2011 DVM_Installation Guide

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Contents 1. General installation Guide 1. Introduction Introduction ······································································· 2. Product Product Outline Outline·································································· ·································································· 3. DVM design design pro process cess ························································· 4. Instal Installation lation process & Guideline········································· 5. Installation Procedure Procedure ························································

4 5 7 8 9

2. Preparation for installation 1. Checking Checking the Install Installation ation Site ·········································· 25 2. Product Product hand handling ling ····························································· 29 3. Materials Materials and To Tools ols ························································· 39

3. Guideline for each installation process

1. Sleeve work ····································································· 2. Insert work and support support work ·········································· 3. Concealed Concealed Box wo work rk ······················································· 4. Refrigerant Refrigerant pipe co constructi nstruction on ·········································· 5. Refrigerant pipe flushing flushing ·················································· 6. Drainpipe Work································································ 7. Insulation Insulation work ································································ 8. Gas leak test···································································· 9. Vacuum drying································································· 10. Charging Charging Refrige Refrigerant······················································ rant······················································

47 49 51 52 71 73 82 84 86 88

 

 

4. Indoor Units installation 1. Ceiling Ceiling Cass Cassette ette Typ Type e (1WA (1WAY/2W Y/2WAY/ AY/4WAY 4WAY)) ···· ·· ···· ···· ···· ···· ···· ···· ···· ····· ····· ···· 90 2. Duct Type ((Slim/MS Slim/MSP)······················································ P)······················································ 96 3. Ceiling ··········································································· 106 4. Console Console ········································································· 109 5. Wall-mounted Wall-mounted T Type ype ······················································· 111

5. Outdoor Units installation 1. Safety Information Information ························································ 114 2. Prepar Preparing ing the Installa Installation tion ················································ 115 3. Selecting Proper Location for Installation ······················· 117 4. Space Requireme Requirements nts ······················································ 118 5. Base Mount Constru Construction ction ··············································· 120 6. Drain Pipe Install Installation ation ····················································· 123 7. Exhaus Exhaustt Duct Installation ················································ 124 8. Installing the Outdoor Unit Harsh Environments ············· 125 9. Louve Louverr Installation Installation ·························································· 127 10. Electri Electrical cal Wiring Work ··················································· 128 11. Pump-D Pump-Down own Operation Operation ················································· 133 12. Pump-Out Procedure ··················································· 134 13. Setting the Option Switches & Function Keys ·············· 135 14. Completing the Installation and Commissioning ······ ··········· ····· 136

 

1. General installation Guide

 

1. Introduction  The diagram below illustrates overall configuration of the refrigerant piping for installing a system air conditioner. Multiple outdoor units with variable capacity control are installed in a location with good air ventilation for cooling and heating and a vibration-proof rubber mat is installed in the bottom of the outdoor unit to prevent vibration from being transferred to the building. The refrigerant pipe and the communication cable from the outdoor unit penetrate the outer wall of the building before reaching the inner area of the building. When penetrating the outer wall of the building, sleeves should be used to prevent air leakage and support water proofing. The refrigerant pipes and electrical wiring works for the indoor unit should be finished by fixing the indoor unit in a level or perpendicular location. In the refrigerant pipe works, you should pay attention to installation of insulation materials as well as branch pipes and its slope. You should also make efforts to remove all alien substances from the inner area of the pipe.  To apply an air conditioning system for the building, you must first design the overall air conditioning system and select components such as outdoor units and indoor units and refer to the construction design diagram in order to prepare a diagram for installing an air conditioning system. System air conditioner installation vendors should refer to the provided construction diagram when preparing a diagram for installation and purchasing components.

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Installation guide

 

2. Product Outline 2-1. Outdoor Units Samsung provides you the perfectly optimized cooling and heating system with its latest and most innovative technology. World’s largest capacity will provide you the powerful performance all year long, no matter how hot or how cold. Furthermore, Samsung’s Samsung’s outdoor units barely make any noise o orr vibration during operations, and they are perfect for residential and commercial buildings, Always stay refreshed with Samsung system air conditioner.

1)   DVM PLUS III, DVM PLUS III HR  DVM PLUS III, DVM PLUS III HR is a module multi-system air conditioner that has the world's largest capacity(8~64HP) with the application a pplication of a DVI (Digital Vapor Injection) compressor, compressor, and can connect up to a maximum of 64 indoor units.



• • • • •

 The world's wor ld's lar larges gestt c capa apa cit cityy. - Compact combinations (8~64 hp) : combinations with the models requiring the smallest installation space - High combinations (16~56 combinations with highly efficient models  The hig highest hest COP lev levels els in thehp) indust ind: ustry ry  The smalle sma llest st ins instal tallat lation ion space spa ce requirem requ irement ent in t he world worl d  The highest high est heatin hea ting gc capa apacit cityy an and d COP in llow ow tempe tem perat rature ure cond iti ition on (-1 (-10°c 0°c)) Possible to connect up to 64 indoor units Digital unit module

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1. General installation Guide

 

2-2. Indoor Units Samsung indoor units are not only equipped with high performing functions, but they are also beautifully designed to enlighten your space. Different types of indoor units will be more than enough to satisfy needs of your space and yourself. Only Samsung’s beautiful indoor units will provide you the conditioned air that you can enjoy.

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Installation guide

 

3. DVM design process DVM is a variable multi air conditioner that modulates its performance by different conditions such as design temperature, indoor and outdoor unit combination rates, heating operation rates, piping length, and level difference. It is important to select the appropriate design condition to the load of each room.

• • •





 Design

temperature  Calculate cooling and heating loads  Power supply, piping length and level difference

  Consider design temperature conditions to select larger indoor types than actual load.

  Determine outdoor units by the sum of the capacity of preliminary selected indoor units: At this time, decide how much combination ratio to permit.









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Calculate actual capacity of outdoor units considering design temperature, indoor and outdoor unit combination ratio, piping length, level difference, heating operation rates, etc.

  Calculate actual capacity of each indoor unit based on the calculated outdoor capacity.

 If Indoor units’ actual capacity is lower than the load, reselect ones with a larger capacity. Depending on designers’ own discretion.   If there is no indoor unit with a larger capacity, add another indoor unit.

 

1. General installation Guide

 

4. Installation process & Guideline Striking a balance between System Installation & General Construction Work. 

.

 

Note: 1. Work scope should

be thoroughly clarified. (This applies particularly to work relating to the connection of control wiring, fitting of remote controller and central ce ntral control panel, boundary work on areas such as connection c onnection of drain piping and humidification supply piping, inspection and foundation) 2. Keep a constant check on the progress of the construction work to avoid deviations from the air conditioning work schedule. 3. For sleeve and insert i nsert work the positions of ceiling girders should be confirmed and sleeve and insert requirement, hole diameters, positioning and numbers decided. This is particularly important in the case of sleeves for drain piping.

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Installation guide

5. Installation Procedure 5-1. Procedure

indicates the order order in which which the individual work operations operations are normally normally Note  The above list indicates carried out but this order may be varied according to the local conditions.

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1. General installation Guide

 

5-2. Step by Step Installation Procedure 1)   Refrigerant piping (1) Pre-estimation with the drawing Picture 

Work Description

Things to do

Measure the actual Check what and how much you prepare for construction installation. drawing.

Check point

Fully familiarize with the diagram to prevent problems while working on the site.

(2) Straightening the refrigerant pipe Picture 

Work Description

Straighten the refrigerant pipe.

Things to do

Considering the job site condition, measure the accurate length to cut.

Check point

- Remove sharp object or something that can cause deformation of the pipe in advance. - Do not apply excessive force for straightening the pipe.

(3) Marking Picture 

Work Description

Things to do

Check point

Consider the diagram and  Accurate marking Compare the marked area with the actual site condition of the length. the diagram accurately. when marking it.

(4) Cutter (cutting) Picture 

Work Description

Things to do

Check point

- Use proper Size & Quality Cutting tool

Use a copper cutter to cut it.

- Do not apply excessive force. (Prevent deformation of the pipe.) 

10

While cutting the copper pipe, check for deformation of the pipe.

 

 

Installation guide

  (5) Pipe cutting Picture 

Work Description

Things to do

Check point - Check if foreign substances

Prevent foreign Cut the pipe.

substances from entering the pipe.

are removed from the pipe. (If foreign substances are found, it can cause performance degradation and malfunctions.)

(6) Removing burr Picture  

Work Description

Removing burr

Things to do

- Remove burrs so that the cut side of the pipe is smooth. - Remove burr in a downward direction to

Check point

Check for burr residuals in the pipe.

keep foreign substances from entering the pipe.

(7) Taping Picture 

Work Description

 Taping

Things to do

Check point

 Tape the pipe to keep foreign substances from Check if taping is done firmly. entering the pipe.

(8) Ready for piping works Picture 

Work Description

Work completed.

Things to do

Check point

Store the pipe in a safe place Store it in a safe place to not affected by other works. prevent damage. Remove all other substances from surroundings.

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1. General installation Guide

 

(9) Anchor works Picture 

Work Description

Refer to the approved construction diagram when marking the indoor unit installation locations and make a hole for anchor installation.

Things to do

Check point

Familiarize with the construction diagram.

- Prevent scattering.

- Accurate location marking

- Safeguard against falling accidents.

- Use a reel wire support.

(10) Full threads bolt and C-channel fixing Picture 

Work Description

Fixing the full threads bolt and the c-channel.

Things to do

Prevent twisting of the pipe. Do not damage the insulation materials.

Check point

Check for pipe damage. Check interferences. Obey the separation of the channels. (1.2 to 1.5 meter)

2) Refrigerant pipe construction (branch pipe works) (1) Preparing a branch pipe Picture 

Work Description

Preparing a branch pipe. 

Things to do

Check point

Check for damage in the Prepare a branch pipe.  branch pipes. 

(2) Connecting the branch pipes Picture 

Work Description

Connecting the branch pipes.

Things to do

Check point

Check the connection. When making a Use Branch kit for the pipe connection, do not apply connection. excessive force that might damage the pipe. (Damage and exterior tests on the branch pipes.)

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Installation guide

  (3) Brazing the branch pipes Picture 

Work Description

Things to do

Check point

- Nitrogen substituted brazing works on the Brazing the branch pipe.

branch pipe to prevent generation of foreign substance/oxide - Check for adequate pressure (0.01 to 2 0.1kg/cm )

Check the pressure and entry of nitrogen.

3) Refrigerant pipe works (air tightness works) (1) Entry of nitrogen Picture 

Work Description

Entry of nitrogen. Inject nitrogen to the pipe to test leakages.

Things to do

Inject nitrogen at the proper pressure. st

2

1 : 10kg/cm   nd

Check point

In the presence of the manager, check air tightness. Fill out the check forms.

2

2 : 41kg/cm  

(2) Finishing the end of the pipe Picture 

Work Description  

Wrap the end of the pipe before connecting the equipment, so

Things to do

Sufficient brazing on the end of the pipe.

Check point

 Visual inspection

that won’tnitrogen escape.

(3) Pressure gauge attached Picture 

Work Description

st

Mark the 1  and nd 2  pressure to see if it leaks.

Things to do

st

Check point

2

1 : 10kg/cm   nd

2

2 : 28kg/cm  look at the scale.

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Check for leakages.

 

1. General installation Guide

 

(4) Insulation of the branch pipe Picture 

Work Description

Things to do

Check point

Insulate the pipe if there is no nitrogen leakage.

Check for leakages.

Check for leakages.

(5) Insulation of the branch pipe Picture 

Work Description

Insulation of the branch pipe

Things to do

Check point

Dense fill up to prevent Check the insulation missing insulation material condition. and swelling.

(6) Slope adjustment of the branch pipe Picture 

Work Description

Check the levelness of the pipe.

Things to do

Do not exceed the levelness limit of 15 degrees.

Check point

Check the levelness condition.

4) Drainpipe construction (1) Inserting insulation materials Picture 

Work Description

Things to do

Insert the insulation Do not damage the materials into the insulation materials.  PVC pipe.

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Check point

- Check for damage in the insulation materials.  - Check for damage in the pipe.

 

 

Installation guide

(2) Mounting the drainpipe Picture 

Work Description

Fix the drainpipe in the channel or hanger.

Things to do

 A group of two person should work on the pipe (not using excessive force).

Check point

Check the channel/hanger fixing intervals (1.5m or less)

(3) Checking the drain slope Picture 

Work Description

Checking the gradients.

Things to do

Obtain good slope to facilitate smooth drainage of the condensed water. (1/100)

Check point

Check the slope.

(4) Pipe connection Picture 

Work Description

Connect the pipes, checking thoroughly if there is leakage on it

Things to do

 Apply sufficient bond to the pipe.

Check point

- Do not install in the winter season.

(5) Pipe connection and socket works on the indoor i ndoor unit side Picture 

Work Description

Use the drainpipe components for the indoor unit side.

Things to do

Check the height and maintain the drain slope while do the drain pipe work

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Check point

Check the height.

 

1. General installation Guide

 

(6) Pipe work on the indoor unit side Picture 

Work Description

Pipe work on the indoor unit side.

Things to do

Secure a slope (1/100)

Check point

Check the slope.

(7) Air vent installation Picture 

Work Description

Install a vent to facilitate smooth

Things to do

Install one unit at the end of the equipment.

Check point

Check vents installation.

drainage of water.

(8) Water containing test Picture 

Work Description

Pour the water in the highest point to test it.

Things to do

Check the pipe slope. If there is a problem, readjust the slope.

Check point

Check the slope and test water leakage.

(9) Connecting the vertical pipe   Picture 

Work Description

If there is no problem in the above items, connect the vertical pipe.

Things to do

- Secure bonding works. - Insulation works

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Check point

Must check the pipe pit’s inner area before finishing the wall.

 

 

Installation guide

5) Power communication works (1) Power cable pipe works Picture 

Work Description

Place a power cable pipe in the correct location.

Things to do

Use Standard quality materials.

Check point

Check for bending of the pipe.

(2) Inserting cables Picture 

Work Description

Insert the standard power communication cable in the pipe.

Things to do

Be careful not to damage the cable while

Check point

Check the cable condition.

inserting it.

6) Indoor unit installation (1) Location determination Picture 

Work Description

Select an accurate location (check the diagram and on-site measurement)

Things to do

Fully familiarize with the diagram and mark accurate locations. Select a location with a

Check point

Check if it is in accordance with the diagram.

laser point.

(2). Fastener / Anchor Bolt Picture 

Work Description

 Anchor works on accurate points.

Things to do

- Anchor drilling - Full threads bolts mounting

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Check point

Check the condition of the full thread bolts.

 

1. General installation Guide

 

(3) Connecting the equipment Picture 

Work Description

Things to do

Mounting an indoor unit.

 A group of two works on the indoor unit.

Check point

Check for levelness of the indoor unit and damage to the indoor unit.

(4) Inserting a vibration-proof rubber mat Picture 

Work Description

Insert a vibration proof rubber mat between the bolt and the indoor unit to prevent transfers

Things to do

Do not allow the vibration proof rubber mat to be inclined toward either side. Do not omit any of them.

Check point

Check the insertion condition of the vibration proof rubber mat.

of the vibration.

(5) Check the horizontal height Picture 

Work Description

 Adjust the horizontal height.

Things to do

Check point

Considering the ceiling Check if the indoor unit finishing line, check your is horizontally flat? installation.

(6) Installation completed Picture 

Work Description

Things to do

Check point

-

-

-

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Installation guide

(7) Connecting the power communication cables Picture 

Work Description

Connect the power communication cable to the indoor unit.

Things to do

Check point

Use a ring terminal to

Check if the ring terminal is

make a connection.

used.

(8) Drain insulation Picture 

Work Description

Pipe insulation works.

Things to do

Do not damage the insulation materials.

Check point

Check the insulation materials and drainage slope.

(9) Wrapping indoor unit  Picture 

Work Description

Indoor unit wrapping.

Things to do

Wrap the indoor unit with polythene to avoid any dust, due to other work progress in the vicinity.

Check point

Check the indoor unit wrapping status.

7) Outdoor unit installation (1) Vibration-proof board installation Picture 

Work Description

Mount the outdoor machine in the correct location by referring to the diagram.

Things to do

- Acquire levelness of the vibration proof board. - Accurate measurement and safe mounting.

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Check point

Check if it is in accordance with the diagram. Check the levelness.

 

1. General installation Guide

 

(2) Conveying the outdoor unit Picture 

Work Description

Things to do

Check point

Checking the

 A group of four move

Check for damages in the

outdoor unit.

the outdoor unit(22HP)

outdoor unit.

(3) Mounting the vibration-proof board Picture 

Work Description

Mounting the vibration-proof board.

Things to do

Install it in the upper area.

Check point

- Do not change the location of the vibrationproof board. - Check the location in the diagram once again.

(4) Connecting the vibration-proof board Picture 

Work Description

Things to do

Connect the outdoor unit to the vibration-proof board.

Bolting of the vibrationproof board.

Check point

Check bolt installation and the final levelness.

(5) Completed installation of outdoor units Picture 

Work Description

Completed installation

Things to do

Reinforce the outdoor unit.

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Check point

Check for reinforcement.

 

 

Installation guide

(6) Connecting the outdoor unit’s pipes Picture 

Work Description

Things to do

Connecting the outdoor unit’s

Connect the pipe to the outdoor unit and

pipe.

perform insulation.

Check point

Check the insulation of the outdoor unit.

(7) Vacuum works Picture 

Work Description

Things to do

Connect a vacuum pump to the service valve of the outdoor unit and create vacuum all (Discharge, Suction

Create vacuum inside the pipe.

Check point

Check the vacuum condition.

& Oil) line.

(8) Checking the vacuum gauge Picture 

Work Description

Things to do

Check the vacuum gauge condition.

Check point

Continue the vacuum.

Check the normal vacuum gauge.

Things to do

Check point

8) Refrigerant charging (1) Refrigerant calculation Picture  

Work Description

 Accurately calculate the amount of refrigerant.

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Estimate the accurate amount of refrigerant from the diagram.

 

1. General installation Guide

 

(2) Refrigerant injection Picture 

Work Description

Things to do

Check point

- Accurate refrigerant injection Refrigerant injection

- Keep the Gas cylinder vertically downward during charging.

Estimate the adequate amount of refrigerant.

(3) Completed injection of refrigerant Picture  

Work Description

Completed injection of refrigerant

Things to do

Check if the amount of injection is accurate.

Check point

Check the adequate amount.

9) Decoration Panel installation (other than the reference floor) (1) Check the levelness of the indoor unit Picture 

Work Description

Things to do

Maintain a distance between

Use a paper pattern to maintain an adequate separation (adjust the

the the ceiling indoor and unit.

height of the indoor unit).

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Check point

Check the levelness of the indoor unit.

 

 

Installation guide

(2) Panel installation Picture 

Work Description

Panel installation

Things to do

Check point

- Do not apply excessive force.

- Check if the exterior is dirty.

- Use a clean glove.

- Check for damage.

(3) Finish Picture 

Work Description

End

Things to do

Check point

Check the levelness and any blade damage.

Check for twisting and test the entire unit.

10) Test operation (1) Indoor unit address setting Picture 

Work Description

 Assign a unique number to the indoor unit.

Things to do

 Assign an accurate address to it.

Check point

Check the address of the indoor unit.

(2) Outdoor unit address setting Picture 

Work Description

 Assign a unique number to the outdoor unit.

Things to do

 Assign an accurate address to it.

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Check point

Check the address to the outdoor unit.

 

1. General installation Guide

 

(3) Connecting a interface module Picture 

Work Description

Connect a interface module to the outdoor unit.

Things to do

 Assign an accurate interface module number.

Check point

Check the interface module number.

(4) Connecting a interface module to S-net Picture 

Work Description

Connecting the Snet program to the interface module.

Things to do

Make a correct cable connection.

Check point

Check the condition of the laptop.

(5) S-net connection Picture 

Work Description

Connecting the S-net terminal to the outdoor unit PCB.

Things to do

Check point

Check for normal condition. If abnormal, inject refrigerant and request services.

Check for normal condition.

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 Prre 2. P

 

aration for installation 

Installation guide

1. Checking the Installation Site Item 

Noise vibration

Pre-check checkpoint 

Handling methods and guideline 

Picture 

- Is the place affected by noises ※ Necessary to install a or vibration at all? soundproof wall to prevent noise transfer to houses. - residential Is the outdoor unit close to a area? -Use a gallery for soundproof - Is the bottom of the outdoor wall constructions. unit affected by vibration? Claims for noises

Weight

- The foundation of outdoor unit is strong enough to withstand the weight of the outdoor unit?

※ In renewal case, onsider the

weight of the outdoor unit and review the columns and the beams for construction. Need to consider the weight.

Outdoor - Which type of base is the unit base most appropriate ?

- Base area size: 1.5 times the floor. - Total height: 150mm↑  Wooden palette installation prohibited. ※ In case of soil sands, the

Outdoor unit base

- Is Is the outdoor unit placed on a flower garden or soil? (Including the foundation.)

ground can get deformed during rain. So make the base with concrete pads or H beams. Ground base

- Is the outdoor unit installed in  Air a disclosed area? circulation ※ Need to determine whether I  to use a discharge duct.

※ CFD (Computational Fluid

Dynamics) simulation is available upon request to HQ Need to improve the air vent structure.

- Is there any blockage Within 2 meters from the discharge plane of the upper area?

※ Need to use a discharge duct.

 Air circulation II - Is there any blockage

within 1.5 meters from the

※ Need to install in a gallery.  

discharge plane of the front area?

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2. Preparation for installation Item 

Louver

Pre-check checkpoint 

- Louver specification is suggested ?

Handling methods and guideline 

Picture 

- Louver angle should be less than 20° - Opening rate of more than 80%. - Select a louver with a smooth cross section. (Do not use a rainwater prevention louver.)

- Can you clear 500mm(20inch) or more from the front of the outdoor unit and 300mm(12inch) or more from  Top discharge the rear? [Tray and interfering pipes unit included.] - Can you access the outdoor unit?

 To secure service area ※ 2 level stacking not allowed.

-Is the service space available? Side discharge unit - Can you have more than 1500mm(60inch) in front of the outdoor unit?

- Possible when the metal frame is used. Height of 300mm(12inch), side of 100mm(4inch) ※ When the front and the rear are

face to face, secure the minimum distance of 3000mm between 2-level stacking prohibited. outdoor units.

- Is the outdoor unit located close to a bathroom/ kitchen vent/cooling tower or air vent? Corrosion in the

- Is the installation location close to a beach or hot spring?

outdoor unit - All units are concentrated in a specific area on a rooftop or in a gallery?

※ Corrosion in the outdoor unit and

the pipe may possibly cause refrigerant leakage -free Select where it is fromother salty location wind and intoxicating gas Installation near toxic gas source is prohibited.

Outdoor - All units are concentrated in a unit ※ Check the CFD simulation. installation specific area on a rooftop or - Request to HQ’s. in a gallery? Where units stand close to each other, it possibly lacks sufficient air circulation

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Installation guide

Item 

Ceiling finishing

Pre-check checkpoint 

Handling methods and guideline 

Picture 

- If the ceiling is made of plaster boards, secure an inspection hole. - What is the finishing material for - If the ceiling is made of ceiling tile, ceiling? then no need to install an inspection hole. ※ Need space at least

- Is the ceiling sunken? - Can you secure an inspection hole for interior finishing? - Did you check the work scope Inspection of access hole installation? hole - Did you notify the access hole size of the duct type indoor unit in advance?

500mm(20inch) away from the equipment to sunken part of. ※ Access hole is necessary for

Duct type indoor unit, ERV, MCU and distribution kit. - Check the inspection hole size for each product.

-

※ Conform to the installation guide

Installation -Is the installation space for the space indoor unit sufficient?

Installation height

of product slope and drain pump’ss pumping limit. pump’ - Drain incline (1/100) - Drain pumping height should be less than 750mm(30inch) from the bottom of the indoor unit.

-

- Is the 4way indoor unit installed ※ If the ceiling height exceeds within 3.5 m(11.5ft) from the 3.5m, then be sure to adopt High ground? Ceiling Kit for 4way cassette Inefficient or poor sensible cooling/heating

 Vertical piping Horizontal piping

- Did you review the path for the ※ Not allowed to install it in the EPS vertical pipe? - Check maximum horizontal st piping length from the 1   branch.

- Maximum vertical height between indoor and outdoor Maximum unit is 50/40* below? vertical Maximum vertical height height between indoor units is 15m below?

room or high voltage room. ※ Avoid to install the brazed joints

and branch pipe in the room.

* As an outdoor unit is located in a lower position than indoor unit, level difference is 40m.

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2. Preparation for installation Item 

Drain

Pre-check checkpoint 

- Any drain pipes wrongly connected with other pipes carrying bad odors?

Handling methods and guideline 

Picture 

※ Do not join rainwater pipes and

sewage water pipes. If unavoidable, then join them below the first floor to prevent

-

reverse flows into the indoor unit.

※ If installed near human residence

Installation - Is the location of the MCU, or location EEV proper?

such as living rooms or indoor, it can generate noise. ※ Do not install it in a fire fighting zone.



※ In case of 3 phase/380V/50Hz,

- Electricity specification is correctly delivered? capacity is Electricity  Amperage-carrying specification fairly enough for the units?

Clarify whether it is 3 or 4 line type. - Ring terminals are to be sized in -

accordance specification.with electricity  Again, indoor unit power consumption to be considered. - Need to check the additional spec of the indoor power.

※ Criteria for selecting a circuit

Circuit breaker

breaker. - Circuit breakers and wires are - Must install a leakage breaker properly sized? Not based on (ELCB) in the indoor unit’s power operating current, but on start- system. up current - Install a leakage breaker (ELCB) for an individual or group of outdoor units.

MCCB

28

ELB

 

 

Installation guide

2. Product handling Problem analysis

 

Product is falling down due to rough or careless handling

of the product during unloading process. Consequence

 

It will cause the product damage/deformation and may also cause motor fixation kit to fall off. Such consequences will interrupt normal operation of the product and lead to noise generation. Furthermore, severe damages to the electrical parts may cause performance decrease and even serious accident which may involve personal injury. 

Standard procedure  

Product is future property of our clients. We must take steps to protect the product while during d uring loading, unloading and transporting process in order to prevent damage and operational/functional problem. 

Proper method

 

When moving the indoor units, you must form a group of 2 people to move the indoor units together. Move the indoor units slowly with extra care and lift it down gently.  You should never drop the indoor units from higher ground or handle them roughly. 

29

 

2. Preparation for installation Problem analysis

   A

chassis of outdoor unit is bent and a heat exchanger of the condenser is damaged due to inappropriate transportation method.

Consequence

 When

moving the product, you must lift up and down the product gently. When the product is scratched, sc ratched, product will corrode or get rust. If the heat exchanger of the condenser gets damaged, it will cause deteriorating performance and even make a leakage from the pipe. 

Standard procedure  Since

the product is valuable, you must take extra care when moving it. You must protect the product from exterior or structure damage. 

Proper method

 When

moving with crane : 1) To prevent the surface damage or scratch while moving the product, put 1.5mm thick cloth or other soft material between the product and rope. 2) Use 4 wire ropes From the figure on the left, A > 1.5m 

30

 

 

Installation guide

Problem analysis  

Product is left alone in the open site. If the ground gets wet with water after rain or due to other reasons, it will cause bad effect on the product.

Consequence

  If

the indoor unit products gets soaked, water will wi ll damage the packaging first and then it may get into the indoor unit and damage the electrical parts. Such damage may cause critical safety trouble. 

Standard procedure

handling the product in the site, you must store them properly. Do not put the product on the ground.  You must use some sort of a support, with certain height, underneath the product to prevent the product from getting soaked in water in case of water floods. 

  When

Proper method   Utilize a

support with at least 200mm(8inch) high above the ground and put the product on top of those supporting structure. 

31

 

2. Preparation for installation Problem analysis

  Pile

of indoor units in the site is too high and some of the

products are even piled up vertically. Consequence

  Pile

may fall down and cause personal injury. Indoor units lying on the bottom of the pile may get damaged due to weight. 

Standard procedure

  Pile

cannot be over 6rows and exceed e xceed 2m(6.5ft) in height. You cannot pile them vertically either. 

Proper method

1. Do not pile the indoor units too high. - When the product is lighter than 50kg, pile cannot be over 6 rows. - When the product is heavier than 50kg, pile cannot be over 3 rows.  2. Height of the pile cannot exceed 2m(6.5ft) and you must put the warning signboard around the pile.  

32

 

 

Installation guide

Problem analysis

  Indoor

units are stored vertically. Not only that, it is left on the ground and the ground is full of water.

Consequence   Pile

may fall down and cause personal injury. Indoor units lying on the bottom of the pile may get damaged due to weight.

  If

the indoor units get soaked, water will damage the packaging first and then it may get into the indoor unit and damage the electrical parts

Standard procedure   Store

the indoor units horizontally. Do not leave them vertically. 

Proper method   Store

the indoor units horizontally (or horizontally piled up) with the supporting structure at least 200mm(8inch) high underneath the product. 

33

 

2. Preparation for installation Problem analysis

  Products

are stored messily in the site and there is no manager in charge.

Consequence

  Products

are bumped into each other and a nd pressed by one another which cause structural deformation. Internal parts of the product may get damaged or even lost. 

Standard procedure

 

When storing the indoor unit : 1. Do not mix different models. 2. Do not leave them upside down. 3. Do not leave them vertically. 4. Do not tilt the indoor units. 5. Do not exceed standard height he ight when storing them in pile. 

Proper method    Assign

exclusive manager to manage.

 And store each models least 200mm(8inch) high. on the supporting structure at

34

 

 

Installation guide

Problem analysis

  Inappropriate

product management caused outer

packaging damage. Consequence    After

damage to the outer packaging of indoor unit, dust and other foreign substances entered to the product. Furthermore, you may lose <Installation manual>, <User manual>, drainpipe or other parts needed for installation. 

Standard procedure  

Strictly regulate the package removal before installing the indoor units. Manage and keep all the related parts and manuals thoroughly. 

Proper method

   After

indoor units arrive in the site, do not remove the package until it is being installed. When removing the package upon the installation of the product, keep the

manuals separately properly. and use other accessories (such as drainpipe)  Take extra care to prevent from losing them. 

35

 

2. Preparation for installation Problem analysis

 

Dust, foreign substances, rain water, industrial water and dew got inside of the indoor unit. Because it was left with all the packaging removed while installation was put on hold.

Consequence

  Dust

and other foreign substances will get inside and cause pipe blockage or other malfunctions. 

Standard procedure

  After

indoor unit arrives in the site, do not remove the packaging until it is being installed. If the installation was stopped or put on hold for any reasons, wrap the indoor units for protection. 

Proper method

  Protect

the indoor unit by wrapping it.  

36

 

 

Installation guide

Problem analysis

Indoor unit, which is still in the middle of the installation process, is hanging on the ceiling cei ling without any protection.

 

Consequence

 

Indoor unit was hanging on the ceiling without any Protection which allows dust and other foreign substances to enter and cause malfunction. mal function. 

Standard procedure

 

Wrap the indoor unit with vinyl 

Proper method

 

Wrap the indoor unit with vinyl if the installation is still in process to prevent dust, foreign substances and water from entering. 

37

 

2. Preparation for installation Problem analysis

  Safety

net is not installed on 4-way cassette indoor unit.

Consequence

 

Safety of client and service agent can be at risk. 

Standard procedure

 

Install the safety net for safety reasons. re asons. 

Proper method

 

Make sure safety net is installed and let the customer know that they must not remove them for their own safety. 

38

 

 

Installation guide

3. Materials and Tools  Problem analysis

 

R410a refrigerant system has relatively high pressure. If material does not meet the pressure-proof standards, then it may cause copper pipe p ipe explosion.

Consequence

 

Intensity and material specification doesn’t meet factory requirement and this could lead to explosion while using the product which could even bring personal injury. 

Standard procedure

  Installation

material requirement Material : phosphorous deoxidized copper, purple copper pipe  Analysis result shows that chemical component should meet the below condition (KSD 1651) Cu ≥ 99.90% ; P : 0.015%~0.040% Mechanical properties need to meet KSD 5301 

Proper method   Selecting

copper pipe C1220T-O(JIS) : Soft type C1220T-1/2H(JIS) C1220T-1/2 H(JIS) : Semi-hard type 

39

 

2. Preparation for installation Problem analysis

  Layer

of carbon, rust and dirty foreign fore ign substances were found on the outer surface of the copper pipe. Pipes must not have any scratches, indents or stains etc.

Consequence

 

Such defects decrease the strength stre ngth of the pipe which may result in explosion or leakage. 

Standard procedure

  You

must select clean and dry copper pipe. Check inside of the pipe for any dust, water, indents or any signs of damage. 

Proper method

  Select

a copper pipe according to the standards. 

40

 

 

Installation guide

Problem analysis

 

Due to inappropriate protection management of the internal/external surface of the copper, large amount of oxidation, dust and foreign substances were seen.

Consequence

  R410a

refrigerant is very sensitive with foreign substances : Mineral oil and compress oil will not solve with each other due to different chemical characteristics.  Therefore, wax type materials may clog the hole of EEV or oil filters. 

Standard procedure   Check

if it is clean enough. Foreign substances in the copper pipe < 30mg/10m   R410a copper pipe must be kept clean until it is installed.  Proper method

 

Select the clean copper pipes and make sure no dust or foreign substances get into the pipe when you keep them. Ifclean the copper pipes are stored for ainstallation long period time, them(blow Nitrogen) before to of remove undesired material from inside of the pipe

41

 

2. Preparation for installation Problem analysis

   After

purchasing the pipe, it was not kept properly so

dust, substances, water industrial waterand got insideforeign of the pipe. Also pipe p ipe wasand left on the ground people just walked on them.

Consequence

  Water

or foreign substances within the pipe will cause blockage that can lead to product malfunction or performance decrease. 

Standard procedure

  When

storing the pipe, use cover c over or tape to block the entrance and do not leave them on the ground but keep them on the supporting structure with at least 30mm in height. 

Proper method

  Strictly

follow the standards. 

42

 

 

Installation guide

Problem analysis

  Thickness

of the pipe does not meet the standards.

Consequence  

Strength and the duration of the pipe will decrease which may cause breakup. Especially, R410a is a high pressure gas. Pipe with less thickness will have less strength, which may cause the pipe breakup. breakup.

Standard procedure

Required thickness – Soft type Outer diameter(mm) Min. Thickness(mm) Ø6.35 0.8 Ø9.52 0.8 Ø12.70 0.8 Ø15.88 1.0 Required thickness – Semi hard type Outer diameter(mm) Min. Thickness(mm) Ø19.05 0.9 Ø22.23 0.9 Ø25.40 1.0 Ø28.58 1.1 Ø31.75 1.1 Ø38.10 1.35 Ø44.45 1.6 Ø50.80 2.0

Proper method

  Select

the pipe according to above specification 

43

 

2. Preparation for installation Problem analysis

  Selecting

ø22.23 copper pipe, and 10mm insulation as shown in the picture.

Consequence

  Low

insulation effect cause large energy consumption and decrease in system performance.   Condensation will easily form and leakage may occur when performing heating operation in regions with high temperature and humidity.

Standard procedure

  Insulation

material and quality must meet the minimum standard thickness requirements.   Good installation will prevent condensation and a nd guarantee air conditioning performance. 

Proper method

  Follow

the below specification strictly and aware of the Minimum thickness requirements.

Pipe size [mm] Ø6.35~19. 05 Ø6.35~19.05 Ø22.23~31.75 Ø38.10 Ø44.45~   The

Minimum thickness of insulation [mm] PE foam EPDM foam 13 10 19 13 25 19 32 25

thickness of insulation must be increased in case of high humid humid conditions (over than than 27°C 27°C and RH 80%) like below place -  Tropical / Subtropical regions or equivalent with this region -  The region where problems due to high temperature and humidity are expected - Restaurant, hot spring, sauna, basement, seaside - Ceiling inside with high humidity humidi ty due to weak ventilation

44

 

 

Installation guide

Problem analysis

 

Regular vacuum pump was used in vacuum vac uum operation.

Consequence

  If

the power of the vacuum pump cuts off unexpectedly then the oil gets back to the refrigerant r efrigerant system due to pressure difference. 

Standard procedure

  Use

the vacuum pump which is 100% dedicated for R410a system with stop valve.  

Proper method

  Purchase

and use the vacuum pump with the stop valve. 

45

 

2. Preparation for installation Problem analysis

  R22

gauge was used in R410a system.

Consequence

  If

you use R22 gauge, remaining oil inside can generate wax type material which definitely badly affect POE oil of R410a system, possibly clogging refrigerant passage or causing compressor failure. 

Standard procedure

  Never

utilize R22 gauge for R410a system to prevent the mineral oil from flowing in to the R410a system.   Use the measuring instruments that meets the standard requirement. High pressure side : -0.1 ~ 5.3MPa Low pressure side : -0.1 ~ 3.8MPa

Proper method

 

Install in accordance with the standards. 

46

 

3. Guideline for each installation process

Installation guide  

1. Sleeve work 1-1. Positioning of the pipe holes 1) The drilling holes for the drain piping should be positioned such that the pipes have a downward gradient. (Theconsideration.) gradient must be at least 1/100. The thickness of the insulation materials must also be taken into 2) The diameter of the drilling holes for the refrigerant piping should incl include ude allowance for the thickness of the insulation materials. 3) Attention should be paid to the construction of the beam themselves since there are sometimes parts of the beam which cannot be used to accommodate drilling holes.

1-2. Selection of sleeve 1) Sleeve work should be performed to make a space for passing pipe and wire through the wall or ground under construction 2) Use of shielded transmission cable is recommended to avoid the problem of electrical noise

3) Depending on the selected product or the installation environment, if the insulation material’s thickness is subject to change, then additional calculations are necessary. Sleeve diameter [mm] = (Liquid pipe diameter+ insulation material thickness x2) + (Gas pipe diameter + insulation material thickness x2) +20 4) Maintain a minimum separation separation of 10m 10mm m between the pipes to facilitate smooth smooth air flows. (To prevent dew forming)

47

 

 

3. Guideline for each installation process  Selection of the refrigerant pipe sleeve’s diameter (a) Classification

Liquid pipe diameter(mm) 6.35 9.52 Insulation (Based on 9t)

12.7

15.88 19.05 Insulation (Based on 13t)

22.22

27.52 80

38.7 91

41.88 94

45.05 97

48.22 101

Gas pipe diameter (mm)

Gas pipe diameter + Insulation (based on 19t)

6.35

32.35

24.35 77

9.52

47.52

92

95

106

109

113

116

12.7

50.7

95

98

109

113

116

119

15.88

53.88

98

101

113

116

119

122

19.05

57.05

101

105

116

119

122

125

22.22

60.22

105

108

119

122

125

128

25.4

63.4

108

111

122

125

128

132

28.58

66.58

111

114

125

128

132

135

31.75

69.75

114

117

128

132

135

138

38.1

76.1

120

124

135

138

141

144

44.45

82.45

127

130

141

144

148

151

※ If the insulation material’s material’s thickness is subject to change depending on the installation location,

you must reselect a new sleeve pipe diameter.

48

 

 

Installation guide

2. Insert work and support work 2-1. Insert work Example  :  : Drilling holes in a reinforced concrete beam

Full thread bolt works

49

 

3. Guideline for each installation process  2-2. Support work 1)  Installation guideline for a vertical vertical piping

▶  Down-stopper fixing guide Height

Fixing interval

1

lower

Fix a pipe every 5m(16.5ft)

If there is a pit, fix a pipe at each floor

Remarks

2

Higher than 15m

Install a down stopper every 3floor or every 15m height

Pipe must be fixed at every 5m

※ How to fix a pipe

- Utilize “U”  shape volt or circular band on the the insulation of the pipe

Fixing with a circular band

Fixing with a Down-stopper  

2)  Down-stopper installation ①  Attaching the Down-stopper to the vertical pipe 

②  Brazing work

 Attaching the down stopper to the vertical pipe

Heat uniformly until a base metal become cherry red in color than apply a filter metal

⑤  Finished sample

④  Insulating a pipe

 Tightly wrap the insulation with a finishing tape

50

③  Assembly of wall contact part

Assembled sample

 

 

Installation guide

3. Concealed Box work 3-1. Concealed Box work 1) Objectives - The concealed box aims at enhancing the interior inside the building by burying the drains, the copper pipes, the insulation materials, and the wires in the earlier phase, when you need to install an indoor unit

2) Functions (1) Buried in the wall on the pipe installation site and connecting the pipes, the drains and the wires. (2) Copper pipe protection, enhancing the exterior. (3) Mounting a pressure gauge to check the air tightness at any time.

Concealed box

Buried box connection board

51

 

3. Guideline for each installation process  4. Refrigerant pipe construction 4-1. Drawing review 1) Compare the actual site with the drawing. When installing the refrigerant pipes, check interferences

and the requirements for each eac h pipe diameter size/length/quantity ahead of time.

Temper grade and minimum thickness of the refrigerant pipe Outer diameter

Minimum thickness

6.35

0.7

9.52

0.7

12.70

0.8

15.88

1.0

19.05

0.9

22.23

0.9

25.40

1.0

28.58

1.1

31.75

1.1

38.10

1.35

44.45

1.6

50.80

2.0

Temper grade

C1220T-O

C1220T-1/2H Or C1220T-H

Make sure to use C1220T-1/2H(Semi-hard) pipe for more than ∮19.05mm. Cautions

In case of using C1220T-O (soft) pipe for ∮19.05mm, pipe may be broken, which whi ch can can result result iin n an an in ur .

(1) Soft or hard pipes (Annealed, Drawn temper)

52

 

 

Installation guide

2) Preparing a pipe  (1) On the drawing, check the pipe diameter/length and the insulation material’s thickness and length. Prepare some margins for the dimension d imension shown in the drawing (to give elastic te tensions), nsions), Use a special cutter to cut the pipes.

3) Check the quantities of the branch pipe/header and the outdoor unit’s branch pipes. (1) Additionally purchased items Type

 Y-joint

 Y-joint (Only for DVM plus Ⅲ HR module)

Header Joint Outdoor Joint Outdoor Joint (Only for DVM plus Ⅲ HR module)

Model

Total capacity

MXJ-YA1509*  MXJ-YA2512*  MXJ-YA2812*  MXJ-YA2815* 

15.0kW below 15.0~40.6kW 40.6~46.4 kW 46.4~69.6 kW

MXJ-YA3119*  MXJ-YA3819*  MXJ-YA4422*  MXJ-YA1500*  MXJ-YA2500*  MXJ-YA3100*  MXJ-YA3800*  MXJ-HA2512*  MXJ-HA3115*  MXJ-HA3819*  MXJ-T3819*  MXJ-T4422*  MXJ-T3100*  MXJ-T3800* 

69.6~98.6 kW 98.6~139.2 kW 139.2 kW and over 23.2kW and below 23.2~69.6 kW 69.6~139.2 kW 139.2 kW and over 46.4kW and below(For 4 rooms) 69.6kW(For 8 rooms) 69.6kW and over (For 8 rooms) 48HP and below 50HP and over 48HP and below 50HP and over

53

 

3. Guideline for each installation process  4-2. Pipe Cutting 1) Burring - When performing burring works, point the pipe face downward to prevent entry of burr.

2) Taping – To prevent entry of moisture or dust, seal off the pipe completely.

54

 

 

Installation guide

Covering is an extremely important operation as it prevents water, dirt or dust from getting inside the pipes. Moisture inside the pipes was a constant source of trouble in the past. The

utmost care is required to nip this problem in the bud. The end of each pieces of pipe must be covered. “Pinching” is the most effective method but

“taping” is an simple alternative al ternative which may be used ac according cording to the work area and term of work. Location

Outdoors Indoors

Term of Work

Covering Method

1 months or more

Pinching

Less than 1 months

Pinching or taping

Irrelevant

Pinching or taping

①  Pinching method  The end of the copper pipe is squeezed together and the gap brazed. ②   Taping method  The end of the copper pipe is covered with PVC tape (vinyl tape).

<Taping method>

Particular care should be taken ta ken during the following operations: When passing copper pipe through a penetration hole (Dirt easily gets into the pipe). When copper pipe is located outside (Rainwater gets in) (Special care is needed when the pipes are standing vertically outside)

55

 

3. Guideline for each installation process  4-3. Insulating the Pipe, the Branch Pipe and the Header 1) Insulating the pipe 

(1) To block off external air, insulate the pipe with insulation material. (2) Insert the insulation material into the pipe and use a special EPDM glue to finish it.

Materials 

The thermal insulation materials which are used must be well able to withstand the heat from the pipes. Example :

Heat pump type: Heat resistant polyethylene foam (heat resistance of at least 120°C) Cooling only: Polyethylene foam (heat resistance of 100°C or more)

Essential Points of Thermal Insulation

 The insulation of jointed areas such as the soldered, flared or flanged sections should only be carried out after the successful completion of the air a ir tight test.  Attention should be paid to the unit model and its operating conditions since there are occasions when the gas and liquid pipes also need to be thermally insulated.

Example of incorrect work

Gas and liquid piping should not be insulated together

Example of correct work Insulation of both gas and li uid i e onl

Insulation of gas pipe only

Jointed areas must also be thoroughly insulated

56

Insulation of support brackets

 

 

Installation guide ▶  Important points

①   The thickness of the thermal insulation material must be determined in the light of the pipe sizes. Pipe size in. (mm) Thickness of insulation material Pipe size in(mm)

Thickness of insulation material

1/4~1 (6.4mm~25.4mm) (6.4mm~25.4mm)

1/2 or more (12.5mm or more)

②  It will be necessary to increase the values in the above table for top floors or where conditions are hot and humid. (Refer to Installation manual "6-5 Pipe insulation" for more detail) detail ) ③  Where a customer supplies his own specifications then these must be adhered to. ④  Where it is anticipated that the air conditioning unit will be operated at external air temperatures of 10°C or less then thermal insulation will also be required for the liquid pipes.

Heat Recovery Series

Suction, Discharge Gas piping, liquid piping must be insulated. Example of thermal insulation work.

3 piping section (between outdoor unit and MCU unit)

2 piping section (between MCU unit and indoor unit)

If you think that the humidity around the cooling piping might exceed 86°F and RH80%, reinforce the insulation on the cooling piping (at least 13/16" thick). Condensation might form on the surface of the insulation. insula tion.

2) Insulating the refrigerant pipe  (1) Insulating the refrigerant  You must check if there is a gas leak before completing all the installation process. Use EPDM insulation which meets the following condition. Item

Unit

Density Dimension change route by heat

g/cm   %

Water absorption rate

Standard

3

0.048~0.096 -5 or less

g/cm  

3

0.005 or less

 Thermal conductivity

kcal/m·h·˚C

0.032 or less

Moisture transpiration factor Moisture transpiration grade

ng/(m²·s·Pa) g/(m²·24h)

15 or less 15 or less

mg/L

-

%

25 or less

Formaldehyde dispersion Oxygen rate

57

 

3. Guideline for each installation process  (2) Selecting the insulation of the refrigerant re frigerant pipe Insulate the gas side and liquid side pipe referring to the thickness according to the pipe size.  The thickness according to the pipe size is calculated at the indoor temperature of 27°C and humidity of 80%. If installing in an unfavorable conditions from it, use thicker one. Pipe size (mm)

Minimum thickness of insulation (mm) Remarks PE foam EPDM foam

ø6.35~19.05

13

10

ø22.23~31.75

19

13

ø38.10

25

19

-

32

25

If you install the pipe underground, at the seaside, a spa or on the lake, use thicker one according to the pipe size.

(3) Insulating the refrigerant pipe Be sure to insulate the refrigerant pipe, joints and connections with class ‘o’ material. If you insulate the pipes, the condensed water does not fall from the pipes and the capacity of the air conditioner is improved. Check if there are any insulation cracks on the bent pipe.

Pipe insulation •



Pipe insulation after insulating EEV kit

 Insulation of the gas and liquid pipes can be in contact with each other but they should not be pressing each other.  When contacting the gas side and liquid side pipe, use thicker insulation.





  When installing the gas side and liquid side pipes, leave 10mm of space.  When contacting the gas side and liquid side pipe, use thicker insulation.

Insulating the refrigerant pipe •

Cautions

 Install the insulation not to be get wider and use the adhesives on the connection part of it to prevent moisture entering.  Wind the refrigerant pipe with insulation tape if it is exposed to outside sunlight.  Install the refrigerant pipe respecting that the





insulation not get thinner on the bent be nt part or hanger does of pipe.

58

 

 

Installation guide

(4) Insulating the branch joint   Y-joint

liquid side of the outdoor unit

 Attach the insulation provided with a branch joint to the insulation purchased individually without a gap. Wrap the connected part with an insulation (purchased in the market) of a thickness of at least 10mm. Use an insulation that should be able to handle the interior temperature over 120°C. Wrap the branch joint with an a n insulation of a thickness of at least 10mm.

  Header

joint

Fasten the header joint using a cable tie and cover the connected part. Insulate the header joint and the brazed part and wrap the connected part with an adhesive insulation tape to prevent it from fr om defrosting. Before starting the insulation work on joints(brazed part), ensure that the e)pressure test is done (no leakage)

Fix the header joint after insulating it.

.

59

 

3. Guideline for each installation process  4-4. Mounting the Pipe, the Branch Pipe and the Header 1) Mounting the insulated pipes. – The liquid/gas pipes should be mounted at the different position horizontally in order not to interfere with each other.

2) Install a hanger before and behind the branch pipe. - Install a hanger before and behind the branch pipe.

60

 

 

Installation guide

3) When installing the branch pipe, pay attention to tthe he following cautionary items.  Horizontally installed

 Vertically installed

 

Install the Y-joint within ±15° on the horizontal or on the vertical. 

Model

Name

MXJ-HA2512 

MXJ-HA3115 

Liquid side

Gas side Insulation (Liquid side/Gas side)

Liquid Side Socket Gas side

61

MXJ-HA3819 

 

3. Guideline for each installation process   Header

joint

①  Select the reducer fitted on the diameter of the pipe.

②  Braze the pipes ends with caps if the number of connected indoor unit is fewer than header

 joint ports.

< Liquid side >



Cautions



• •

< Gas side >

 When using A~J type of header joint, connect the header joint to the pipe with provided reducer.  When using K~Z type of header joint, connect the header joint to the pipe by cutting the provided reducer properly.  Connect the header joint in order respecting the number of the indoor unit.  Connect the indoor unit as the highest capacity comes first.

③  Install the header joint horizontally.

- Install the header joint horizontally so that it is not faci facing ng down.

< Liquid side >

Note

< Gas side >

Incorrect installation of Y-joint and header joint cause poor oil and refrigerant distribution between indoor units. It may decrease the system’s performance or cause compressor failure.

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Installation guide

4) Installing the branch joints   Outdoor

joint

Installation of outdoor joint

Use the attached reducer properly according to the selected pipe size.

<Liquied pipe >  

<Gas pipe, High pressure gas pipe>

Note



 When using A~J type of Outdoor joint, connect the Outdoor joint to the pipe with provided reducer.  When using K~Z type of Outdoor joint, connect the Outdoor joint to the pipe by cutting provided reducer properly.



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3. Guideline for each installation process  4-5. Connecting the Pipe/Branch Pipe 1) Reducer mounting - differences. When connecting the pipes/branch pipes, you need a reducer to compensate for the diameter The following specs are applied.   Y-Joint

Name  

Model

MXJ-YA1509  MXJ-YA2212  MXJ-YA2512  MXJ-YA2815 MXJ-YA3119  MXJ-YA3819 

Liquid side

Gas side Insulation (Liquid side/Gas side) Liquid Side

Socket Gas side

2) Reducer mounting methods

- If the pipe is inserted deep into the reducer, it can cause refrigerant noises, so be careful.

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4-6. Installing the Branch Pipe for the Outdoor Unit 1)  Connecting the outdoor unit pipe Heat Pump Pump  

Connection from front side side  

 First, remove the cover from unit.  Separate the knock-out hole to use. If the hole is open, small animals such as squirrels and rats may get into the unit through the hole and the unit may be damaged.  Fix the pipe cover of bottom side and fix the pipe cover of upper side thereafter.

• •

Working process



Single Installation

Combination installation

Connection from bottom at the left/right side Working process

  Separate the knock-out hole at the bottom side of the unit and install the pipe.  After installing and insulating the pipe, close up the remaining gap. If the gap is remain open, small animals such as rats and squirrels may get inside the unit and cause damage to the unit.





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3. Guideline for each installation process  Heat Recovery Recovery  

Connection from front side side  

Connection from bottom at the left/right side

Single Installation

Combination installation

Cautions

Caution for connecting the pipe   When connecting the pipe to the unit, the unit may get damaged by a brazing fire and a flame. Use a flame proofing cloth to protect the unit from a brazing fire or flame.  Ambient air temperature sensor for detecting outside temperature is located on the left side of the welding part. Make sure not to damage the temperature sensor when welding it.  The O-ring and Teflon packing inside service valve may get damaged by a welding fire. Wrap the bottom side of the service valve with a wet cloth and weld it as shown above. Make sure not to interrupt the brazing with the drops of the wet cl cloth. oth.  The connecting pipes of liquid liqui d side and gas side should not contact each other.  Vibration may cause a damage to the pipes.







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2) Piping works among outdoor units    The additional branch joints are needed for module installation of the outdoor units. When outdoor units are installed in module, there is no designation of outdoor unit’s location according to capacity.  The connected piping should be positioned at the same or lower level with pipe cover hole. Cautions

 The refrigerant piping should be the same level or lower than connecting position of piping to outdoor units.

Piping work should be run with side direction for better uniform distribution of refrigerant and oil like next diagram.

Outdoor joint kits should be installed in a horizontal direction even it is a low pressure pipe.

When the piping length between outdoor and branch  joints is 2m or more, a vertical trap has to be installed like right diagram.

Correct piping work  work 

Wrong piping work  work 

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3. Guideline for each installation process  4-7. Brazing 1) Nitrogen substituted welding (1) Perform nitrogen substituted brazing works.  Brazing

the pipe

Make sure that there is no moisture inside the pipe. Make sure that there are no foreign materials and impurities in the pipe. Make sure that there is no leak. Make sure to follow the instruction when brazing b razing the pipe. The use of Nitrogen gas pipe s as shown ①  Use Nitrogen gas when brazing the pipes

in the picture. ②  If you do not use Nitrogen gas when brazing the pipes, oxide may form inside the pipe. It can cause the damage of the compressor, valves. ③  Adjust the flow rate of the Nitrogen gas with a pressure regulator to maintain 0.05m3/h or less. Direction of the pipe when brazing

Performing the brazing of the pipe should be headed downward or horizontally.

Note 

Avoid brazing the pipe upward.

Nitrogen substitution for prevention of copper pipe corrosions 

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2) Comparison with a case without nitrogen substitution 

With Nitrogen substitution

Without Nitrogen substitution 

3) Be cautious for pipe-to-pipe brazing works Brazing work should be carried out either downwards or sideways.  An upward direction should be avoided.

CAUTION 1. Generally expending pipe brazing is performed with pan-coil type copper pipe, and socket blazing is performed with straight copper pipe. 2. Do not perform flare part brazing or butt-brazing. 3. Brazing should be performed on welding table. 4. No dust should enter in the pipe while brazing. 5. Distance of copper pipe support spacing is within 1~2m. 6. The copper pipe should not be secured directly by metal brackets.

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3. Guideline for each installation process  4-8. Nitrogen Pressurization Test 1) Leakage test Perform individual finishing of the liquid/gas pipe or connect the liquid/gas pipes for pinching and brazing.

 Air tightness test

Nitrogen pressurization, 4MPa

No change in the gauge for 24 hours

2

41kgf/cm (4.1Mpa)pressure maintained

Maintains 4Mpa for 24 hours. If no leakage, then pressure down to 1MPa. Maintain 1Mpa until connecting the outdoor/indoor units. Prevent corrosion in the copper c opper pipes.

Maintain a pressure of 10kgf/cm 2 (1Mpa) 

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5. Refrigerant pipe flushing  Flushing is a method of cleaning extraneous matter out of pipes using pressurized gas.

[3 major effects]

(1) Removal of oxidation bubbles formed inside copper pipes when “nitrogen replacement is insufficient” during brazing work (2) Removal of extraneous material and moisture from pipes when covering has been iinsufficient nsufficient (3) Check connection in pipes linking l inking outdoor and indoor units (Both liquid and gas pipes) [Example of procedure]

(1) Set pressure regulator on nitrogen cylinder. cyli nder. ∗  The gas used must be nitrogen. (There is a danger of condensation if fleon or carbon dioxide are used and oxygen carries the risk of explosions.)

(2) Connect the charge hose from the pressure regulator to the service port on the liquid pipe side of the outdoor unit. (3) Fit blanking plugs to all indoor units (B) other than unit A.

(4) Open the main valve on the nitrogen cylinder and set the pre pressure ssure regulator to 72 psi.

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3. Guideline for each installation process  (5) Check that the nitrogen is passing passi ng through the unit A liquid pipe. (6) Flushing. ①  Block the end of the pipe with the insulation of your hand. ↓ 

②  When the gas pressure becomes too great to contain remove insulation quickly. (First flush) ↓  ③  Block the end of the pipe with insulation again. ↓  (Carry out second flushing)

(The nature and amount of the extraneous material inside the pipe ca can n be checked during flushing by placing a rag lightly l ightly over the end of the pipe. In the unlikely case that even a small quantity of moisture is found then the inside of the pipe should be dried out thoroughly.)

 Action:

①  Flush the inside of the pipe with nitrogen gas. (Until such time as the moisture disappears.) ②  Carry out a thorough vacuum drying operation. (See page 34) - Close the main valve on the nitrogen cylinder. -Repeat the above operation for unit B. -When the liquid pipe operations have been completed then do the same with the gas pipes.

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6. Drainpipe Work 6-1. Diagram Review

1) On the diagram check the locations of the horizontal, branch and vertical pipes. (1) What is a horizontal pipe? It is a drainpipe where the drainpipes from the indoor unit are merged. (2) What is a branch pipe? It is a drainpipe drai npipe from an indoor unit to a horizontal pipe.. (3) What is a vertical pipe? It is a vertical drainpipe that a horizontal pipe is connected for drain purpose.

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3. Guideline for each installation process  2) On the diagram, check the location of the hanger for the drainpipe.

(1) Due to the weight of the drainpipe and the condensed water, it can cause bending. The hangers should be separated by 1 to 1.5 meters. meter s.

3) Check the drainpipe diameter (horizontal, branch, vertical pipe) on the diagram.

4) Review installation of a horizontal pipe first. Install a branch pipe after installing an indoor unit. (Since the drainpipe location and direction could be changed.)

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6-2. Drainpipe Cutting and Insulation 1) Cut the drainpipe as its dimension and size are shown in the diagram.

Use a specialized cutter for drainpipe

2) Use a special cutter for the PVC pipes. A PVC pipe cutter is shown in the following .

(PVC pipe cutter photo)

3) Insulate the drainpipe that is cut. (Thickness of 5~10T, attach a photo of inserted insulation materials)

Inserting the drainpipe insulation material 

(1) The drainpipe insulation materials should be non-flammable. (2) Recommended insulation thickness is 5~10T and select the desirable insulation thickness according to the humidity/temperature of the ceiling.

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3. Guideline for each installation process  6-3. Mounting the Drainpipes 1) Mount a horizontal pipe in the hanger.

Cutting and mounting the drainpipe

2) Perform 1/100 slope works on the horizontal pipe in the direction of the vertical pipe. (Discharge the condensed water.)

Checking the slope

1/100 or more downward slope

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Installation guide

6-4. Connecting the Drainpipe 1) At the area where the branch pipe is connected to the horizontal pipe, use a T joint to make connections connections between between the horizontal pipe pipe & branch pipe. pipe.

2) A T-joint should be faced upward .

Precaution:  T-joints should not be connected horizontally.

3) When you connect the horizontal pipe to the vertical pipe, do not make horizontal connections. Because the condensed water flowing from the upper area of the vertical pipe can back-flow into the horizontal pipe.

No horizontal connection from the horizontal pipe to the vertical pipe

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3. Guideline for each installation process  4) Branch pipe (indoor unit – horizontal pipe) construction method (1) Indoor unit with a drain pump ① The pipe coming from the indoor unit should have a trap to prevent reverse flows.

anges from 300 to 550mm. ② The max height from the indoor unit’s drainpipe exit to the trap rranges ③  In the upperwater’s area of back the trap (max of the drainpipe), install an air vent to prevent condensed flows intoheight the drainpipe caused by an increase in the pressurethe in the drainpipe. ④  The end of the air-vent should form a T or 7 shape to prevent entry of dust or foreign substances.

Check for leakages after 24 hours.

⑤ 

Installing the air-vent

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Installation guide

(2) Indoor unit without a drain pump preve ntion P or U-trap on the pipe coming from the indoor unit. ① Form a reverse flow prevention P-Trap, U-Trap pipe photo inserted here.

② An air-vent should be installed on the indoor unit side and located higher than the drainpipe height.

③  Or, install an air vent on the vertical pipe.

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3. Guideline for each installation process  6-5. Drainpipe Combination and Bonding 1) Apply PVC glue to the joint area and wait for one to two minutes before combining them.

6-6. Drainpipe Water Soaking Test 1) Pour the water through the uppermost drainpipe or an air vent to check if the water flows smoothly. After that, for twenty-four hours, perform water soaking test to test leakages. In this test, the amount of water injection should be same as the amount of water discharge. 2) In the winter, use anti-freezing liquid instead of water. 3) If the water discharge is not smooth, recheck the tilt of the drainpipe.

Drain water soaking test

Check for leakages after 24 hours

Check for leakages after 24 hours. 

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Installation guide

6-7. Insulation Material Finishing 1) 1)   In a water soaking test, if there is no leakage, then insulate the bonded areas.

Insulating bonded/joint area of Drainpipe 

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3. Guideline for each installation process  7. Insu Insu lation wo rk

7-1. Purposes of Insulation and Piping (1) Explain the purposes. (2) List the pipes to be insulated. ① Refrigerant pipe

② Branch pipe ③ Drainpipe

7-2. Insulation Method (Procedure)

①  Operational steps

①  EPDM length should be longer then pipe length. Do not extend EPDM by force 

②  Put the pipe in EPDM insulation carefully so that the pipe will not get damaged with EPDM.

③  Apply bond on both side of cut surface. Make sure to use the correct type of bond for EPDM cut surface attaching.

④ Dry it until it becomes

thick, sticky and does not get detached. 

②  Bending vertical side of insulation

Use the original uncut insulation material. 

Only in special case is the vertical cutting of the insulation allowed. 

 Apply bond both sides of the surface of EPDM and press them together for long lasting bonding.

Dry it until it becomes thick and sticky.

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③  ‘L’ Fitting connection part insulation

 All of the fitting connecting parts should be insulated. Bring face to face the each end of EPDM on fitting connection part. 

Make fitting cover to fit the EPDM insulation. Fitting cover should be overlapped with insulation min 1inch(2.5m). 

①  Insertion type: general insulation method ②  Partitioning: Vertical insertion type i nsulation methods ③  Elbow & edge area insulation

Bond the both cutting sides of fitting cover. 

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3. Guideline for each installation process  8. Gas leak test 8-1. Purposes 1) Leakage test step st

(1) 1  leakage test: After installing the pipe and the branch pipe, use Nitrogen at 4Mpa for testing. →  Maintain 1Mpa. nd

(2) 2  leakage test: After connecting the pipe to the outdoor/indoor unit, use Nitrogen at 4Mpa for testing.

2) Detect leakages that can occur while connecting the pipe to the outdoor/indoor units. st

nd

3) 1  leakage test is completed, so now proceed with the 2  leakage test. 

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8-2. Procedures (HR Module Installation Standard) 1) Before starting (1) Check if all the service valves are closed (liquid, gas, high pressure gas, Oil Equalizing pipes). (2) When using a nitrogen charging container, install pressure control regulator. (3) R410a gauge manifold – minimum 4 units, manifold hoses – five units or more.

2) The following pipes should pass a leakage test. (1) Liquid pipe (2) Gas pipe (3) High-pressure gas pipe (4) Oil Equalizing pipe

3) Connect the prepared two manifold gauges and five hoses as shown below and connect to each service valve. (1) If due to the shortage of manifold gauge, you can’t test all the equal oil pipes at the same time, then first test the three main pipes and perform final tests. 4 ) Pressure up the inner in ner area of the pipe to 4.1MPa for a leakage test and maintain

the pressure for 24 hours. 5) If there is no leakage for 24 hours, then depressurize to 1Mpa and maintain the pressure. The reason is to prevent corrosion in the pipes.

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3. Guideline for each installation process  9. Vacuum drying 9-1. Purposes Using vacuum drying, the moisture inside the product p roduct or pipe can be evaporated.

9-2. Procedure (HR Modulation Installation Standard) 1) Before starting (1) Check if the second air a ir tight test (outdoor unit, MCU, indoor unit pipes a are re all connected.). (2) After the second air tight test, check if the pressure is down to 1Mpa and check if there is any leakage of nitrogen gas. (3) Minimum two sets of R410a gauge manifolds, five or more manifold hoses, more than one vacuum pump. (4) Power up the indoor/outdoor unit. In case of HR, if the power is not on, then all the valves inside the MCU are closed. So the vacuum may not be achieved by using the S/V of the outdoor unit.

2) Connect the gauge manifold to achieve a vacuum for the following pipes. (1) Liquid pipe (2) Gas pipe (3) High-pressure gas pipe (4) Oil Equalizing pipe (If the manifold can’t achieve a perfect vacuum, then purge it with refrigerants.)

3 ) Connect the prepared two manifold gauges g auges and five hoses as shown below and

connect to each service valve.

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(1) Connect a hose to the liquid/gas/high pressure gas pipes and make the vacuum with a vacuum pump. (2) The  The equal oil pipe has gas type of refrigerants. Purge oxygen inside the equal oil pipe. (3) Compare the external temperature with the temperature below. Keep the vacuum until the gauge pressure reaches the value in the below table. (For more than 2-and–a-half hours) Boiling point

Gauge pressure

of water( ℃)

mmHg

Pa

Torr

40

-705

7333

55

30

-724

4800

36

26.7

-735

3333

25

24.4

-738

3066

22

22.2

-740

2668

20

20.6

-742

240

18

17.8

-745

2000

15

15.0

-747

1733

13

11.7

-750

1333

10

7.2 0

-752 -755

1066 667

8 5

Have been achieved in the vacuum drying operation

(4) After  After making the vacuum, check if the gauge pressure has changed. If no change is found, then move to the additional refrigerant charging phase.

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3. Guideline for each installation process  10. Charging Refrigerant 10-1. Purposes  Add an additional amount of refrigerant for the installed pipe length to guarantee product performance and reliability.  The additional amount of refrigerant varies depending on the product, the liquid pipe diameter and so on, so you must check the installation installa tion manual before proceeding.

10-2. Procedures (HR Module Installation Standards) 1) Before starting (1) Check the necessary amount of additional refrigerant injection depending on the liquid pipe diameter. (2) Check the liquid pipe length for the system. (3) Based on the above value, calculate the additional amount of refrigerant. (4) Prepare an electronic scale and refrigerants.

2) 2)   As show shown n belo below, w, pr prep epar are e a gaug gauge e mani manifo fold ld,, a re refr frig iger eran antt box box and and an an elec electr tron onic ic scal scale. e.

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(1) Connect a refrigerant box to the manifold gauge. (2) Since oxygen exists in the hose between the gauge manifold and the refrigerant box, open the refrigerant box valve to purge oxygen from the hose. (3) Place the refrigerant box on top of the electronic scale. (4) If it is a commercial product (sales with 11kg), then turn the refrigerant box upside down to place it on top of the electronic scale. If the refrigerant box type is chargeable (multiple use), then you don’t need to turn it upside down as long as the gauge manifold is connected to the liquid valve of the refrigerant box. If not connected, then turn it i t upside down before placing it on the electronic scale.  The reason is because you want to inject liquid refrigerants.

3) Inject the amount of refrigerant calculated above. (1) Open the gauge manifold and check the amount of refrigerant injection. (2) If entire refrigerant flows in smoothly, then turn off the valve and separate the gauge manifold from the system. (3) If the pipe is too long and entire refrigerant can’t be injected, then perform cooling operation to gradually inject the refrigerant.

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4. Indoor Units installation  1.  Ceiling Cassette Type (1WAY/2WAY/4WAY)

1-1. Installation Standard - The installation location and direction of the indoor unit should be determined based on the relationship with various other processes such as the refrigerant pipe, the drainpipe and the power/communication cables and they should meet various requirements for other facilities (firefighting facilities etc.).

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(1) Fire fighting detector(1.5m) and beam projector(2m) need to be away from indoor unit.

 At least 1.5m away from indoor indoor unit. 

 Avoid installation in the direction of discharge

(2) 4-way indoor unit height limited

< High Ceiling Kit, front/rear > ※  If the height limit is exceeded, Cooling/heating performance may det deteriorate eriorate

- High Ceiling Kit makes it possible to install indoor unit at the high ceiling condition up to 5.2m height (3) Separately install power cables, communication cables and refrigerant pipes

- Fix the power/communication cable on the top part of the full thread bolts (which is used to fix the pipe hanger) and make sure to keep distance from the pipe.

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4. Indoor Units installation  (4) Y terminals are to be used in connection with wired remote controller

<Terminal <Terminal not used>

<Y terminal used>

- If connected without a terminal, they are likely to make contact with the power ca cable ble and damage the PCB. (5) Indoor unit’s ring terminal connection c onnection

<Terminal <Terminal not used/Y terminal used> - Ring terminal should be used for power line connection

<Ring terminal used>

(6) Inspection hole installation

- If the ceiling is made of plaster boards, depending on the internal ceiling height, install an inspection hole. (If the ceiling is made of separable single sheet textile, no additional inspection hole is required.) (Inspection hole basic size: 450X450)

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(7) Decoration panel installation

(8) Drain installation

① The drainpipe should be installed within 100mm from the flexible hose, lift up from 100mm to

550mm and lift down 20mm or more. ② Install horizontal drainpipe with a slope of 1/100 or more and fix it by hanger space of 1~1.5m. ③ Install the air vent in the horizontal drainpipe to prevent water flow back to the indoor unit.

- You You may not need to install it if there were proper slope in the horizontal drainpipe. ④ The flexible hose should not be installed upward position, it may cause water flow back to the

indoor unit. smel l to reach the indoor unit. ⑤ Install U-trap at the end of the drainpipe to prevent a nasty smell

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4. Indoor Units installation 

① Install main air vent at the front of the farthest indoor unit from the main drain when installed

indoor units are more than 3. ② You may need to install individual air vent to prevent water flow back at the top of each indoor

unit drainpipe.

 AIR-VENT interval of 10m~15m. 10m~15m.

Drainpipe hanger fixed within 1~1.5m. 

If the interval is more than 1~1.5m, bending of the PVC pipe can cause poor water drainage.

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1-2. Installation Steps Sleeve work should be performed to make a space for passing pipe and wire through the wall or ground under construction.

①  Place the pattern sheet on the ceiling at the spot where you want to install the indoor unit. paper, it may shrink or stretch   Since the diagram is made of paper, slightly due to temperature or humidity. humidity. For this reason, before drilling the holes maintain maintai n the correct dimensions between the markings. ②  Insert bolt anchors, use existing ceiling supports supports or construct a suitable support as shown in figure. ③  Install the suspension bolts depending on the ceiling type. ※ Ensure that the ceiling is strong enough to support the weight

of the indoor unit. Before hanging the unit, test the strength of each attached suspension bolt.  

If the length of suspension bolt is more than 1.5m, it is i s required to prevent vibration.

④  Screw eight nuts to the suspension bolts making space for hanging the indoor unit. ※ You must install the suspension bolts more than four when

installing the indoor unit.

leveler. A tilt of the ⑤  Check the level of the indoor unit by using a leveler. indoor unit may cause malfunction of a built-in float switch and water leaks.

⑥  Adjust the height of the the indoor unit by using the gauge of dimensions.    You  You should adjust the gauge of dimensions and the pattern sheet to fit the cutting dimensions of ceiling. cei ling.   Make sure that the indoor unit is installed at a level if the indoor unit slants too much, there can be water leaks. ⑦ Tighten the upper part nuts ⑧  Remove the gauge of dimensions after installing the indoor unit.

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4. Indoor Units installation  2. Duct Type (Slim/MSP) Type 

Slim Duct 

MSP Duct 

Product 

Model 

 AVXDSH022/028/036/040/045  AVXDSH022/028/036/040/0 45   /056/071/090/112/140*  /056/071/0 90/112/140*** 

 AVXDUH056/071/090/    AVXDUH056/071/090/  112/128/140**  

2-1.  Installation Standard 2-1.

2-2. Selecting the Installation

(1) There must be no obstacles near the air inlet and outlet. c eiling that can support its weight. (2) Install the indoor unit on a ceiling (3) Maintain sufficient clearance around the indoor unit. (4) Make sure that the water dripping from the drain hose runs away correctly and safely. (5) The indoor unit must be installed in such a way, that they a are re out of public access. (Not touchable by the users) (6) After connecting a chamber, insulate the connection part between the indoor unit and the chamber with t10 or thicker insulation. Otherwise, there can be air leak or dew from the connection part. (7) Rigid wall without vibration. (8) Where it is not exposed to direct sunshine. (9) Where the air filter can be removed and cleaned easily.

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2-3. Space Requirements for Indoor Unit 1) If the ceiling is separable to single sheets like textile, then no need to install an inspection hole.  2) If the ceiling is not separable like plaster board:

Depending on the distance between the product bottom and the ceiling top, install holes as follows. (1)  500 mm or more from the product bottom to the ceiling top: Only install inspection hole B (PBA inspection) (2) 500 mm or less from the product bottom to the ceiling top: Install inspection holes A, B (2)

Type

Product size (mm)

Model Name

Inspection hole A Inspection hole (mm) B (mm)

D

W

H

D

W+100

D

 AVXDSH022/028/036*

600

900

199

600

1000

600

 AVXDSH040/045/056/071*

600

1100

199

600

1200

600

 AVXDS090/112/128/140*

690

1300

295

690

1400

690

MSP

 AVXDUH056/071/090/112*

480

480

1250

480

Duct

 AVXDUH128/140*

650

650

1300

650

Slim Duct

900/1150 260/320 1200

360

C

500

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4. Indoor Units installation  2-4. Indoor Units Installation 1)  Place the pattern sheet on the ceiling at the spot where you want to install the indoor unit. 2) Insert bolt anchors, use existing ceiling supports or construct a suitable support as shown in figure. 3) Install the suspension bolts depending on the 3 the ceiling type. 4) Screw eight nuts to the suspension bolts making space for hanging the indoor unit. 5) Hang the indoor unit to the suspension bolts between two nuts. (1) Small: The opposite side of the drainpipe is 3 mm higher than the drain side. (2) Large: The opposite side of the drainpipe is 5 mm higher than the drain side. 6) If the ceiling bottom is likely to generate vibration due to indoor unit installation, then install an additional spring mount when installing the ceiling base bolts. 7) Screw the nuts to suspend the unit. 8) Adjust level of the unit by using measurement plate for all 4 sides.

9) Installation of cupper pipe (1) On delivery, the indoor unit is loaded with inert gas. unscrew the pinch pipe at the end of each refrigerant pipe. (2) Connect the Refrigerant Pipe of units. (3) In order to detect basic refrigerant leaks, before recreating the vacuum and re-circulating the R410A, it’s responsiblility of installer to pressurize the whole system with nitrogen (using a pressure regulator) at a pressure above 4.1MPa (gauge).

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10) Install drainpipe and drain hose. (1) Using a flexible hose clamp, fix the flexible hose.

Clamp  (2) Without the drain pump

MSP Duct

Slim Duct

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4. Indoor Units installation  (3) With the drain pump

11) Power and communication communication cable connection

Indoor unit

Indoor unit

Indoor unit

 

Use Y-type terminal for the Communication Connection (Outdoor to Indoor unit / Indoor to Indoor unit) & for Wired remote connection.

 

Use Ring Type terminal for the power connection c onnection to the indoor unit.

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2-5. Precaution with Duct type 1) The suction side should have at least the same cross sectional area as the discharge side. (1.2 times or higher recommended) recommended) 2) Diffuser suction/discharge wind speed(->wind velocity) velocity) : 3 m/s or less 3) Duct’s curvature radius should be greater than the circular duct diameter  wind(-> airflow rate), noises problems →

4) Design and construction pursuant to the duct design pressure standard 5) Use of a suction/discharge suction/discharge chamber containing soundproofing materials → To minimize the air flow noise, attach a suction/discharge chamber with built-in soundproofing materials.

6) When the duct suction hole is located on the ceiling, consider the performance and noise levels.  → Foreign substances can clog the filter.

7) Obey the standard for fixing a duct. duct . - Spiral 2.5m (0.5t), Flexible Duct fixed fi xed within 1.0m. - To prevent damage to flexible duct by the hanger band, insert a saddle or use a flexible duct hanger (band).

8) Obey the duct insulation handling rules. - Air supply (SA) duct should be insulated. i nsulated. - Suction unit (RA) duct should be insulated insula ted according to the on-site condition.

9) Duct’s suction (diffuser/product) should have a filter attached to it.

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4. Indoor Units installation  2-6. Drain Pump Installation Process 1) Slim Duct (AVXDSH**)_Drain (AVXDSH**)_Drain pump(MDP-E075S**1) (1) Please, Separate the cabinet cabi net of the indoor unite.

Cabinet Base

(2) Separate the cabinet base of the indoor unit and fix it wi with th the drain pump. Ceiling

Cabinet base

(3) Connect the drain pump and the flexible hose pump.

(4) Connect the flexible hose to the flexible hose pump.

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(5) Connect the float switch of the drain drai n pump(Yellow) and power supply unit(Black) to the PCB of the indoor unit.

(6) Adjust K4 DIP switch(SW03) to the "OFF" position.

(7) Check water leakage of the drain d rain hose port and the drainpipe after completing installation

2) Slim Duct (AVXDSH** (AVXDSH** 01)_ Drain pump(MDP-E075S**3) (1) Release the two screws on the control box and separate the cover and the cabinet side.

(2) Remove the terminal and install the Drain Pump. Using screws, fix the d drain rain pump case.

(3) Connect the drain pump wire. (Yellow terminal.) (Float Switch is a black terminal.) (4) On the PCB, turn OFF the DIAL-UP SWITCH K4 corresponding to SW05 SW05..

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(5) Tie the drain drai n pump wire and install the control box case.

3) MSP Duct (AVXDUH**)_ Drain pump(MDP-M075S***) (1) Remove the Control Cover

(2) Remove the wire from PCB. Then remove the Control Box

(3) Remove the part as seen in the picture. Assemble the Drain Kit and drain socket.

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(4) After connecting the Drain Hose with the Drain Socket ,Assemble the Drain Pump

(5) Insert the flexible hose into the drain socket until it clicks.

(6) Connect the cable to the electrical e lectrical component box as shown at the figure  Adjust K4 DIP switch(SW05) to the the “OFF” position.

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4. Indoor Units installation  3. Ceiling 3-1. Space Requirements for Indoor Unit AVXTF**

Type 

Under Ceiling 

Floor Standing  50mm

Installation 

50mm

300mm 300mm

3-2. Indoor Units Installation 1) Ceiling Installation (1)  Select pipe directions. When the directions are selected, sel ected, drill 4''(100mm, for pipe and cable cables) s) and 1-5/8'' (40mm, for drain hose) diameter holes on the wall

(2)  Drill holes for anchor a nchor bolts according to the distance and mount them. (3) Install the unit onto the ceiling. Be sure to arrange the drain hose so that it is leveled lower than the drain hose connecting port of the indoor unit.

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(4)  If installing on dropped ceiling, install threaded rod onto anchor bolt-(expansion bolt) to long enough to suspend the unit right below the dropped ceiling and the install the unit suspending on the threaded rod.

2) Floor Installation (1)  Select pipe directions. When the directions are selected, drill 4''(100mm, for pipe and cables) cabl es) and 1-5/8'' (40mm, for drain hose) diameter holes on the wall

(2)  Install the hanging plate according acc ording to the distance and mount it.

(3) Install the unit and be sure to arrange the drain hose so that it is leveled lower than the drain hose connecting port of the indoor unit.

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4. Indoor Units installation  3) EEV Kits Installation Installation (1) Check dimension and installation location. (2) Check installation place.

(3) Connect the “IN” refrigerant pipe to the outdoor unit. (4) Connect the “OUT” refrigerant pipe to each eac h indoor unit(A, B and C) (5) Insulate the connection piping. A joint part par t of pipe needs double thickness of insula insulation. tion.

(6)The EEV kit has to be installed that the user has no access to it. (built-in type)

4) Drain Hose Installation Care must be taken when installing the drain hose for the indoor unit to ensure that any condensation water is correctly drained outside. When passing the drain hose through the hole drilled in the wall, check that none of the following situations occur

 The drain pipe can be extended by connecting as following figure.

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4. Console  4-1. Space Requirements for Indoor Unit AVXTJ**

4-2. Indoor Units Installation (1)  When you install the indoor with side-pipe connection, please make space more than 300mm from the wall (2) When you install the indoor at the inclined floor, please lean the set toward the drain hose and pipe connection to prevent water overflowing.

(3) The   The body front should be opened to connect pipes Please release the 4 screws of body front and then pull it out from the bottom of the set.

(4) Make a hole on the wall.

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4. Indoor Units installation  (5) The   The pipes & cable should be gone through the bottom back hole.

(6) Please remove 6 items when set is installed.

(7) Drain Hose Installation 6-Ways to connect Drain Hose and Pipe

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5. Wall-mounted Wall-mou nted Type Type 5-1. Installation Standard 1) Overview 

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4. Indoor Units installation  <MB>

<Vivace>

<Neo-Forte>

Before fixing the installation plate to the wall or window frame, you must determine the position of the 3-1/8”(80mm) hole through which the cable, pipe and hose pass to connect the indoor unit to the outdoor unit. When facing the wall, the pipe and cable can be connected from the: ●  Right ●  Left ●  Underside (right) ●  Rear (right or left)

① Determine the position of the pipe and drain hose hole as seen in the picture and drill the hole with an inner diameter di ameter of 3-1/8”(80mm) so that it slants slightly downwards. the indoor indoor unit unit to to a... Follow step(s)... ② If you fix the Wall 3. Window frame 4 to 6.

③ Fix the installation plate pla te to the wall giving attention to the weight of the indoor unit. â If you mount the plate to a concrete c oncrete wall with anchor bolts, the anchor bolts must not project more than 20mm. ④ Determine the positions of the wooden uprights to be attached a ttached to the window frame.5.  Attach the wooden uprights to the window frame giving attention to the weight of the indoor unit.

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Connection of refrigerant piping

Insulation

①  Insert bolt anchors, use existing ceiling ce iling supports or construct

a suitable support. Ensure the ceiling is strong enough to support the weight of the indoor unit. Before hanging the unit, test the strength of each attached suspension bolt. ②  Connect the “IN” refrigerant pipe to the outdoor unit. ③  Connect the “OUT” refrigerant pipe to each indoor unit(A, B

and C).  The liquid and gas pipes should not be crossed during piping connection. ④  Insulate the connection piping. A joint part pa rt of pipe needs

double thickness of insulation.  The EEV kit has to be installed that the user has no access to it. (built-in type) 

You can select the direction of the the drain hose indoor unit.

depending on where you wa nt to install install the

①  Detach the rubber cap with the flyer. ②  Detach the drain hose by pulling pulli ng it and turning to the left. ③  Insert the drain hose by fixing it into the groove of the drain hose and the outlet of the drain pan. ④  Attach Attach the rubber cap with a screwdriver by turning it to the right until it fixes to the end of the

groove.

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5. Outdoor Units installation  1.  Safety Information 1) Caution Signs (1) Make sure of a earthing. ear thing.

①  Do not connect the earth wire to the gas pipe, water pipe, lighting rod or telephone wire. If earthing is incomplete, electric shock or fire may occur. (2) Do not connect the heater to the outdoor unit and do not install altered duct as you please.

①  The capacity may reduce, electric shock or fire may occur. (3) Make sure that the condensed water dripping from the drain hose runs out properly and insulate the drainpipe so that frost does not generate.

①  Household goods may get wet if the the drainpipe is not properly installed. (4) Install the indoor unit away from fr om lighting apparatus using the ballast.

①  If you use the the wireless remote control, it may not not operate normally. (5) Do not install the air conditioner in following places. ①  The place where there is mineral oil or arsenic acid.

②  Those parts may get damaged due to burned resin. ③  The efficiency of the heat exchanger may reduce or the air conditioner may be out of order. ④  The place where corrosive gas such as sulfurous acid gas generates from the vent pipe or air outlet. ⑤  The copper pipe or connection pipe may corrode and refrigerant may leak. ⑥  The place where there is a machine that generates electromagnetic waves. ⑦  The air conditioner may not operate normally due to control system. ⑧  The place where there is a danger of existing combustible gas, thinner or gasoline is handled. ⑨  The place where carbon fiber or flammable dust is. ⑩  The place where like spa and shore. (6) Install the power cable and communication cable of the indoor and outdoor unit at least 1.5m away from the electric appliances and install it at least 2m away from the cable from the lightning rod. ①  Noise may heard depending on the electric elec tric wave though the cables.

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(7) Install the outdoor unit within the angle of 25~55˚ depending on the building height as below table. Building height 

Protective angle 

Below 20m 

55° 

Below 40m 

35° 

Below 60m 

25° 

Remarks 

2. Preparing the Installation 1) Moving the Outdoor Unit (1) When moving with a crane or straps.

①  Fasten the wire rope rope as seen in the picture.  A.  To protect damage or scratches, insert a piece of cloth between the outdoor unit and the wire rope.

(2) When moving with a fork lift.

①  Insert the fork into the bottom of the outdoor unit carefully. ②  Be careful that the fork does does not damage the outdoor outdoor unit.

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5. Outdoor Units installation  2) Detaching Fasteners

①  Open the bottom cabinet with screw driver.

②  Detach nut washer, washer and stopper nut from compressors with a tool.

③  Refasten the nut washer only.

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3. Selecting Proper Location for Installation 1) Caution (1) Install the indoor unit away from any interfering sources such as radio, c computer, omputer, stereo equipment and also select the place where the electrical wiring work can be possible. ①  Especially keep the unit at least 3m away from the electrical equipment in an area electromagnetic waves generated and install the protection tube to protect the main power cable and communication cable.

②  Make sure that there is no equipment electromagnetic waves generate. If not, malfunction of the control system may occur due to the effect of the electromagnetic wave. (For example: The remote control sensor of the indoor unit may not be received well of electronic lighting style fluorescent lamps, such as fluorescent lamps are in the same space when using a remote control.) (2) Make sure to install the outdoor unit in a safe place where snowfall will not be obstructed. The frame should be installed in a place where the air inlet and heat exchanger of the unit are not buried in the snow.will be better installed for the case of the refrigerant leakage in a closed room (3) Ventilation system even if R410A is nonpoisonous and noninflammable refrigerant. (4) Install the railing around the outdoor unit to prevent falling when the unit is installed at high place of roof on the building. (5) Avoid installing the units in places such as an exhaust pipe and ventilating opening exposed to corrosive gas, oxides of sulfur, ammonia gas or sulfur gas herbicides. (Corroding copper pipes or soldered parts may result in refrigerant leakage.)

2) Caution for MCU (1) Make sure to install MCU when using HR products. (2) When you select the location to install MCU, the location is far away from indoor rooms because the refrigerant running of MCU may create cre ate noise.

3) Caution for Seashore (1) Install the outdoor unit like a place where the product can be protected from a direct sea breeze. (2) If you cannot help installing the outdoor unit by the seashore, construct a protection wall around the outdoor unit to protect the sea breeze. ( Protection wall size : 150% larger than outdoor unit size) (Min. 700mm distance for air circulation ci rculation from the protection wall)

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5. Outdoor Units installation  4. Space Requirements  1) Single Installation

2) Group Installation

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3) Recommended Case (1) At least 200mm(8inch) of space between the outdoor units is needed for service area and heat radiation.

(2) When the product is installed in the site near the sea, wind-proof cover must be installed additionally, considering effects from typhoon and seasonal wind. Anti-corrosion type must be selected. (Special coating must be applied.) (3) All the ventilation systems, which are installed outdoors, should be apart from the outdoor unit. In case they cannot be apart, the direction of the ventilation should be opposite direction to the outdoor unit.

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5. Outdoor Units installation  5. Base Mount Construction  1) Base Mount Construction 

2) Outdoor Unit Installation Installation 

3) Outdoor Unit Base Mount and Anchor Bolt Position

Heat Pump 

RVXVHT080/100/120 

RVXVHT140/160 

Heat Recovery 

RVXVRT080/100/120 

RVXVRT140/160 



880 

1200 



738 

1058 

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4) Anchor Specifications Specifications 

Size 

Diameter of drill bit(a) 

Anchor length(b) 

Sleeve length(c) 

Insert depth 

Fastening torque 

Φ10 

14mm 

75mm 

40mm 

50mm 

30N·m 

5) Caution (1) When tightening the anchor bolt.  Tighten the rubber washer to prevent the outdoor unit bolt connection part from from corroding.

(2) When connecting the pipes.

① Check the strength of the roof to install the outdoor unit and make sure to have a waterproof floor of the roof. ② Make sure that a proper drainage system has been put in place around the outdoor unit. ③  To To protect the internal components of the outdoor unit, secure the pipe work entrance to the unit.

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5. Outdoor Units installation  6) Recommended Case (1) Construct a concrete foundation in accordance with the standards for the site where outdoor unit is being installed.

① H-beam: over 200mm Area of the concrete foundation must be 1.5 times larger than the outdoor outdoor unit. ②  Area ③ Concrete foundation shouldn’t be slanted and condensed water needs to flow away without any stagnation

(2) After  After placing the outdoor unit on the basic foundation, fix the outdoor unit with the anchor bolt(M12).

(3)  Install the anti-vibration pad between the outdoor unit, H-beam and the concrete foundation. (t = over 20mm)

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6. Drain Pipe Installation  1) Installing the Drainpipe (1)  Insert the provided drain plug at the 2 sides of the bottom of the unit and then connect the drainpipe. (2) Install the drainpipe at the rear side of the unit to get a sufficient space for repairs and service.

2) When Installing Single Outdoor Unit

3) When Installing Multiple Outdoor Unit

4) Caution (1) Do not install a trap on the pipe. And, install the drainpipe horizontally with a sl slope ope of 1/50 or more. (2) Insulate the drainpipe and drain plug with insulation over 10t. (3) Install heating device to the drainpipe to prevent it from being frozen. Install the safety equipment for a heating appliance.

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5. Outdoor Units installation  7. Exhaust Duct Installation 1) Installing Duct for Horizontal Exhaust Duct

2) Recommended Case [Before]

[After]

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8. Installing the Outdoor Unit Harsh Environments  1) General Instructions (1) In abnormally harsh environments such as cold and/or windy areas, sufficient countermeasures to guard against excessive wind and snow should be taken to ensure the unit’s correct operation. (2) Snow-proof duct (field supply) should be fitted to the unit and direct exposure to the wind should be avoided as much as possible. (3) When the unit is expected to operate in heating mode in condition under -10℃, in snowy area, in environments subject to strong winds or rain, rai n, install air inle inlett and outlet ducting as shown below.

Caution

a. The frame/foundation should be higher than expected snowfall. b. When installing on a roof subject to strong wind, countermeasures must be taken to prevent the unit from being overturned. c. Any lack of strength may cause unit to fall down, resulting in a personal injury.  Installation example.

- When the product is installed in the site near the sea, wind-proof cover must be installed additionally, considering effects from typhoon and seasonal wind. Anti-corrosion type must be selected. (Special coating must be applied) 

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5. Outdoor Units installation  2) Dimensional Drawing of Snow-proof Duct (1) Small Chassis 

(2) Large Chassis 

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9. Louver Installation 1) Requirements of Louver installation (1) Opening rate: 80% and more.

(2) Louver angle(Blade Slope): 20° and less. le ss. (3) Louver shape: Don’t use drainable blade type. Good 

(4)  Air Air velocity of inlet side: 2.0m/s and less.

Bad  

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5. Outdoor Units installation  10. Electrical Wiring Work 1) General Instructions (1) All wiring, components and materials to be procured on the site must comply with the applicable local and national codes. (2) Be sure to comply with the specifications of the circuit breaker and power cable in installation manual.

2) Power Supply and Communication Cable Configuration

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3) Circuit Breaker Breaker Installation I nstallation (1) 3 phase 4 wires

①  Case 1

②  Case 2

(2) 3 phase 3 wires and a nd 1 phase 2 wires

①  Case 1

②  Case 2

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5. Outdoor Units installation  4) Wiring Diagram (1) CO/HP Model

(2) HR Model

※ If the communication cable between indoor and outdoor units and the communication cable

among outdoor units are crossed, communication isn’t available.

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5) Connecting the power terminal (1) Use solderless ring terminal to connect cable and terminal block. Good  

Bad  

(2) Install the cable according to a blueprint. (3) Install the wire box, with wi th uncovered insulation tube, to the product. (4) During the installation in the site, make sure the wires and pipes do not contact each other because the vibration of compressor and high temperature pipe can make damage to wiring.

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5. Outdoor Units installation  6) Power Cable Arrangement (1) Make sure all wiring should not contact with piping line during the field wiring work. If not, the vibration of compressor and high temperature pipe can c an make damage to wiring Good 

Bad  

7) Circuit Breaker Breaker Installation I nstallation  (1) Install a circuit breaker. For safety and maintenance, we strongly recommend that MCCB and ELB and(or ELCB alone) have to be installed install ed every outdoor unit. (2) Every system must be installed individual MCCB and ELB and the specification must meet the requirements.  Good 

Bad  

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11. Pump-Down Operation 1) General Instructions (1) Pump-down operation is to gather the refrigerant into outdoor unit. (2) If system is under extremely low pressure, compressor will be damaged. When low pressure go down 2kgf/ ㎠  or below, close the service valve quickly. quickly.

2) Procedure of Pump down operation Single Installation

Close Liquid SVC Valve

Group Installation

ose

as

a ve o

u

Press “K2” button 3 times for pump down operation

Press “K2” button 3 times for pump down operation

Comp. On

Comp. On

Push “K4” button 4 times for checking low pressure *1)

n

Wait 20~30minutes

Close Liquid SVC Valve of Sub Unit

If low pressure ≤  2kgf/㎠ 

Close Gas SVC Valve (of Main Unit)

Press “K2” button 2 times or “K3” button 1 time for the end of pump down operation

Close Liquid SVC Valve of Main Unit

*1) “40 32” - “4” means low pressure view mode - “0 32” means low pressure is 3.2kgf/ ㎠g

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5. Outdoor Units installation  12. Pump-Out Procedure 1) General Instructions (1) Pump-out is the name of operation which pumps out the refrigerant refr igerant from outdoor unit. (2) Pump out operation can be put into operation with more than 2 outdoor units installed. (3) If system is under extremely low pressure, compressor will be damaged. When low pressure go down 2kgf/ ㎠  or below, close the service valve quickly. quickly.

2) Procedure of Pump down operation  roup ns a a on

Close Liquid SVC Valve of outdoor unit to carry out pump out operation

Press “K1” button for assigning the outdoor unit *1)

*1) Press 1 time

 Main

Outdoor unit

2 times  Sub 1 Outdoor unit Comp. On 3 times  Sub 2 Outdoor unit Push “K4” button 4 times for checking low pressure

If low pressure ≤  2kgf/㎠ 

Close Gas SVC Valve of operating outdoor unit

Press “K2” button 2 times or “K3” button 1 time for the end of pump out operation

4 times  Sub 3 Outdoor unit

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13. Setting the Option Switches & Function Keys  1) General Instruction (1) Refer to the installation manual for details. (2) Functions are activated by PCB of “Main unit” only. 

2) Check List Contents 

 The number of connected indoor unit  Outdoor Unit 

Outdoor unit address   The number of connected MCU (HR model model only)  Indoor unit address 

EEV Kit  Indoor unit’s unit’s activating switch setting  MCU 

Indoor unit address  MCU address 

Indoor Unit 

Indoor unit address (Main, RMC) 

Check 

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5. Outdoor Units installation  14. Completing the Installation and Commissioning 1) Check List Contents 

 Are the outdoor and indoor unit fixed securely?  Is the place well-ventilated and ensures space for service?   Is total number of connecting indoor units in the allowable range?   Are the length and the difference between the refrigerant pipes within the allowable range?  Is the ref. and drain properly insulated?  Have you completed the gas leak and drain test?  Is the wiring route correct?  Have you performed the earth work to the outdoor unit?   Are wiring specifications according to the installation manual and national standards? Is the length of the wire is in the limited range?  Have you completed the drain test?    Are the addresses of the indoor and outdoor units properly set?  Is the switch setting of the indoor i ndoor units for centralized control properly made?  Have you written the installation check card? 

Check 

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