SPLIT-TYPE AIR CONDITIONER
INSTALLATION MANUAL
MODEL
IMPORTANT NOTE:
Read this manual carefully before installing
or operating your new air conditioning
unit. Make sure to save this manual for
future reference.
42QHB026N8-1/ 38QHB026N8-1
42QHB035N8-1/ 38QHB035N8-1
42QHB050N8-1/ 38QHB050N8-1
42QHB070N8-1/ 38QHB070N8-1
42QHB080N8-1/ 38QHB080N8-1
42QHB020N8-1/ 38QHB020N8-1
42QHB090N8-1/ 38QHB090N8-1
Table of Contents
Installation Manual
Indoor Unit Installation........ 11
1. Select installation location..........................
11
2. Attach mounting plate to wall....................
12
3. Drill wall hole for connective piping............
12
4. Prepare refrigerant piping...........................
14
5. Connect drain hose....................................
15
6. Connect signal cable..................................
17
7. Wrap piping and cables..............................
18
8. Mount indoor unit.....................................
18
Outdoor Unit Installation...
20
8
1. Select installation location.................. 20
2. Install drain joint................................
21
3. Anchor outdoor unit..........................
22
4. Connect signal and power cables.......23
Safety Precautions........................... 4
0
1
5
Accessories........................................ 6
2
4
Unit Parts.......................................... 10
3
Installation Summary - Indoor Unit........
Refrigerant Piping Connection........ 25
A. Note on Pipe Length................................................ 25
B. Connection Instructions –Refrigerant Piping............. 25
1. Cut pipe..............................................................
25
2. Remove burrs......................................................
26
3. Flare pipe ends....................................................
26
4. Connect pipes.....................................................
27
Air Evacuation................... 29
1. Evacuation Instructions......................
(for R32/R290 refrigerant ony )
29
2. Note on Adding Refrigerant...............30
Electrical and Gas Leak Checks........ 31
Test Run............................................ 32
European Disposal Guidelines........ 34
6
7
8
9
10
Information servicing .................... 35
11
MC MC
Caut ion: Risk of fire
Page 4
This symbol indicates that ignoring instructions may cause death or serious
injury.
This symbol indicates that ignoring instructions may cause moderate injury
to your person, or damage to your unit or other property.
Safety Precautions
Read Safety Precautions Before Installation
Incorrect installation due to ignoring instructions can cause serious damage or injury.
The seriousness of potential damage or injuries is classified as either a WARNING or CAUTION.
WARNING
CAUTION
WARNING
Do not modify the length of the power supply cord or use an extension cord to power the unit.
Do not
Do not
share the electrical outlet with other appliances. Improper or insufficient power supply
can cause fire or electrical shock.
When connecting refrigerant piping, do not
let substances or gases other than the specified
refrigerant enter the unit. The presence of other gases or substances will lower the unit’s capacity,
and can cause abnormally high pressure in the refrigeration cycle. This can cause explosion and injury.
allow children to play with the air conditioner. Children must be supervised around the
unit at all times.
1.
Installation must be performed by an authorized dealer or specialist. Defective installation can
cause water leakage, electrical shock, or fire.
2.
Installation must be performed according to the installation instructions. Improper installation can
cause water leakage, electrical shock, or fire. (In North America,installation must be performed in
accordance with the requirement of NEC and CEC by authorized personnel only.)
3.
Contact an authorized service technician for repair or maintenance of this unit.
4.
Only use the included accessories, parts, and specified parts for installation. Using non-standard
parts can cause water leakage, electrical shock, fire, and can cause the unit to fail.
5.
Install the unit in a firm location that can support the unit’s weight. If the chosen location cannot
support the unit’s weight, or the installation is not done properly, the unit may drop and cause
serious injury and damage.
This symbol indicates that you must never perform the action indicated.
6.
7.
8.
9.
10.
Do not use means to accelerate the defrosting process or to clean, other than those
recommended by the manufacturer.
The appliance shall be stored in a room without continuously operating ignition sources
(for example: open flames,an operating gas appliance or an operating electric heater)
Do not pierce or burn.
Appliance shall be stored in a well -ventilated area where the room size corresponds to the
room area as specifiec for operation.
Be aware that refrigerants may not contain an odour.
NOTE: Clause 7 to 10 are required for the units adopt R32/R290 Refrigerant.
Page 5
WARNING
11.
For all electrical work, follow all local and national wiring standards, regulations, and the
Installation Manual. You must use an independent circuit and single outlet to supply power. Do
not connect other appliances to the same outlet. Insufficient electrical capacity or defects in
electrical work can cause electrical shock or fire.
12.
For all electrical work, use the specified cables. Connect cables tightly, and clamp them securely to
prevent external forces from damaging the terminal. Improper electrical connections can overheat
and cause fire, and may also cause shock.
13.
14.
15.
16.
All wiring must be properly arranged to ensure that the control board cover can close properly. If
the control board cover is not closed properly, it can lead to corrosion and cause the connection
points on the terminal to heat up, catch fire, or cause electrical shock.
This appliance can be used by children aged from 8 years and above and persons with reduced
Physical, sensory or mental capabilities or lack of experience and knowledge if they have been given
supervision or instruction concerning use of the appliance in a safe way and understand the hazards
involved. Children shall not play with the appliance. Cleaning and user maintenance shall not be
made by children without supervision.
CAUTION
For units that have an auxiliary electric heater, do not install the unit within 1 meter (3 feet) of
any combustible materials.
Do not
install the unit in a location that may be exposed to combustible gas leaks. If combustible
gas accumulates around the unit, it may cause fire.
Do not operate your air conditioner in a wet room such as a bathroom or laundry room. Too
much exposure to water can cause electrical components to short circuit.
1.
The product must be properly grounded at the time of installation, or electrical shock may occur.
In certain functional environments, such as kitchens, server rooms, etc., the use of specially designed
air-conditioning units is highly recommended.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly
qualified persons in order to avoid a hazard.
Note about Fluorinated Gasses
1. This air-conditioning unit contains fluorinated gasses. For specific information on the type of gas
and the amount, please refer to the relevant label on the unit itself.
Compliance with national gas
regulations shall be observed.
2. Installation, service, maintenance and repair of this unit must be performed by a certified technician.
3. Product uninstallation and recycling must be performed by a certified technician.
4. If the system has a leak-detection system installed, it must be checked for leaks at least every 12 months.
When the unit is checked for leaks, proper record-keeping of all checks is strongly recommended.
2. Install drainage piping according to the instructions in this manual. Improper drainage may cause
water damage to your home and property.
3.
The appliance shall be stored so as to prevent mechanical damage from occurring.
4. Any person who is involve with working on or breaking into a refrigerant circuit should hold a
current valid certificate from an industry-accredited assessment authority, which authorizes
their competence to handle refrigerants safely in accordance with an industry recognized
assessment specification.
Name
Shape Quantity
1
1
1
(for cooling & heating
models only)
Clip anchor
Mounting plate fixing
screw ST3.9 X 25
Remote controller
Fixing screw for remote
controller holder ST2.9 x 10
Remote controller holder
Dry battery AAA.LR03
Seal
Drain joint
Mounting plate
1
Accessories
The air conditioning system comes with the following accessories. Use all of the installation
parts and accessories to install the air conditioner. Improper installation may result in water
leakage, electrical shock and fire, or cause the equipment to fail.
5
5
2
1
Optional
Parts
2
Page 6
WARNING
2
2
2
2
2
2
1
1
1
Owner’s manual
Installation manual
Remote controller
illustration
Page 7
Name
Shape Quantity
Parts you must purc hase.
Consult the dealer about
the pipe size.
Connecting pipe
assembly
Liquid side
Gas side
Φ
6.35( 1/4 i n)
Φ9.52( 3/8in)
Φ9.52( 3/8in)
Φ12.7( 1/2in)
Φ 16( 5/8in)
IMPORTANT NOTE:
Read this manual carefully before installing
or operating your new air conditioning
unit. Make sure to save this manual for
future reference.
AIR CO NDITIO NER
REM OTE CONT ROLLE R ILLUS TRATIO N
Appliance shall be stored in a well -ventilated area where the room size corresponds to the
room area as specifiec for operation.
For R32 frigerant models:
Appliance shall be installed, operated and stored in a room with a floor area larger than 4m .
Appliance shall not be installed in an unvertilated space, if that space is smaller than 4m .
For R290 refrigerant models, the minimum room size needed:
<=9000Btu/h units: 13m
>9000Btu/h and <=12000Btu/h units: 17m
>12000Btu/h and <=18000Btu/h units: 26m
>18000Btu/h and <=24000Btu/h units: 35m
SPLIT-TYPE ROOM AIR CONDITIONER
CS78421-548-754
IMPORTANT NOTE:
Read this manual carefully before installing
or operating your new air conditioning
unit. Make sure to save this manual for
future reference.
Owner’s Manual
Aurora Series
All Model Numbers
SPLIT-TYPE ROOM AIR CONDITIONER
CS78421-548-754
IMPORTANT NOTE:
Read this manual carefully before installing
or operating your new air conditioning
unit. Make sure to save this manual for
future reference.
Installation Manual
Aurora Series
All Model Numbers
Φ
19( 3/4in)
Magnetic ring and belt
N*
* means that according to the
actual quantity.
1 2 3
(if supplied and packed with the
accessories, please refer to the
wiring diagram to install it on the
connective cable. )
Pass the belt through
the hole of the Magnetic
ring to fix it on the cable
Page 8
Installation
Overview
Installation Summary - Indoor Unit
2
Select Installation Location
(Page 11)
Attach Mounting Plate
(Page 12)
Drill Wall Hole
(Page 12)
Determine Wall Hole Position
(Page 12)
1 2
3 4
12cm
(4.75in)
2.3m (90.55in)
12cm
(4.75in)
15cm (5.9in)
Page 9
Installation
Overview
Mount Indoor Unit
(Page 18)
STEP
8
Wrap Piping and Cable
(not applicable for some locations in the US )
(Page 18)
Connect Piping
(Page 25)
Connect Wiring
(Page 17)
Prepare Drain Hose
(Page 14)
5 6 7
8
9
Page 10
Unit Parts
3
Installation
Overview
Fig. 3.1
NOTE ON ILLUSTRATIONS
Illustrations in this manual are for explanatory purposes. The actual shape of your indoor
unit may be slightly different. The actual shape shall prevail.
NOTE: The installation must be performed in accordance with the requirement of local and
national standards. The installation may be slightly different in different areas.
Wall Mounting Plate
Power Cable (Some Units)
Refrigerant Piping
Signal Cable
Remote Controller
Drainage Pipe
Louver
Remote controller Holder
(Some Units)
Functional Filter (On Front of
Main Filter - Some Units)
Front Panel
Outdoor Unit Power Cable
(Some Units)
1
2
3
4
5
6
7
8
9
10
11
（1）（2）
1
2
3
4
6
7
8
9
10
11
Air-break switch
3
1
2
4
5
6
7
8
11
5
Page 11
Indoor Unit Installation
4
Installation Instructions – Indoor
Unit
PRIOR TO INSTALLATION
Before installing the indoor unit, refer to the
label on the product box to make sure that the
model number of the indoor unit matches the
model number of the outdoor unit.
Step 1: Select installation location
Before installing the indoor unit, you must
choose an appropriate location. The following
are standards that will help you choose an
appropriate location for the unit.
Proper installation locations meet the
following standards:
Good air circulation
Convenient drainage
Noise from the unit will not disturb other
people
Firm and solid—the location will not vibrate
Strong enough to support the weight of the
unit
A location at least one meter from all other
electrical devices (e.g., TV, radio, computer)
DO NOT install unit in the following
locations:
Near any source of heat, steam, or
combustible gas
Near flammable items such as curtains or
clothing
Near any obstacle that might block air
circulation
Near the doorway
In a location subject to direct sunlight
NOTE ABOUT WALL HOLE:
If there is no fixed refrigerant piping:
While choosing a location, be aware that you
should leave ample room for a wall hole (see
Drill wall hole for connective piping step)
for the signal cable and refrigerant piping
that connect the indoor and outdoor units.
The default position for all piping is the right
side of the indoor unit (while facing the unit).
However, the unit can accommodate piping to
both the left and right.
Indoor Unit
Installation
Fig. 3.1-a
Page 12
Refer to the following diagram to ensure proper distance from walls and ceiling:
Step 2: Attach mounting plate to wall
The mounting plate is the device on which you
will mount the indoor unit.
1.
Remove the screw that attaches the mounting
plate to the back of the indoor unit.
2.
Place the mounting plate against the wall
in a location that meets the standards in
the Select Installation Location step. (See
Mounting Plate Dimensions for detailed
information on mounting plate sizes.)
3.
Drill holes for mounting screws in places that:
• have studs and can support the weight of
the unit
• correspond to screw holes in the mounting
plate
4.
Secure the mounting plate to the wall with
the screws provided.
5.
Make sure that mounting plate is flat against
the wall.
NOTE FOR CONCRETE OR BRICK WALLS:
If the wall is made of brick, concrete, or similar
material, drill 5mm-diameter (0.2in-diameter)
holes in the wall and insert the sleeve anchors
provided. Then secure the mounting plate to
the wall by tightening the screws directly into
the clip anchors.
Step 3: Drill wall hole for connective piping
You must drill a hole in the wall for refrigerant
piping, the drainage pipe, and the signal cable
that will connect the indoor and outdoor units.
1.
Determine the location of the wall hole based
on the position of the mounting plate. Refer
to Mounting Plate Dimensions on the
next page to help you determine the optimal
position. The wall hole should have a 65mm
(2.5in) diameter at least, and at a slightly
lower angle to facilitate drainage.
CAUTION
When drilling the wall hole, make sure to
avoid wires, plumbing, and other sensitive
components.
Indoor Unit
Installation
Fig. 3.1-b
12cm (4.75in)
or more
2.3m (90.55in) or more
12cm (4.75in)
or more
15cm (5.9in) or more
2.
Using a 65mm (2.5in) or 90mm(3.54in)
(depending on models )core drill, drill a
hole in the wall. Make sure that the hole
is drilled at
a slight downward angle, so
that the outdoor end of the hole is lower
than the indoor end by about 5mm to 7mm
(0.2-0.275in). This will ensure proper water
drainage. (See Fig. 3.2)
3.
Place the protective wall cuff in the hole. This
protects the edges of the hole and will help
seal it when you finish the installation process.
42QHB020N8-1/42QHB026N8-1/42QHB035N8-1
42QHB050N8-1/42QHB070N8-1
42QHB080N8-1/42QHB090N8-1
Page 14
Indoor Unit
Installation
CAUTION
Be extremely careful not to dent or damage the piping while bending them away from the
unit. Any dents in the piping will affect the unit’s performance.
Step 4: Prepare refrigerant piping
The refrigerant piping is inside an insulating
sleeve attached to the back of the unit. You must
prepare the piping before passing it through the
hole in the wall. Refer to the Refrigerant Piping
Connection section of this manual for detailed
instructions on pipe flaring and flare torque
requirements, technique, etc.
1. Based on the position of the wall hole relative
to the mounting plate, choose the side from
which the piping will exit the unit.
2. If the wall hole is behind the unit, keep the
knock-out panel in place. If the wall hole is to
the side of the indoor unit, remove the plastic
knock-out panel from that side of the unit.
(See Fig. 3.3 ). This will create a slot through
which your piping can exit the unit. Use
needle nose pliers if the plastic panel is too
difficult to remove by hand.
3.
Use scissors to cut down the length of the
insulating sleeve to reveal about 15cm (6in)
of the refrigerant piping. This serves two
purposes:
• To facilitate the Refrigerant Piping
Connection process
• To facilitate Gas Leak Checks and enable
you to check for dents
4.
If existing connective piping is already
embedded in the wall, proceed directly to
the Connect Drain Hose step. If there is no
embedded piping, connect the indoor unit’s
refrigerant piping to the connective piping
that will join the indoor and outdoor units.
Refer to the Refrigerant Piping Connection
section of this manual for detailed instructions.
5.
Based on the position of the wall hole
relative to the mounting plate, determine the
necessary angle of your piping.
6.
Grip the refrigerant piping at the base of the
bend.
7.
Slowly, with even pressure, bend the piping
towards the hole. Do not dent or damage the
piping during the process.
NOTE ON PIPING ANGLE
Refrigerant piping can exit the indoor unit from
four different angles:
•
Left-hand side
•
Left rear
•
Right-hand side
•
Right rear
Refer to
Fig. 3.4 for details.
Fig. 3.3
Fig. 3.4
Knock-out Panel
Page 15
Indoor Unit
Installation
Step 5:
Connect drain hose
By default, the drain hose is attached to the left-
hand side of unit (when you’re facing the back
of the unit). However, it can also be attached to
the right-hand side.
1.
To ensure proper drainage, attach the drain
hose on the same side that your refrigerant
piping exits the unit.
2.
Attach drain hose extension (purchased
separately) to the end of drain hose.
3.
Wrap the connection point firmly with Teflon
tape to ensure a good seal and to prevent
leaks.
4.
For the portion of the drain hose that will
remain indoors, wrap it with foam pipe
insulation to prevent condensation.
5.
Remove the air filter and pour a small amount
of water into the drain pan to make sure that
water flows from the unit smoothly.
NOTE ON DRAIN HOSE
PLACEMENT
Make sure to arrange the drain hose
according to
Fig. 3.5.
DO NOT
kink the drain hose.
DO NOT
create a water trap.
DO NOT
put the end of drain hose in
water or a container that will collect
water.
PLUG THE UNUSED DRAIN HOLE
To prevent unwanted leaks you must plug
the unused drain hole with the rubber plug
provided.
CORRECT
Make sure there are no
kinks or dent in drain
hose to ensure proper
drainage.
NOT CORRECT
Kinks in the drain hose
will create water traps.
NOT CORRECT
Do not place the end
of the drain hose in
water or in containers
that collect water. This
will prevent proper
drainage.
NOT CORRECT
Kinks in the drain hose
will create water traps.
Fig. 3.5
Fig. 3.6
Fig. 3.7
Fig. 3.8
Page 16
Indoor Unit
Installation
BEFORE PERFORMING ELECTRICAL WORK, READ THESE REGULATIONS
1.
All wiring must comply with local and national electrical codes, and must be installed by a
licensed electrician.
2.
All electrical connections must be made according to the Electrical Connection Diagram
located on the panels of the indoor and outdoor units.
3.
If there is a serious safety issue with the power supply, stop work immediately. Explain your
reasoning to the client, and refuse to install the unit until the safety issue is properly resolved.
4.
Power voltage should be within 90-110% of rated voltage. Insufficient power supply can
cause malfunction, electrical shock, or fire.
5.
If connecting power to fixed wiring, install a surge protector and main power switch with a
capacity of 1.5 times the maximum current of the unit.
6.
If connecting power to fixed wiring, a switch or circuit breaker that disconnects all poles and
has a contact separation of at least 1/8in (3mm) must be incorporated in the fixed wiring. The
qualified technician must use an approved circuit breaker or switch.
7.
Only connect the unit to an individual branch circuit outlet. Do not connect another appliance
to that outlet.
8.
Make sure to properly ground the air conditioner.
9.
Every wire must be firmly connected. Loose wiring can cause the terminal to overheat,
resulting in product malfunction and possible fire.
10.
Do not let wires touch or rest against refrigerant tubing, the compressor, or any moving parts
within the unit.
11.
If the unit has an auxiliary electric heater, it must be installed at least 1 meter (40in) away
from any combustible materials.
WARNING
BEFORE PERFORMING ANY ELECTRICAL OR WIRING WORK, TURN OFF THE MAIN POWER
TO THE SYSTEM.
Page 17
Indoor Unit
Installation
Step 6: Connect signal cable
The signal cable enables communication between
the indoor and outdoor units. You must first
choose the right cable size before preparing it for
connection.
Cable Types
•
Indoor Power Cable
(if applicable):
H05VV-F or H05V2V2-F
•
Outdoor Power Cable:
H07RN-F
•
Signal Cable: H07RN-F
Minimum Cross-Sectional Area of
Power and Signal Cables
Other Regions
Rated Current of
Appliance (A)
Nominal Cross-Sectional
Area (mm²)
> 3 and ≤ 6 0.75
> 6 and ≤ 10 1
> 10 and ≤ 16 1.5
> 16 and ≤ 25 2.5
> 25 and ≤ 32 4
> 32 and ≤ 40 6
CHOOSE THE RIGHT CABLE SIZE
The size of the power supply cable, signal
cable, fuse, and switch needed is determined
by the maximum current of the unit. The
maximum current is indicated on the nameplate
located on the side panel of the unit. Refer to
this nameplate to choose the right cable, fuse,
or switch.
TAKE NOTE OF FUSE SPECIFICATIONS
The air conditioner’s circuit board (PCB) is
designed with a fuse to provide overcurrent
protection. The specifications of the fuse
are printed on the circuit board, such as:
Indoor unit: T5A/250VAC
Outdoor unit(applicalbe to units adpot
R32 or R290 refrigerant only):
T20A/250VAC(<=18000Btu/h units)
T30A/250VAC(>18000Btu/h units)
NOTE: The fuse is made of ceramic.
1.
Prepare the cable for connection:
a.
Using wire strippers, strip the rubber jacket
from both ends of signal cable to reveal
about 40mm (1.57in) of the wires inside.
b.
Strip the insulation from the ends of the
wires.
c.
Using wire crimper, crimp u-type lugs on
the ends of the wires.
PAY ATTENTION TO LIVE WIRE
While crimping wires, make sure you clearly
distinguish the Live (“L”) Wire from other wires.
2. O
pen front panel of the indoor unit.
3.
Using a screwdriver, open the wire box cover
on the right side of the unit. This will reveal
the terminal block.
Terminal block
Wire cover
Screw
Cable clamp
WARNING
4.
Unscrew the cable clamp below the terminal
block and place it to the side.
Fig. 3.9
The Wiring Diagram is located
on the inside of the indoor unit’s
wire cover.
North America
Appliance Amps (A)
AWG
10 18
13 16
18 14
25 12
30 10
ALL WIRING MUST PERFORMED STRICTLY
IN ACCORDANCE WITH THE WIRING
DIAGRAM LOCATED ON THE INSIDE OF THE
INDOOR UNIT S WIRE COVER.
’
Page 18
Indoor Unit
Installation
5.
Facing the back of the unit, remove the plastic
panel on the bottom left-hand side.
6. Feed the signal wire through this slot, from
the back of the unit to the front.
7. Facing the front of the unit, match the wire
colors with the labels on the terminal block,
connect the u-lug and and firmly screw each
wire to its corresponding terminal.
CAUTION
DO NOT MIX UP LIVE AND NULL WIRES
This is dangerous, and can cause the air
conditioning unit to malfunction.
8.
After checking to make sure every connection
is secure, use the cable clamp to fasten the
signal cable to the unit. Screw the cable clamp
down tightly.
9.
Replace the wire cover on the front of the
unit, and the plastic panel on the back.
NOTE ABOUT WIRING
Step 7: Wrap piping and cables
Before passing the piping, drain hose, and the
signal cable through the wall hole, you must
bundle them together to save space, protect
them, and insulate them.
1.
Bundle the drain hose, refrigerant pipes, and
signal cable according to Fig. 3.10.
Indoor Unit
Space behind unit
Refrigerant piping
Drain hose
Signal wire
Insulation tape
DRAIN HOSE MUST BE ON BOTTOM
Make sure that the drain hose is at the bottom
of the bundle. Putting the drain hose at the
top of the bundle can cause the drain pan
to overflow, which can lead to fire or water
damage.
DO NOT INTERTWINE SIGNAL CABLE WITH
OTHER WIRES
While bundling these items together, do not
intertwine or cross the signal cable with any
other wiring.
2.
Using adhesive vinyl tape, attach the drain
hose to the underside of the refrigerant pipes.
3.
Using insulation tape, wrap the signal wire,
refrigerant pipes, and drain hose tightly
together. Double-check that all items are
bundled in accordance with Fig. 3.10.
DO NOT WRAP ENDS OF PIPING
When wrapping the bundle, keep the ends
of the piping unwrapped. You need to access
them to test for leaks at the end of the
installation process (refer to Electrical Checks
and Leak Checks section of this manual).
Step 8: Mount indoor unit
If you installed new connective piping to the
outdoor unit, do the following:
1.
If you have already passed the refrigerant
piping through the hole in the wall, proceed
to Step 4.
2.
Otherwise, double-check that the ends of the
refrigerant pipes are sealed to prevent dirt or
foreign materials from entering the pipes.
3.
Slowly pass the wrapped bundle of refrigerant
pipes, drain hose, and signal wire through the
hole in the wall.
4.
Hook the top of the indoor unit on the upper
hook of the mounting plate.
5.
Check that unit is hooked firmly on mounting
by applying slight pressure to the left and
right-hand sides of the unit. The unit should
not jiggle or shift.
6.
Using even pressure, push down on the
bottom half of the unit. Keep pushing down
until the unit snaps onto the hooks along the
bottom of the mounting plate.
7.
Again, check that the unit is firmly mounted
by applying slight pressure to the left and the
right-hand sides of the unit.
Fig. 3.10
THE WIRING CONNECTION PROCESS MAY
DIFFER SLIGHTLY BETWEEN UNITS.
Page 19
Indoor Unit
Installation
If refrigerant piping is already embedded in
the wall, do the following:
1.
Hook the top of the indoor unit on the upper
hook of the mounting plate.
2.
Use a bracket or wedge to prop up the unit,
giving you enough room to connect the
refrigerant piping, signal cable, and drain
hose. Refer to Fig. 3.11 for an example.
Fig. 3.11
Fig. 3.12
Move to left or right
30-50mm
(1.2-1.95in)
30-50mm
(1.2-1.95in)
3.
Connect drain hose and refrigerant piping
(refer to Refrigerant Piping Connection
section of this manual for instructions).
4.
Keep pipe connection point exposed to
perform the leak test (refer to Electrical
Checks and Leak Checks section of this
manual).
5.
After the leak test, wrap the connection point
with insulation tape.
6.
Remove the bracket or wedge that is propping
up the unit.
7.
Using even pressure, push down on the
bottom half of the unit. Keep pushing down
until the unit snaps onto the hooks along the
bottom of the mounting plate.
UNIT IS ADJUSTABLE
Keep in mind that the hooks on the mounting plate are smaller than the holes on the back of the
unit. If you find that you don’t have ample room to connect embedded pipes to the indoor unit, the
unit can be adjusted left or right by about 30-50mm (1.25-1.95in), depending on the model. (See
Fig. 3.12
.)
Page 20
Outdoor Unit Installation
5
Outdoor Unit
Installation
evoba )ni42( mc06
60cm (24in)
on right
30cm (12in)
on left
120cm (79in)
in front
20cm (12in)
from back wall
Installation Instructions – Outdoor
Unit
Step 1: Select installation location
Before installing the outdoor unit, you must
choose an appropriate location. The following
are standards that will help you choose an
appropriate location for the unit.
Proper installation locations meet the
following standards:
Meets all spatial requirements shown in
Installation Space Requirements (Fig. 4.1)
Good air circulation and ventilation
Firm and solid—the location can support the
unit and will not vibrate
Noise from the unit will not disturb others
Protected from prolonged periods of direct
sunlight or rain
DO NOT
install unit in the following locations:
Near an obstacle that will block air inlets
and outlets
Near a public street, crowded areas, or
where noise from the unit will disturb others
Near animals or plants that will be harmed
by hot air discharge
Near any source of combustible gas
In a location that is exposed to large
amounts of dust
In a location exposed to a excessive amounts
of salty air
Fig. 4.1
Page 21
SPECIAL CONSIDERATIONS FOR EXTREME
WEATHER
If the unit is exposed to heavy wind:
Install unit so that air outlet fan is at a 90°
angle to the direction of the wind. If needed,
build a barrier in front of the unit to protect it
from extremely heavy winds.
See Fig. 4.2 and Fig. 4.3 below.
Strong wind
Strong wind
Strong wind
If the unit is frequently exposed to heavy
rain or snow:
Build a shelter above the unit to protect
it from the rain or snow. Be careful not to
obstruct air flow around the unit.
If the unit is frequently exposed to salty air
(seaside):
Use outdoor unit that is specially designed to
resist corrosion.
Step 2: Install drain joint
Heat pump units require a drain joint. Before
bolting the outdoor unit in place, you must install
the drain joint at the bottom of the unit. Note
that there are two different types of drain joints
depending on the type of outdoor unit.
If the drain joint comes with a rubber seal
(see Fig. 4.4 - A ), do the following:
1.
Fit the rubber seal on the end of the drain joint
that will connect to the outdoor unit.
2.
Insert the drain joint into the hole in the base
pan of the unit.
3.
Rotate the drain joint 90° until it clicks in place
facing the front of the unit.
4.
Connect a drain hose extension (not included)
to the drain joint to redirect water from the
unit during heating mode.
If the drain joint doesn’t come with a rubber
seal (see Fig. 4.4 - B ), do the following:
1.
Insert the drain joint into the hole in the base
pan of the unit. The drain joint will click in
place.
2.
Connect a drain hose extension (not included)
to the drain joint to redirect water from the
unit during heating mode.
Seal
Drain joint
(A) (B)
Base pan hole of
outdoor unit
Seal
IN COLD CLIMATES
In cold climates, make sure that the drain hose
is as vertical as possible to ensure swift water
drainage. If water drains too slowly, it can
freeze in the hose and flood the unit.
Fig. 4.2
Fig. 4.3
Fig. 4.4
Outdoor Unit
Installation
Wind Baffle
38QHB020N8-1/38QHB026N8-1/
38QHB035N8-1
38QHB050N8-1/38QHB070N8-1
38QHB090N8-138QHB080N8-1/
Page 23
If you will install the unit on a wall-mounted
bracket , do the following:
CAUTION
Before installing a wall-mounted unit, make
sure that the wall is made of solid brick,
concrete, or of similarly strong material. The
wall must be able to support at least four
times the weight of the unit.
1.
Mark the position of bracket holes based on
dimensions in the Unit Mounting Dimensions
chart.
2.
Pre-drill the holes for the expansion bolts.
3.
Clean dust and debris away from holes.
4.
Place a washer and nut on the end of each
expansion bolt.
5.
Thread expansion bolts through holes in
mounting brackets, put mounting brackets
in position, and hammer expansion bolts into
the wall.
6.
Check that the mounting brackets are level.
7.
Carefully lift unit and place its mounting feet
on brackets.
8.
Bolt the unit firmly to the brackets.
TO REDUCE VIBRATIONS OF WALL-
MOUNTED UNIT
If allowed, you can install the wall-mounted
unit with rubber gaskets to reduce vibrations
and noise.
Step 4: Connect signal and power cables
The outside unit’s terminal block is protected by
an electrical wiring cover on the side of the unit.
A comprehensive wiring diagram is printed on
the inside of the wiring cover.
BEFORE PERFORMING
ELECTRICAL WORK,
READ THESE REGULATIONS
1.
All wiring must comply with local and
national electrical codes, and must be
installed by a licensed electrician.
2.
All electrical connections must be made
according to the Electrical Connection
Diagram located on the side panels of the
indoor and outdoor units.
3.
If there is a serious safety issue with the
power supply, stop work immediately. Explain
your reasoning to the client, and refuse
to install the unit until the safety issue is
properly resolved.
4.
Power voltage should be within 90-110% of
rated voltage. Insufficient power supply can
cause electrical shock or fire.
5.
If connecting power to fixed wiring, install a
surge protector and main power switch with
a capacity of 1.5 times the maximum current
of the unit.
6.
If connecting power to fixed wiring, a switch
or circuit breaker that disconnects all poles
and has a contact separation of at least 1/8in
(3mm) must be incorporated in the fixed
wiring. The qualified technician must use an
approved circuit breaker or switch.
7.
Only connect the unit to an individual branch
circuit outlet. Do not connect another
appliance to that outlet.
8.
Make sure to properly ground the air
conditioner.
9.
Every wire must be firmly connected. Loose
wiring can cause the terminal to overheat,
resulting in product malfunction and possible
fire.
10. Do not
let wires touch or rest against
refrigerant tubing, the compressor, or any
moving parts within the unit.
11.
If the unit has an auxiliary electric heater, it
must be installed at least 1 meter (40in) away
from any combustible materials.
Outdoor Unit
Installation
Page 24
WARNING
1.
Prepare the cable for connection:
USE THE RIGHT CABLE
•
Indoor Power Cable (if applicable): H05VV-F
or H05V2V2-F
•
Outdoor Power Cable: H07RN-F
•
Signal Cable: H07RN-F
Minimum Cross-Sectional Area of
Power and Signal Cables
Other Regions
Rated Current of
Appliance (A)
Nominal Cross-
Sectional Area (mm²)
> 3 and ≤ 6 0.75
> 6 and ≤ 10 1
> 10 and ≤ 16 1.5
> 16 and ≤ 25 2.5
> 25 and ≤ 32 4
> 32 and ≤ 40 6
a. Using wire strippers, strip the rubber
jacket from both ends of cable to reveal
about 40mm (1.57in) of the wires inside.
b. Strip the insulation from the ends of the
wires.
c. Using a wire crimper, crimp u-lugs on the
ends of the wires.
PAY ATTENTION TO LIVE WIRE
While crimping wires, make sure you clearly
distinguish the Live (“L”) Wire from other wires.
2.
Unscrew the electrical wiring cover and
remove it.
3.
Unscrew the cable clamp below the terminal
block and place it to the side.
4.
Match the wire colors/labels with the labels on
the terminal block, and firmly screw the u-lug
of each wire to its corresponding terminal.
5.
After checking to make sure every connection
is secure, loop the wires around to prevent
rain water from flowing into the terminal.
6.
Using the cable clamp, fasten the cable to the
unit. Screw the cable clamp down tightly.
7.
Insulate unused wires with PVC electrical tape.
Arrange them so that they do not touch any
electrical or metal parts.
8.
Replace the wire cover on the side of the unit,
and screw it in place.
Outdoor Unit
Installation
Cover
Outdoor Unit Wiring Diagram
is located on the inside of the
wire cover on the outdoor unit.
Fig. 4.6
BEFORE PERFORMING ANY ELECTRICAL
OR WIRING WORK, TURN OFF THE MAIN
POWER TO THE SYSTEM.
WARNING
ALL WIRING MUST PERFORMED STRICTLY
IN ACCORDANCE WITH THE WIRING
DIRGRAM LOCATED INSIDE THE OUTDOOR
UNIT S WIRE COVER.
’
North America
Appliance Amps (A)
AWG
10 18
13 16
18 14
25 12
30 10
2.6kW/3.5kW
5.0kW/7.0kW
9.0kW
Page 26
DO NOT DEFORM PIPE
WHILE CUTTING
Be extra careful not to damage, dent, or
deform the pipe while cutting. This will
drastically reduce the heating efficiency
of the unit.
Step 2: Remove burrs
Burrs can affect the air-tight seal of refrigerant
piping connection. They must be completely
removed.
1.
Hold the pipe at a downward angle to prevent
burrs from falling into the pipe.
2.
Using a reamer or deburring tool, remove all
burrs from the cut section of the pipe.
Pipe
Reamer
Point down
Step 3: Flare pipe ends
Proper flaring is essential to achieve an airtight
seal.
1.
After removing burrs from cut pipe, seal
the ends with PVC tape to prevent foreign
materials from entering the pipe.
2.
Sheath the pipe with insulating material.
3.
Place flare nuts on both ends of pipe. Make
sure they are facing in the right direction,
because you can’t put them on or change
their direction after flaring. See
Fig. 5.3.
Flare nut
Copper pipe
4.
Remove PVC tape from ends of pipe when
ready to perform flaring work.
5.
Clamp flare form on the end of the pipe.
The end of the pipe must extend beyond the
edge of the flare form in accordance with the
dimensions shown in the table below.
Fig. 5.2
Fig. 5.3
Fig. 5.4
Refrigerant
Piping
Connection
PIPING EXTENSION BEYOND FLARE FORM
Outer Diameter of
Pipe (mm)
A (mm)
Min. Max.
Ø 6.35 (Ø 0.25”) 0.7 (0.0275”) 1.3 (0.05”)
Ø 9.52 (Ø 0.375”)
1.0 (0.04”) 1.6 (0.063”)
Ø 12.7 (Ø 0.5”) 1.0 (0.04”) 1.8 (0.07”)
Ø 16 (Ø 0.63”)
Ø 19 (Ø 0.75”)
2.0 (0.078”) 2.2 (0.086”)
2.0 (0.078”) 2.4 (0.094”)
Flare form
Pipe
A
Fig. 5.5
Page 27
6.
Place flaring tool onto the form.
7.
Turn the handle of the flaring tool clockwise
until the pipe is fully flared.
8.
Remove the flaring tool and flare form, then
inspect the end of the pipe for cracks and
even flaring.
Step 4: Connect pipes
When connecting refrigerant pipes, be careful
not to use excessive torque or to deform the
piping in any way. You should first connect the
low-pressure pipe, then the high-pressure pipe.
MINIMUM BEND RADIUS
When bending connective refrigerant piping,
the minimum bending radius is 10cm. See
Fig.5.6.
≥10cm (4in)Radius
Instructions for Connecting Piping to
Indoor Unit
1.
Align the center of the two pipes that you will
connect. See Fig. 5.7
.
Indoor unit tubing Flare nut Pipe
2.
Tighten the flare nut as tightly as possible by
hand.
3.
Using a spanner, grip the nut on the unit
tubing.
4.
While firmly gripping the nut on the unit
tubing, use a torque wrench to tighten the
flare nut according to the torque values in the
Torque Requirements table below. Loosen
the flaring nut slightly, then tighten again.
Fig. 5.6
Fig. 5.7
Fig. 5.8
Refrigerant
Piping
Connection
TORQUE REQUIREMENTS
Outer Diameter of Pipe (mm) Tightening Torque (N•cm)Add. Tightening Torque (N•cm)
Ø 6.35 (Ø 0.25”) 1,500 (11lb•ft) 1,600 (11.8lb•ft)
Ø 9.52 (Ø 0.375”) 2,500 (18.4lb•ft) 2,600 (19.18lb•ft)
Ø 12.7 (Ø 0.5”) 3,500 (25.8lb•ft)3,600 (26.55lb•ft)
Ø 16 (Ø 0.63”)
Ø 19 (Ø 0.75”)
4,500 (33.19lb•ft)
6,500 (47.94lb•ft)
4,700 (34.67lb•ft)
6,700 (49.42lb•ft)
DO NOT USE EXCESSIVE TORQUE
Excessive force can break the nut or damage the refrigerant piping. You must not exceed torque
requirements shown in the table above.
Page 28
Instructions for Connecting Piping
to Outdoor Unit
USE SPANNER TO GRIP MAIN
BODY OF VALVE
Torque from tightening the flare nut can snap
off other parts of valve.
Refrigerant
Piping
Connection
1.
Unscrew the cover from the packed valve on
the side of the outdoor unit. (See Fig. 5.9)
2.
Remove protective caps from ends of valves.
3.
Align flared pipe end with each valve, and
tighten the flare nut as tightly as possible by
hand.
4.
Using a spanner, grip the body of the valve.
Do not grip the nut that seals the service
valve. (See Fig. 5.10)
5.
While firmly gripping the body of the valve,
use a torque wrench to tighten the flare nut
according to the correct torque values.
6.
Loosen the flaring nut slightly, then tighten
again.
7.
Repeat Steps 3 to 6 for the remaining pipe.
Fig. 5.9
Fig. 5.10
Valve cove
Page 29
Air Evacuation
7
Preparations and Precautions
Air and foreign matter in the refrigerant circuit
can cause abnormal rises in pressure, which
can damage the air conditioner, reduce its
efficiency, and cause injury. Use a vacuum pump
and manifold gauge to evacuate the refrigerant
circuit, removing any non-condensable gas and
moisture from the system.
Evacuation should be performed upon initial
installation and when unit is relocated.
BEFORE PERFORMING EVACUATION
Check to make sure that both high-
pressure and low-pressure pipes between
the indoor and outdoor units are
connected properly in accordance with the
Refrigerant Piping Connection section of
this manual.
Check to make sure all wiring is connected
properly.
Evacuation Instructions
Before using the manifold gauge and vacuum
pump, read their operation manuals to familiarize
yourself with how to use them properly.
Manifold Gauge
Compound gauge
-76cmHg
Low pressure valve
High pressure
valve
Pressure hose /
Charge hose
Charge hose
Vacuum
pump
Pressure gauge
Low pressure valve
1.
Connect the charge hose of the manifold
gauge to service port on the outdoor unit’s
low pressure valve.
2.
Connect another charge hose from the
manifold gauge to the vacuum pump.
MC MC
Fig. 6.1
Air Evacuation
3.
Open the Low Pressure side of the manifold
gauge. Keep the High Pressure side closed.
4.
Turn on the vacuum pump to evacuate the
system.
5.
Run the vacuum for at least 15 minutes, or
until the Compound Meter reads -76cmHG
(-10 Pa).
5
Page 30
6.
Close the Low Pressure side of the manifold
gauge, and turn off the vacuum pump.
7.
Wait for 5 minutes, then check that there
has been no change in system pressure.
8.
If there is a change in system pressure, refer
to Gas Leak Check section for information
on how to check for leaks. If there is no
change in system pressure, unscrew the cap
from the packed valve (high pressure valve).
9.
Insert hexagonal wrench into the packed valve
(high pressure valve) and open the valve by
turning the wrench in a 1/4 counterclockwise
turn. Listen for gas to exit the system, then
close the valve after 5 seconds.
10.
Watch the Pressure Gauge for one minute
to make sure that there is no change in
pressure. The Pressure Gauge should read
slightly higher than atmospheric pressure.
Flare nut
Cap
Valve body
Valve stem
11.
Remove the charge hose from the service port.
12.
Using hexagonal wrench, fully open both the
high pressure and low pressure valves.
13.
Tighten valve caps on all three valves (service
port, high pressure, low pressure) by hand.
You may tighten it further using a torque
wrench if needed.
OPEN VALVE STEMS GENTLY
When opening valve stems, turn the hexagonal
wrench until it hits against the stopper. Do not
try to force the valve to open further.
Note on Adding Refrigerant
ADDITIONAL REFRIGERANT PER PIPE LENGTH
Connective Pipe
Length (m)
Air Purging
Method
Additional Refrigerant
< Standard pipe length Vacuum Pump N/A
> Standard pipe
length
Vacuum Pump
Liquid Side: Ø 6.35 (ø 0.25”)
R32:
(Pipe length – standard length) x 12g/m
(Pipe length – standard length) x 0.13oZ/ft
Liquid Side: Ø 9.52 (ø 0.375”)
R32:
(Pipe length – standard length) x 24g/m
(Pipe length – standard length) x 0.26oZ/ft
CAUTION
DO NOT
mix refrigerant types.
Fig. 6.2
Air Evacuation
Some systems require additional charging depending on pipe lengths. The standard pipe length varies
according to local regulations. For example, in North America, the standard pipe length is 7.5m (25’).
In other areas, the standard pipe length is 5m (16‘). The refrigerant should be charged from the
service port
on the outdoor unit’s low pressure valve.
The additional refrigerant to be charged can be
calculated using the following formula:
Page 31
Electrical and Gas Leak Checks
8
Electrical Safety Checks
After installation, confirm that all electrical wiring
is installed in accordance with local and national
regulations, and according to the Installation
Manual.
BEFORE TEST RUN
Check Grounding Work
Measure grounding resistance by visual detection
and with grounding resistance tester. Grounding
resistance must be less than 0.1Ω.
Note: This may not be required for some
locations in the US.
DURING TEST RUN
Check for Electrical Leakage
During the Test Run, use an electroprobe and
multimeter to perform a comprehensive electrical
leakage test.
If electrical leakage is detected, turn off the unit
immediately and call a licensed electrician to find
and resolve the cause of the leakage.
Note: This may not be required for some
locations in the US.
Gas Leak Checks
There are two different methods to check for gas
leaks.
Soap and Water Method
Using a soft brush, apply soapy water or liquid
detergent to all pipe connection points on the
indoor unit and outdoor unit. The presence of
bubbles indicates a leak.
Leak Detector Method
If using leak detector, refer to the device’s
operation manual for proper usage instructions.
AFTER PERFORMING GAS LEAK CHECKS
After confirming that the all pipe connection
points DO NOT leak, replace the valve cover on
the outside unit.
Electrical and Gas
Leak Checks
WARNING – RISK OF
ELECTRIC SHOCK
ALL WIRING MUST COMPLY WITH LOCAL
AND NATIONAL ELECTRICAL CODES,
AND MUST BE INSTALLED BY A LICENSED
ELECTRICIAN.
Page 32
Test Run
9
Before Test Run
Only perform test run after you have completed
the following steps:
•
Electrical Safety Checks – Confirm that
the unit’s electrical system is safe and
operating properly
•
Gas Leak Checks – Check all flare nut
connections and confirm that the system is
not leaking
•
Confirm that gas and liquid (high and low
pressure) valves are fully open
Test Run Instructions
You should perform the Test Run for at least 30
minutes.
1.
Connect power to the unit.
2.
Press the ON/OFF button on the remote
controller to turn it on.
3.
Press the MODE button to scroll through the
following functions, one at a time:
•
COOL – Select lowest possible temperature
•
HEAT – Select highest possible temperature
4.
Let each function run for 5 minutes, and
perform the following checks:
List of Checks to Perform PASS/FAIL
No electrical leakage
Unit is properly grounded
All electrical terminals
properly covered
Indoor and outdoor units
are solidly installed
All pipe connection
points do not leak
Outdoor
(2):
Indoor
(2):
Water drains properly
from drain hose
All piping is properly
insulated
Unit performs COOL
function properly
Unit performs HEAT
function properly
Indoor unit louvers
rotate properly
Indoor unit responds to
remote controller
Test Run
Page 33
Test Run
DOUBLE-CHECK PIPE CONNECTIONS
During operation, the pressure of the
refrigerant circuit will increase. This may
reveal leaks that were not present during your
initial leak check. Take time during the Test
Run to double-check that all refrigerant pipe
connection points do not have leaks. Refer to
Gas Leak Check section for instructions.
5.
After the Test Run is successfully completed,
and you confirm that all checks points in List
of Checks to Perform have PASSED, do the
following:
a.
Using remote control, return unit to
normal operating temperature.
b.
Using insulation tape, wrap the indoor
refrigerant pipe connections that you
left uncovered during the indoor unit
installation process.
IF AMBIENT TEMPERATURE IS BELOW 17°C
(63°F)
You can’t use the remote controller to turn
on the COOL function when the ambient
temperature is below 17°C. In this instance,
you can use the MANUAL CONTROL button
to test the COOL function.
1.
Lift the front panel of the indoor unit, and
raise it until it clicks in place.
2.
The MANUAL CONTROL button is located
on the right-hand side of the unit. Press it 2
times to select the COOL function. See
Fig.8.1
.
3.
Perform Test Run as normal.
Fig. 8.1
Manual control button
Page 34
European Disposal Guidelines
10
This appliance contains refrigerant and other potentially hazardous materials. When disposing of
this appliance, the law requires special collection and treatment. Do not dispose of this product as
household waste or unsorted municipal waste.
When disposing of this appliance, you have the following options:
• Dispose of the appliance at designated municipal electronic waste collection facility.
• When buying a new appliance, the retailer will take back the old appliance free of charge.
• The manufacturer will take back the old appliance free of charge.
• Sell the appliance to certified scrap metal dealers.
Special notice
Disposing of this appliance in the forest or other natural surroundings endangers your health and is
bad for the environment. Hazardous substances may leak into the ground water and enter the food
chain.
Disposal
Information
Page 35
Information Servicing
(Required for the units adopt R32/R290 Refrigerant only)
11
Information
Servicing
1. Checks to the area
3. General work area
4. Checking for presence of refrigerant
5. Presence of fire extinguisher
If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate
fire extinguishing equipment shall be available to hand. Have a dry power or CO2 fire extinguisher
adjacent to the charging area.
7. Ventilated area
Ensure that the area is in the open or that it it adequately ventilated before breaking into the system
or conducting any hot work. A degree of ventilation shall continue during the period that the work is
carried out. The ventilation should safely disperse any released refrigerant and preferably expel it
externally into the atmosphere.
8. Checks to the refrigeration equipment
Where electrical components are being changed, they shall be fit for the purpose and to the correct
specification. At all times the manufacturer s maintenance and service guidelines shall be followed.
If in doubt consult the manufacturer s technical department for assistance. The following checks shall
be applied to installations using flammable refrigerants:
6. No ignition sources
No person carrying out work in relation to a refrigeration system which involves exposing any pipe
work that contains or has contained flammable refrigerant shall use any sources of ignition in such a
manner that it may lead to the risk of fire or explosion. All possible ignition sources, including cigarette
smoking, should be kept sufficiently far away from the site of installation, repairing, removing and
disposal, during which flammable refrigerant can possibly be released to the surrounding space. Prior
to work taking place, the area around the equipment is to be surveyed to make sure that there are
no flammable hazards or ignition risks. NO SMOKING signs shall be displayed.
2. Work procedure
All mintenance staff and others working in the local area shall be instructed on the nature of work
being carried out. work in confined sapces shall be avoided. The area around the work space shall
be sectioned off. Ensure that the conditions within the area have been made safe by control of
flammable material.
Prior to beginning work on systems containing flammable refrigerants, safety checks are necessary
to ensure that the risk of ignition is minimised. For repair to the refrigerating system, the following
precautions shall be complied with prior to conducting work on the system.
Works shall be undertaken under a controlled procedure so as to minimise the risk of a
flammable gas or vapour being present while the work is being performed.
The area shall be checked with an appropriate refrigerant detector prior to and during work,
to ensure the technician is aware of potentially flammable atmospheres. Ensure that the leak
detection equipment being used is suitable for use with flammable refrigerants, i.e. no sparking,
adequately sealed or intrinsically safe.
,,
,,
,
,
Page 36
Information
Servicing
,
9. Checks to electrical devices
10. Repairs to sealed components
the charge size is in accordance with the room size within which the refrigerant containing
parts are installed;
the ventilation machinery and outlets are operating adequately and are not obstructed;
if an indirect refrigerating circuit is being used, the secondary circuits shall be checked
for the presence of refrigerant; marking to the equipment continues to be visible and
legible.
marking and signs that are illegible shall be corrected;
refrigeration pipe or components are installed in a position where they are unlikely to be
exposed to any substance which may corrode refrigerant containing components, unless
the components are constructed of materials which are inherently resistant to being
corroded or are suitably protected against being so corroded.
Repair and maintenance to electrical components shall include initial safety checks and
component inspection procedures. If a fault exists that could compromise safety, then no
electrical supply shall be connected to the circuit until it is satisfactorily dealt with. If the fault
cannot be corrected immediately but it is necessary to continue operation, and adequate
temporary solution shall be used. This shall be reported to the owner of the equipment so all
parties are advised.
Initial safety checks shall include:
that capacitors are discharged: this shall be done in a safe manner to avoid possibility of
sparking
that there no live electrical components and wiring are exposed while charging, recovering
or purging the system;
that there is continuity of earth bonding.
10.1 During repairs to sealed components, all electrical supplies shall be disconnected from the
equipment being worked upon prior to any removal of sealed covers, etc. If it is absolutely
necessary to have an electrical supply to equipment during servicing, then a permanently
operating form of leak detection shall be located at the most critical point to warn of a
potentially hazardous situation.
10.2 Particular attention shall be paid to the following to ensure that by working on electrical
components, the casing is not altered in such a way that the level of protection is affected.
This shall include damage to cables, excessive number of connections, terminals not made
to original specification, damage to seals, incorrect fitting of glands, etc.
Ensure that apparatus is mounted securely.
Ensure that seals or sealing materials have not degraded such that they no longer serve
the purpose of preventing the ingress of flammable atmospheres. Replacement parts shall
be in accordance with the manufacturer s specifications.
NOTE: The use of silicon sealant may inhibit the effectiveness of some types of leak detection
equipment. Instrinsically safe components do not have to be isolated prior to working on them.
Page 37
Information
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11. Repair to intrinsically safe components
Do not apply any permanent inductive or capacitance loads to the circuit without ensuring
that this will not exceed the permissible voltage and current permitted for the equipment in
use. Intrinscially safe components are the only types that can be worked on while live in the
presence of a flammable atmosphere. The test apparatus shall be at the correct rating.
Replace components only with parts specified by the manufacturer. Other parts may result
in the ignition of refrigerant in the atmosphere from a leak.
12. Cabling
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp
edges or any other adverse environmental effects. The check shall also take into account the
effects of aging or continual vibration from sources such as compressors or fans.
15. Removal and evacuation
When breaking into the refrigerant circuit to make repairs of for any other purpose
conventional procedures shall be used, However, it is important that best practice is followed
since flammability is a consideration. The following procedure shall be adhered to:
remove refrigerant;
purge the circuit with inert gas;
evacuate;
purge again with inert gas;
open the circuit by cutting or brazing.
The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be
flushed with OFN to render the unit safe. This process may need to be repeated several times.
Compressed air or oxygen shall not be used for this task.
Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to
fill until the working pressure is achieved, then venting to atmosphere, and finally pulling down
to a vacuum. This process shall be repeated until no refrigerant is within the system.
13. Detection of flammable refrigerants
Under no circumstances shall potential sources of ignition be used in the searching for or
detection of refrigerant leaks. A halide torch(or any other detector using a naked flame)
shall not be used.
14. Leak detection methods
The following leak detection methods are deemed acceptable for systems containing flammable
refrigerants. Electronic leak detectors shall be used to detect flammable refrigerants, but the
sensitivity may not be adequate, or may need re-calibration.(Detection equipment shall be
calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition
and is suitable for the refrigerant. Leak detection equipment shall be set at a percentage of the
LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate
percentage of gas (25% maximum) is confirmed. Leak detection fluids are suitable for use with
most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine
may react with the refrigerant and corrode the copper pipe-work.
If a leak is suspected ,all naked flames shall be removed or extinguished. If a leakage of refrigernat
is found which requires brazing, all of the refrigerant shall be recovered from the system, or
isolated(by means of shut off valves) in a part of the system remote from the leak . Oxygen free
nitrogen(OFN) shall then be purged through the system both before and during the brazing process.
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17. Decommissioning
Before carrying out this procedure, it is essential that the technician is completely familiar
with the equipment and all its detail. It is recommended good practice that all refrigerants
are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall
be taken.
In case analysis is required prior to re-use of reclaimed refrigerant. It is essential that
electrical power is available before the task is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically
c) Before attempting the procedure ensure that:
mechanical handling equipment is available, if required, for handling refrigerant cylinders;
all personal protetive equipment is available and being used correctly;
the recovery process is supervised at all times by a competent person;
recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from
various parts of the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with manufacturer s instructions.
h) Do not overfill cylinders. (No more than 80% volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure that
the cylinders and the equipment are removed from site promptly and all isolation valves
on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigeration system unless it has
been cleaned and checked.
16. Charging procedures
In addition to conventional charging procedures, the following requirements shall be followed:
Ensure that contamination of different refrigerants does not occur when using charging
equipment. Hoses or lines shall be as short as possible to minimize the amount of
refrigerant contained in them.
Cylinders shall be kept upright.
Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
Label the system when charging is complete(if not already).
Extreme care shall be taken not to overfill the refrigeration system.
Prior to recharging the system it shall be pressure tested with OFN. The system shall be
leak tested on completion of charging but prior to commissioning. A follow up leak test
shall be carried out prior to leaving the site.
,
When the final OFN charge is used, the system shall be vented down to atmospheric pressure
to enable work to take place. This operation is absolutely vital if brazing operations on the
pipe-work are to take place.
Ensure that the outlet for the vacuum pump is not closed to any ignition sources and there
is ventilation available.
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1. Transport of equipment containing flammable refrigerants
Compliance with the transport regulations
2. Marking of equipment using signs
Compliance with local regulations
3. Disposal of equipment using flammable refrigerants
Compliance with national regulations
4. Storage of equipment/appliances
The storage of equipment should be in accordance with the manufacturer’s instructions.
5. Storage of packed (unsold) equipment
Storage package protection should be constructed such that mechanical damage to the
equipment inside the package will not cause a leak of the refrigerant charge.
The maximum number of pieces of equipment permitted to be stored together will be
determined by local regulations.
20. Transportation, marking and storage for units
18. Labelling
Equipment shall be labelled stating that it has been de-commissioned and emptied of
refrigerant. The label shall be dated and signed. Ensure that there are labels on the
equipment stating the equipment contains flammable refrigerant.
19. Recovery
When removing refrigerant from a system, either for service or decommissioning, it is
recommended good practice that all refrigerants are removed safely.
When tranferring refrigerant into cylinders, ensure that only appropriate refrigerant
recovery cylinders are employed. Ensure that the correct numbers of cylinders for holding
the total system charge are available. All cylinders to be used are designated for the
recovered refrigerant and labelled for that refrigerant(i.e special cylinders for the
recovery of refrigerant). Cylinders shall be complete with pressure relief valve and
associated shut-off valves in good working order.
Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions
concerning the equipment that is at hand and shall be suitable for the recovery of
flammable refrigerants. In addition, a set of calibrated weighing scales shall be available
and in good working order.
Hoses shall be complete with leak-free disconnect couplings and in good condition. Before
using the recovery machine, check that it is in satisfactory working order, has been
properly maintained and that any associated electrical components are sealed to prevent
ignition in the event of a refrigerant release. Consult manufacturer if in doubt.
The recovered refrigerant shall be returned to the refrigerant supplier in the correct
recovery cylinder, and the relevant Waste Transfer Note arranged. Do not mix refrigerants
in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been
evacuated to an acceptable level to make certain that flammable refrigerant does not
remain within the lubricant. The evacuation process shall be carried out prior to retruning
the compressor to the suppliers. Only electric heating to the compressor body shall be
employed to accelerate this process. When oil is drained from a system, it shall be carried
out safely.
product improvement. Consult with the sales agency or manufacturer for details.
The design and specifications are subject to change without prior notice for
