont install the suction hole and discharge hole of the Outdoor Unit facing the seasonal wind. Installation Manual 15
  16. 16. Installation Installation Foundation for Installation• Check the strength and level of the installation ground so that the unit will not cause any operating vibration or noise after installation.• Fix the unit securely by means of the foundation bolts. (Prepare 4sets of M12 foundation bolts, nuts and washers each which are available on the market.)• It is best to screw in the foundation bolts until their length are 20mm from the foundation surface. Anti-vibration Spring washer materials Frame Nut Concrete Four bolt are base required H-Beam 3 thread ridges 75 75 200 200 100 [Unit:mm] Foundation bolt executing method16 Outdoor Unit
  17. 17. Installation Preparation of Piping ENGLISH Main cause of gas leakage is defect in flaring work. Carry out correct flaring work in the following procedure.1) Cut the pipes and the cable. Copper ■ Use the accessory piping kit or the pipes purchased tube 90° Slanted Uneven Rough locally. ■ Measure the distance between the indoor and the outdoor unit. ■ Cut the pipes a little longer than measured distance. ■ Cut the cable 1.5m longer than the pipe length. Pipe Reamer2) Burrs removal ■ Completely remove all burrs from the cut cross section of pipe/tube. Point down ■ Put the end of the copper tube/pipe to downward direction as you remove burrs in order to avoid to let burrs drop in the tubing.3) Flaring work ■ Carry out flaring work using flaring tool as shown right. Handle Bar Bar Unit : mm(inch) "A" Yoke Indoor unit Pipe " A " Cone [kW(Btu/h] Gas Liquid Gas Liquid 1.6~1.8 1.1~1.3 <5.6(19,100) 12.7(1/2) 6.35(1/4) Copper pipe (0.63~0.71) (0.43~0.51) 1.6~1.8 1.5~1.7 Clamp handle <16.0(54,600) 15.88(5/8) 9.52(3/8) Red arrow mark (0.63~0.71) (0.59~0.67) 1.9~2.1 1.5~1.7 <22.4(76,400) 19.05(3/4) 9.52(3/8) (0.75~0.83) (0.59~0.67) Firmly hold copper tube in a bar(or die) as indicated dimension in the table above. Smooth all round Inside is shining without scratches.4) Check ■ Compare the flared work with figure right. = Improper flaring = ■ If flare is noted to be defective, cut off the flared section and do flaring work again. Inclined Surface Cracked Uneven damaged thickness Even length all round Installation Manual 17
  18. 18. Installation Flare shape and flare nut tightening torquePrecautions when connecting pipes• See the following table for flare part machining dimensions.• When connecting the flare nuts, apply refrigerant oil to the inside and outside of the flares and turn them three or four times at first. (Use ester oil or ether oil.)• See the following table for tightening torque.(Applying too much torque may cause the flares to crack.)• After all the piping has been connected, use nitrogen to perform a gas leak check. pipe size tightenig torque A flare shape mm N.m( mm 90° ±2 Ø9.52 32.7-39.9(327~399) 12.8-13.2 45 ° ±2 A Ø12.7 49.5-60.3(495~603) 16.2-16.6 R=0.4~0.8 Ø15.88 61.8-75.4(618~754) 19.3-19.7 CAUTION • Always use a charge hose for service port connection. • After tightening the cap, check that no refrigerant leaks are Union present. • When loosening a flare nut, always use two wrenches in combination, When connecting the piping, always use a spanner and torque wrench in combination to tighten the flare nut. • When connecting a flare nut, coat the flare(inner and outer faces) with oil for R410A(PVE) and hand tighten the nut 3 to 4 turns as the initial tightening. Opening shutoff valve1. Remove the cap and turn the valve counter clockwise with the hexagon wrench.2. Turn it until the shaft stops. Do not apply excessive force to the shutoff valve. Doing so may break the valve body, as the valve is not a backseat type. Always use the special tool.3. Make sure to tighten the cap securely. Closing shutoff valve1. Remove the cap and turn the valve clockwise with the hexagon wrench.2. Securely tighten the valve until the shaft contacts the main body seal.3. Make sure to tighten the cap securely. * For the tightening torque, refer to the table on the below.Tightening torque Outside diameter Torque mm inch N.m(kgf•cm) Ø6.35 1/4 18~25(180~250) Ø9.52 3/8 34~42(340~420) Ø12.7 1/2 55~66(550~660) Ø15.88 5/8 63~82(630~820) Ø19.05 3/4 99~121(990~1210)18 Outdoor Unit
  19. 19. Installation Heat insulation ENGLISH1. Use the heat insulation material for the refrigerant piping which has an excellent heat-resistance (over 120°C). Fastening band (accessory)2. Precautions in high humidity circumstance: This air conditioner has been tested according to the "KS Standard Conditions with Mist" and confirmed that there is not any default. However, if it is operated for a long time in high humid atmosphere (dew point Refrigerant piping temperature: more than 23°C), water drops are liable Indoor unit to fall. In this case, add heat insulation material Thermal insulator according to the following procedure: (accessory) • Heat insulation material to be prepared... Adiabatic glass wool with thickness 10 to 20mm. • Stick glass wool on all air conditioners that are located in ceiling atmosphere. • In addition to the normal heat insulation (thickness: more than 8mm) for refrigerant piping (gas piping: thick piping) and drain piping, add further 10mm to 30mm thickness material. Installation Manual 19
  20. 20. Refrigerant Piping Refrigerant Piping U3 Chassis (2 Fan Model)■ Connecting the pipes to the outdoor unit• Braze suitable field piping with service valve of gas pipe. CAUTION Take care so that there is no thermal damage on the service valves of the outdoor unit. (Especially packing part of service port.) Wrap the Wet towel service valve with a wet towel when brazing it as shown figure above. <Liquid pipe> <Gas pipe>■ Possible direction for field piping ■ Preventing foreign objects from• The installation piping is connectable in four entering (Figure 4) directions.(refer to figure 1) • Plug the pipe through-holes with putty or insulation• When connecting in a downward direction, knock out material(procured locally)to stop up all gaps,as the knockout hole of the base pan. shown in the figure 3. (refer to figure2, figure3) • Insects or small animals entering the outdoor unit may cause a short circuit in the electrical box. <Figure 1> <Figure 4> Liquid side piping (Smaller Dia.) Gas side piping Backward (Bigger Dia.) Downward Forward Sideways <Figure 2> Connecting wire Drain hose Connection pipe Putty or insulating material (produced locally) Knock-out Base pan CAUTION • You should not dame pipe/base during the work of pipe knock out. • Operate piping work removing burr after pipe knock out. Pipe knock <Figure 3> out during the ground piping.20 Outdoor Unit
  21. 21. Refrigerant Piping CAUTION ENGLISH • Make sure that pipe doesnt contact with the compressor terminal cover and comp bolt. • Always insulate the liquid and gas-side field piping and branch. U4 Chassis (1Fan Model)■ After connecting the refrigerant pipe and checking the refrigerant leakage, cover it with heat insulator and roll around it with vinyl tape. Tighten up the flare nut fitting on regulated torque. (Until “clatter” sounds is made at torque wrench part.) The centers correspond with each other Socket flare Flare nut Screw wrench Torque wrench Refrigerant pipe Flare nut Cap Pipe Pipe Pipe■ Do not bend the pipe more than twice and work on it making it a big half circle. If it is folded over, cooling/heating capacity may decrease and it could be the reason of malfunction. Do not remove the cap on flare side until the connection. Dust and sand inside pipes can be the reason of malfunction.■ Bend it following the wall and connect to outdoor unit valve.Refrigerant pipe connection torque Pipe external 6.35mm 9.52mm 12.7mm 15.88mm diameter (1/4") (3/8") (1/2") (5/8") Torque Installation Manual 21
  22. 22. Refrigerant Piping Cautions for Handling Service Valve• The service valves are closed at shipment from the factory CAUTION Make sure to keep the valve open during operation The names of parts of the service valve are shown in the figure. 1 1. Service point 2. Shut-off Valve 3. Filed piping connection 2 4. Valve cover 3 4• Since the side boards may be deformed if only a torque wrench is used when loosening or tightening flare nuts, always lock the shut-off valve with a wrench and then use a torque wrench. Do not place wrenches on the valve cover. 1. Spanner 2. Torque wrench 1 2Do not apply force on the valve cover, this may result in a refrigerant leak. How to Use the Shut-Off ValveUse hexagonal wrenches 4mm or 6mm• Opening the valve 1. Place the hexagon wrench on the valve bar and turn counter-clockwise. 2. Stop when the valve bar no longer turns. It is now open.• Closing the valve 1. Place the hexagon wrench on the valve bar and turn clockwise. 2. Stop when the valve bar no longer turns. It is now closed. Direction to open Direction to open <Liquid pipe> <Gas pipe>22 Outdoor Unit
  23. 23. Refrigerant Piping Caution ENGLISH 1. Use the following materials for refrigerant piping. • Material: Seamless phosphorous deoxidized copper pipe • Wall thickness : Comply with the relevant local and national regulations for the designed pressure 3.8MPa. We recommend the following table as the minimum wall thickness. Outer diameter 6.35 9.52 12.7 15.88 19.05 22.2 25.4 28.58 31.8 34.9 38.1 41.3 [mm] Minimum 0.8 0.8 0.8 0.99 0.99 0.99 0.99 0.99 1.1 1.21 1.35 1.43 thickness [mm] 2. Commercially available piping often contains dust and other materials. Always blow it clean with a dry inert gas. 3. Use care to prevent dust, water or other contaminants from entering the piping during installation. 4. Reduce the number of bending portions as much as possible, and make bending radius as big as possible. 5. Always use the branch piping set shown below, which are sold separately. Header Y branch 4 branch 7 branch 10 branch ARBLN01621 ARBLN03321 ARBL054 ARBL057 ARBL1010 ARBLN07121 ARBLN14521 ARBL104 ARBL107 ARBL2010 6. If the diameters of the branch piping of the designated refrigerant piping differs, use a pipe cutter to cut the connecting section and then use an adapter for connecting different diameters to connect the piping. 7. Always observe the restrictions on the refrigerant piping (such as rated length, difference in height, and piping diameter). Failure to do so can result in equipment failure or a decline in heating/cooling performance. 8. A second branch cannot be made after a header. (These are shown by .) A A BA To Outdoor UnitB Sealed Piping 9. The Multi V will stop due to an abnormality like excessive or insufficient refrigerant. At such a time, always properly charge the unit. When servicing, always check the notes concerning both the piping length and the amount of additional refrigerant. 10. Never use refrigerant to perform an air purge. Always evacuate using a vacuum pump. 11. Always insulate the piping properly. Insufficient insulation will result in a decline in heating/cooling performance, drip of condensate and other such problems. 12. When connecting the refrigerant piping, make sure the service valves of the Outdoor Unit is completely closed (the factory setting) and do not operate it until the refrigerant piping for the Outdoor and Indoor Units has been connected, a refrigerant leakage test has been performed and the evacuation process has been completed. 13. Always blow nitrogen into pipe which is brazed. Always use a non-oxidizing brazing material for brazing the parts and do not use flux. If not, oxidized film can cause clogging or damage to the compressor unit and flux can harm the copper piping or refrigerant oil. Installation Manual 23
  24. 24. Refrigerant Piping 6 1 2 4 5 3 1 Refrigerant piping 4 Taping 2 Pipe to be brazed 5 Valve 3 Nitrogen 6 Pressure-reducing valve WARNING When installing and moving the air conditioner to another site, be sure to make recharge refrigerant after perfect evacuation. - If a different refrigerant or air is mixed with the original refrigerant, the refrigerant cycle may malfunction and the unit may be damaged. - After selecting diameter of the refrigerant pipe to suit total capacity of the indoor unit connected after branching, use an appropriate branch pipe set according to the pipe diameter of the indoor unit and the installation pipe drawing. WARNING Do not use anti-oxidants when brazing the pipe joints. Residue can clog pipes and break equipment.24 Outdoor Unit
  25. 25. Refrigerant Piping Selection of Refrigerant Piping ENGLISH Outdoor unitGas pipe Liquid pipe Branching pipe Main pipe Branching Indoor unit pipe No. Piping parts Name Selection of pipe size Size of main pipe Liquid pipe Gas pipe Outdoor unit capacity[kW(Btu/h)] Outdoor unit [mm(inch)] [mm(inch)] ① Main pipe 11.0(37,500) Ø9.52(3/8) Ø15.88(5/8) ↓ 1st branching section 14.5(49,500) Ø9.52(3/8) Ø15.88(5/8) 16.0(54,600) Ø9.52(3/8) Ø19.05(3/4) Pipe size of between branching sections Liquid pipe Gas pipe Branching section Indoor unit capacity[kW(Btu/h)] [mm(inch)] [mm(inch)] ② ↓ Branching pipe ≤ 5.6(19,100) Ø6.35(1/4) Ø12.7(1/2) Branching section < 16.0(54,600) Ø9.52(3/8) Ø15.88(5/8) < 22.4(76,400) Ø9.52(3/8) Ø19.05(3/4) Connecting pipe size of indoor unit Branching section Liquid pipe Gas pipe Indoor unit Indoor unit capacity[kW(Btu/h)] ③ ↓ [mm(inch)] [mm(inch)] connecting pipe ≤ 5.6(19,100) Ø6.35(1/4) Ø12.7(1/2) Indoor unit < 16.0(54,600) Ø9.52(3/8) Ø15.88(5/8) Installation Manual 25
  26. 26. Refrigerant Piping Allowable Length/Height Difference of Refrigerant Piping■ Y Branch MethodExample : 5 Indoor Units connected Ⓐ : Outdoor Unit Ⓑ : 1st branch (Y branch) Ⓒ : Indoor Units L150m H 50m l 40m➲ Total pipe length = A+B+C+D+a+b+c+d+e ≤ 300m Longest pipe length Equivalent pipe length(*) L A+B+C+D+e ≤ 150m A+B+C+D+e ≤ 175m Longest pipe length after 1st branch l B+C+D+e ≤ 40m Difference in height(Outdoor Unit ↔ Indoor Unit) H H ≤ 50m ( 40m : Outdoor Unit is lower than Indoor Units) Difference in height (Indoor Unit ↔ Indoor Unit) h h ≤ 15m* : Assume equivalent pipe length of Y branch to be 0.5m, that of header to be 1m, calculation purpose CAUTIONIndoor Unit should be installed at lower position than the header26 Outdoor Unit
  27. 27. Refrigerant Piping■ Header Method ENGLISHExample : 6 Indoor Units connected Ⓐ : Outdoor Unit Ⓑ : 1st branch Ⓒ : Indoor Units Ⓓ : Sealed piping L 150m H 50m 40m➲ Total pipe length = A+a+b+c+d+e+f ≤ 300m Longest pipe length Equivalent pipe length(*) L A+f ≤ 150m A+f ≤ 175m Longest pipe length after 1st branch l f ≤ 40m Difference in height(Outdoor Unit ↔ Indoor Unit) H H ≤ 50m (40m : Outdoor Unit is lower) Difference in height (Indoor Unit ↔ Indoor Unit) h h ≤ 15m* : Assume equivalent pipe length of Y branch to be 0.5m, that of header to be 1m, calculation purpose CAUTIONIndoor Unit should be installed at lower position than the header WARNINGPipe length after header branching (a~f)It is recommended that difference in length of the pipes connected to the Indoor Units isminimized. Performance difference between Indoor Units may occur. Installation Manual 27
  28. 28. Refrigerant Piping■ Combination of Y branch/header methodExample : 5 Indoor Units connected Ⓐ : Outdoor Unit Ⓑ : 1st branch (Y branch) Ⓒ : Y branch Ⓓ : Indoor Unit Ⓔ : Header Ⓕ : Sealed piping H 50m L 150m 40m Branch pipe can not be used after header➲ Refrigerant pipe diameter from branch to branch (B,C) Downward Indoor Unit total capacity Liquid pipe Gas pipe [kW(Btu/h)] [mm(inch)] [mm(inch)] ≤ 5.6(19,100) Ø6.35(1/4) Ø12.7(1/2) < 16.0(54,600) Ø9.52(3/8) Ø15.88(5/8) < 22.4(76,400) Ø9.52(3/8) Ø19.05(3/4)➲ Total pipe length = A+B+C+a+b+c+d+e ≤ 300m Longest pipe length Equivalent pipe length(*) L A+B+b ≤ 150m A+B+b ≤ 175m Longest pipe length after 1st branch l B+b ≤ 40m Difference in height(Outdoor Unit ↔ Indoor Unit) H H ≤ 50m (40m : Outdoor Unit is lower than Indoor Units) Difference in height (Indoor Unit ↔ Indoor Unit) h h ≤ 15m* : Assume equivalent pipe length of Y branch to be 0.5m, that of header to be 1m, calculation purpose CAUTIONIndoor Unit should be installed at lower position than the header WARNING It is recommended that difference of piping length for pipes connected to the Indoor Unit is minimized. Performance difference between Indoor Units may occur.28 Outdoor Unit
  29. 29. Refrigerant Piping The Amount of Refrigerant ENGLISHThe calculation of the additional charge should take into account the length of pipe. Product charge(kg) Additional charge(kg) = Length(m) of liquid pipe of Ø9.52mm x 0.061(kg/m) + Length(m) of liquid pipe of Ø6.35mm x 0.022(kg/m) + Correction factor of outdoor unit + Correction factor of Indoor unit Total charge(kg) = Product charge(kg) + Additional charge(kg) Example : 5 HP L1 L2 L3 a 1WAY b 2WAY c 4WAY d 4WAY 2.2kW 5.6kW 2.2kW 7.1kW L1 Ø9.52:10m L2 Ø9.52:10m L3 Ø9.52:5m a Ø9.52:3m b Ø6.35:3m c Ø6.35:4m d Ø6.35:5m Additional charge amount R (kg) = (Lx x 0.022kg/m) + (Ly x 0.061kg/m) + Correction factor of outdoor unit + Correction factor of indoor unit = (12 x 0.022kg/m) + (28 x 0.061kg/m) + 0 + 0.2 + 0.16 + 0.25 + 0.48 = 3.062 Lx : Real total length of liquid pipe Ø6.35(m) Ly : Real total length of liquid pipe Ø9.52(m)■ Correction factor of Indoor unit (unit : kg) Capacity : kW(kBtu) 1.6 2.2 2.8 3.6 4.5 5.6 7.1 8.2 10.6 12.3 14.1 Indoor unit (5.5) (7.5) (9.6) (12.3) (15.4) (19.1) (24.2) (28.0) (36.2) (42.0) (48.1) Ceiling Concealed Duct(Low Static) - 0.17 0.17 0.17 0.17 0.37 0.37 - - - - Ceiling Concealed Duct(High Static) - 0.17 0.17 0.17 0.17 0.26 0.26 0.44 0.44 0.44 0.62 Wall Mounted - 0.24 0.24 0.24 0.24 0.28 0.28 - - - - 1WAY Ceiling Cassette - 0.20 0.20 0.20 - 0.29 0.29 - - - - 2WAY Ceiling Cassette - - - - - 0.16 0.16 - - - - 4WAY Ceiling Cassette 0.25 0.25 0.25 0.25 0.32 0.32 0.48 0.48 0.64 0.64 0.64 Artcool - 0.10 0.10 0.10 0.10 0.29 0.29 - - - - Floor Standing - 0.17 0.17 0.17 0.17 0.37 0.37 - - - -Note:Fill in the f-gas Label attached on outdoor about the quantity of the fluorinated greenhouse gases① Manufacturing site (See Model Name label)② Installation site (If possible being placed adjacent to the service points for the addition or removal of refrigerant)③ The total Charge (①+②) Installation Manual 29
  30. 30. Refrigerant Piping CAUTIONIf a negative result is obtained from the calculation, no refrigerant needs to be added. WARNINGRegulation for refrigerant leakage: the amount of refrigerant leakage should satisfy the following equation for human safety. Total amount of refrigerant in the system ≤ 0.44 ( kg / m3 ) Volume of the room at which Indoor Unit of the least capacity is installedIf the above equation can not be satisfied, then follow the following steps. - Selection of air conditioning system: select one of the next 1. Installation of effective opening part 2. Reconfirmation of Outdoor Unit capacity and piping length 3. Reduction of the amount of refrigerant 4. Installation of 2 or more security device (alarm for gas leakage) - Change Indoor Unit type : installation position should be over 2m from the floor (Wall mounted type → Cassette type) - Adoption of ventilation system : choose ordinary ventilation system or building ventilation system - Limitation in piping work : Prepare for earthquake and thermal stress WARNINGRefer to model information since the CF Value of correction factor differs depending on model.30 Outdoor Unit
  31. 31. Refrigerant Piping Distribution Method ENGLISH1. Line Distribution 1st 2nd 3rd main pipe distribution 1st 2nd 3rd 1st 2nd 3rd 1st Main pipe Distribution 3nd Main pipe Distribution2. Vertical Distribution Ensure that the branch pipes are attached vertically.3. The others Header Installation Manual 31
  32. 32. Refrigerant Piping Branch Pipe Fitting■ Y branch B A To Outdoor Unit A B To Branch Piping or Indoor Unit • Ensure that the branch pipes are attached horizontally or vertically (see the diagram below.) Horizontal Facing Facing plane downwards upwards Within +/- 10°A Viewed from point A in direction of arrow Within ± 3° Within ± 3°■ Header A • The indoor unit having larger capacity must be installed closer to Ⓐ than smaller one. • If the diameter of the refrigerant piping selected by the procedures described is different from B the size of the joint, the connecting section should be cut with a pipe cutter. C Ⓐ To indoor unit Ⓑ To outdoor unit ⓒ Pipe cutter • When the number of pipes to be connected is smaller than the number of header branches, install a cap to the unconnected branches.32 Outdoor Unit
  33. 33. Refrigerant Piping• When the number of indoor units to be connected to the branch pipes is less than the number of branch pipes available for connection then cap pipes should be fitted to the surplus branches. ENGLISH B Pinched pipe• Fit branch pipe lie in a horizontal plane. Horizontal plane View from point B in the direction of the arrow• Header should be insulated with the insulator in each kit. Insulate the header using the insulation material attached to the branch pipe kit as shown in the figure.• Joints between branch and pipe should be sealed with the tape included in each kit. Tape Insulator Insulator of field pipe• Any cap pipe should be insulated using the insulator provided with each kit and then taped as described above. Insulator for cap pipe Cap pipe Tape Installation Manual 33