AIR CONDITIONER (SPLIT TYPE)
Installation manual
For OUTDOOR USE only
Outdoor Unit
Model name:
RAV-SP240AT2-UL
Installation manual
Air conditioner (Split type)
English
1
Manuel d'installation
Climatiseur (Type split)
Français
23
Installation Manual
Outdoor Unit
1 DIMENSION
0.5"(12)
Drain hole
15.0"(380)
(
1.0"(25) burring hole)
7.9"(200)
2.4"(60)
B legs
Air inlet
port
Mounting bolt hole
(
0.5"(12)~ 0.7"(17) U-shape hole)
Air inlet
port
Details of B legs
3.0"(75)
Air outlet
port
Mounting bolt hole
0.5"(12) ~ 0.7"(17) long hole)
A legs
2.8"(70)
(
15.1"(383)
1.5"(39)
3.8"(96)
Details of A legs
5.9"(150)
23.6"(600)
5-drain hole
0.8"(20) ~ 3.5"(88)
burring hole
35.4"(900)
21.7"(550)
12.6"(320)
Refrigerant pipe
2.0"(52)
connecting port
0.4"(9.5) flare
at liquid side
1.2"(30)
Refrigerant pipe
connecting port
0.6"(15.9) flare
at gas side
Conduit hole
0.9"(22) hole)
(
Refrigerant piping hole
Refrigerant
piping hole
Z
2.4"(60)
2.7"(68)
7"(178)
7"(178)
7"(178)
0.7"(18)
3.9"(99)
2.3"(58)
20.4"(518)
12.9"(327)
0.5"(12)
2.5"(64)
3.3"(83)
0.3"(7)
15.7"(400)
Mounting hole sold separately
(12 - 0.1"(3) emboss)
Knockout for downward piping
Z views
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Installation Manual
Outdoor Unit
2 ACCESSORY PARTS
Part name
Q’ty
Shape
Usage
(Hand this directly to the customer.)
Installation manual
1
This manual
Drain nipple
1
Waterproof rubber cap
Edge Guard
5
1
Protects piping against sharp edges
NOTE
Use drain nipple and waterproof rubber cap as necessary.
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Installation Manual
Outdoor Unit
3 SYSTEM REQUIREMENTS
Refrigerant charge
„Piping (Field supplied)
• Minimum refrigerant line length between the outdoor
unit and indoor unit is 16.5” (5 m)
Length of refrigerant
pipe connected to
indoor/outdoor unit
Additional refrigerant
• Maximum pipe lengths
16’5” - 98’5”
(5 - 30 m)
None
Allowable
pipe length
(ft (m))
Height difference
(Indoor-outdoor H)
(ft (m))
Number of
Add 0.43 oz/ft (40 g/m) of
refrigerant for piping that exceeds
98’5” (30 m) up to 164’1” (50 m).
bent portions
*98’5” - 164’1”
(30 - 50 m)
Totallength
L
Indoor unit: Outdoor unit:
Upper
Lower
10 or less
* Caution during addition of refrigerant
Max. amount of additional refrigerant is 1.8 lbs (800
g).
Charge the refrigerant accurately. Overcharging
may cause serious trouble with the compressor.
164’1” (50)
98’5” (30)
98’5” (30)
Figure of Single
Indoor Unit
* Minimum refrigerant pipe is 16’5”(5 m).
This may cause a malfunction of the compressor or
other devices.
Metering Device is an electronic EXV (PMV) in
outdoor unit.
Outdoor Unit
„
Connecting power and control
cables (Field supplied)
• The main power is supplied to the outdoor unit. The
field supplied connecting cables from the outdoor
unit to the indoor unit consist for 4 wires and provides
the power for the indoor unit as well as the
communication signal between the outdoor and
indoor unit.
Refrigerant sizes
Liquid side
Outer
Gas side
Outer
Thickness
Thickness
diameter
diameter
• System interconnection wire size must be AWG12.
• Breaker must have a capacity specified in the
following table.
• All wiring must comply with local electric codes and
NEC (National Electric Code) or CEC (Canadian
Electric Code).
0.04”
(1.0 mm)
Ø3/8”
0.03”
Ø5/8”
(9.5 mm)
(0.8 mm)
(15.9 mm)
Flare nuts and flaring
• The flare nuts and flaring are different from those for
the conventional refrigerant.
Use the flare nuts supplied with the air conditioner or
those for R410A.
Model RAV-
SP240
208/230 V, 60 Hz
24 A
• Before performing flaring, carefully read
“REFRIGERANT PIPING”
Power supply
MCA
MOCP (MAX Fuse/CB)
Breaker
40 A
Insulation
Both lines need to be insulated. Use a minimum 0.4”
(10 mm) wall thickness.
25 A
System interconnection wires
MCA = Minimum Circuit Amps
AWG12
MOCP =Maximum Over Protection Device Amps.
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Installation Manual
Outdoor Unit
4 PRECAUTIONS FOR SAFETY
Installing, starting up, and servicing air--conditioning equipment can be hazardous due to system pressures,
electrical components, and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should install, start--up, and service this equipment.
Untrained personnel can perform basic maintenance functions such as cleaning coils. All other operations should
be performed by trained service personnel.
When working on the equipment, observe precautions in the literature and on tags, stickers, and labels attached
to the equipment.
Follow all safety codes. Wear safety glasses and work gloves. Keep quenching cloth and fire extinguisher nearby
when brazing. Use care in handling, rigging, and setting bulky equipment.
Read these instructions thoroughly and follow all warnings or cautions included in literature and attached to the
unit. Consult local building codes and National Electrical Code (NEC) for special requirements. Recognize safety
information. This is the safety--alert symbol
. When you see this symbol on the unit and in instructions or
manuals, be alert to the potential for personal injury.Understand these signal words: DANGER, WARNING, and
CAUTION. These words are used with the safety--alert symbol.
DANGER identifies the most serious hazards which will result in severe personal injury or death. WARNING
signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which
may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which
will result in enhanced installation, reliability, or operation.
WARNING
•
Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.
Perform installation work properly according to the Installation Manual.
Inappropriate installation may result in water leakage, electric shock or fire.
• Be sure to ground the equipment
Improper grounding may cause an electric shock.
Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone wires.
• Turn off the main power supply switch or breaker before attempting any electrical work and maintenance.
Make sure all power switches are off. Failure to do so may cause electric shock.
Use an exclusive power circuit for the air conditioner. Use the rated voltage.
• When moving the air conditioner for installation to another place, be very careful not to allow the specified
refrigerant (R410A) to become mixed with any other gaseous body into the refrigeration cycle.
If air or any other gas mixes with the refrigerant, the gas pressure in the refrigeration cycle will become abnormally
high and it may result in the pipe bursting or personal injuries.
• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety interlock
switches.
• Do not touch the intake or aluminium fins of the outdoor unit.
Doing so may result in injury.
• Tighten the flare nut with a torque wrench in the specified manner.
Excessive tightening of the flare nut may cause a crack in the flare nut after a long period, which may result in
refrigerant leakage.
• Install the air conditioner securely in a location where the base can sustain the weight of the unit adequately.
• If refrigerant gas has leaked during the installation work, ventilate the room immediately.
If the leaked refrigerant gas comes in contact with fire, noxious gas may be generated.
• After the installation work, confirm that refrigerant gas does not leak.
If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may be
generated.
• Electrical work must be performed by a qualified electrician in accordance with the NEC or local code. Make
sure the air conditioner uses an exclusive power supply.
An insufficient power supply capacity or inappropriate installation may cause fire.
• Use only the specified wiring during the unit installation. Ensure that all terminals are securely fixed, so
preventing any external forces having a negative effect on the terminals.
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Installation Manual
Outdoor Unit
WARNING
• When the air conditioner cannot cool or heat a room well, contact the dealer from whom you purchased the
air conditioner as refrigerant leakage is considered as the cause.
In the case of repair that requires refill of refrigerant, ask service personnel about details of the repair.
The refrigerant used in the air conditioner is harmless.
Generally, the refrigerant does not leak. However, if the refrigerant leaks in a room and a heater or stove burner in
the room catches fire, it may generate toxic gas.
When you ask service personnel for repairing refrigerant leakage, confirm that the leakage portion has been
completely repaired.
• Do not install the air conditioner in a location that may be subjected to a risk of exposure to a combustible
gas.
If a combustible gas leaks and becomes concentrated around the unit, a fire may occur.
• Install the refrigerant pipe securely during the installation work before operating the air conditioner.
If the compressor is operated with the valve open and without the refrigerant pipe, the compressor sucks air and the
refrigeration cycle is over pressurized, which may cause a burst or injury.
• When carrying out the pump-down work, shut down the compressor before disconnecting the refrigerant
pipe.
Disconnecting the refrigerant pipe with the service valve left open and with the compressor still operating will cause
air, etc. to be sucked in, raising the pressure inside the refrigeration cycle to an abnormally high level, and possibly
resulting in rupturing, injury, etc.
CAUTION
• Do not climb onto or place objects on top of the outdoor unit.
You may fall or the objects may fall off of the outdoor unit and result in injury.
• Wear heavy gloves during the installation work to avoid injury.
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage or improper operation.
Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must be
a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length is
buried, refrigerant may migrate to the cooler buried section during extended periods of system shutdown. This causes
refrigerant slugging and could possibly damage the compressor at start-up.
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Installation Manual
Outdoor Unit
5 INSTALLATION OF NEW REFRIGERANT
AIR CONDITIONER
CAUTION
New Refrigerant Air Conditioner Installation
• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY
OZONE LAYER.
R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working
pressure of R410A refrigerant is approx. 1.6 times as that of refrigerant R22. Accompanied with the adoption of the new
refrigerant, the refrigerant oil has also been changed. Therefore, during installation work, be sure that water, dust,
former refrigerant, or refrigerant oil does not enter the new type refrigerant R410A air conditioner cycle.
To prevent mixing of refrigerant or refrigerant oil, the sizes of connecting sections of charging port on main unit and
installation tools are different from those of the conventional refrigerant units. Accordingly, special tools are required for
the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings
made for R410A only, so that water and/or dust does not enter.
„Required Tools/Equipment and Precautions for Use
Prepare the tools and equipment listed in the following table before starting the installation work.
: R410A exclusive
: Generic
Tools/equipment
Manifold gauge*
Use
Vacuuming/charging refrigerant
and operation check
Charging hose
Gas leak detector
Gas leak check
Vacuum drying
Vacuum pump with backflow
prevention function
Flare tool
Flare machining of pipes
Bending pipes
Usable if dimensions are adjusted.
Bender
Refrigerant recovery equipment
Torque wrench
Pipe cutter
Refrigerant recovery
Tightening flare nuts
Cutting pipes
Ø1/2” (12.7 mm) and 5/8” (Ø15.9 mm)
Brazing torch and nitrogen
cylinder
Braze pipes
Refrigerant charging scales
4 mm hexagon wrench
Charging refrigerant
Opening liquid valve
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Installation Manual
Outdoor Unit
When an outdoor unit is installed in a location that is
always exposed to strong winds like a coast or on
the high stories of a building, one of the following is
recommended.
• Install the unit so that its discharge faces the wall of
the structure.
„Installation Location
WARNING
Install the outdoor unit in a location that can support
the weight of the outdoor unit.
Insufficient durability may cause the outdoor unit to fall,
which may result in injury.
Keep a distance 19.7” (500 mm) or more between the
unit and wall.
19.7" (500 mm)
CAUTION
Do not install the outdoor unit in a location that is
subject to combustible gas leaks.
Accumulation of combustible gas around the outdoor
unit may cause a fire.
Install the outdoor unit in a location that meets the
following conditions.
• A well-ventilated location free from obstacles near the
air inlets and air outlet
• Install the unit so that the discharge is at a right angle
relative to the wind direction.
• A location that does not increase the operating noise
or vibration of the outdoor unit
• A location that does not produce any drainage
problems from discharged water
Strong wind
Strong wind
• Location with easy access to power.
Do not install the outdoor unit in the following
location.
• A location with a saline atmosphere (coastal area) or
one that is full of sulfide gas (hot-spring area) (Special
maintenance is required.)
• Use wind baffle. Produce those parts in the field.
• When outside temperature conditions are 23 °F (-5
°C) or lower and unit is running in cooling mode.
<Example>
Wind baffle
Wind baffle
• A location subject to oil, vapor, oily smoke, or
corrosive gases
• A location in which organic solvent is used
• A location where high-frequency equipment (including
inverter equipment, private power generator, medical
equipment, and communication equipment) is used
(Installation in such a location may cause malfunction
of the air conditioner, abnormal control or problems
due to noise from such equipment.)
• A location in which the discharged air of the outdoor
unit blows against the window of a neighboring house
• A location where the operating noise of the outdoor
unit is transmitted
• When the outdoor unit is installed in an elevated
position, be sure to secure its feet.
• A location in which drain water poses any problems.
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Installation Manual
Unit : in (mm)
Outdoor Unit
„Required Clearances
Barrier at rear side
Barrier in front
▼ Upper side is free
1. Single unit installation
▼ Above unit is free
1. Single unit installation
2. Barrier on right, left and rear.
2. Multiple units installation
The height of the
barrier should be
lower than the height
of the outdoor unit.
5.9” (150)
or more
11.8” (300) or more
3. Multiple units installation
▼ Barrier also above unit
39.4” (1000)
or more
5.9”
(150)
or more
11.8”
11.8”
11.8”
(300)
(300)
(300)
or more
or more
or more
The height of the obstacle should be lower than the
height of the outdoor unit.
▼ Barrier also above unit
5.9” (150)
or more
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Installation Manual
Outdoor Unit
Barriers in front and back of unit
„Installation of Outdoor Unit
• Before installation, check the strength and horizontal
of the base so that abnormal sounds do not
emanate.
• According to the following base diagram, fix the base
firmly with the anchor bolts.
(Anchor bolt, nut: 3/8” (M10) x 4 pairs)
Open above and to the right and left of the unit.
The height of an barrier in both the front and rear of the
unit, should be lower than the height of the outdoor
unit.
▼ Standard installation
1. Single unit installation
Drain hole
5.9” (150)
20.7” (525)
5.9” (150)
23.6” (600)
1.8” (45)
Drain
nipple mounting hole
2. Multiple unit installation
Drain hole
a. Intake and supply parallel
1) Field fabricate a snow or an ice stand for the
unit using the above dimension.
2) Place snow or ice stand on a foundation/pad
and secure it to the foundation/pad and secure
it to the foundation/pad by anchor bolts.
NOTE
11.8” (300)
or more
When the outdoor unit is anchored directly on
the foundation/pad (cooling only protrude a
minimum of 6” (15 mm)).
11.8” (300) or more
b. Intake and supply in line
Open above and to the right and left of the unit.
The height of an obstacle in both the front and
rear of the unit should be lower than the height
of the outdoor unit.
0.6” (15 mm) or less
▼ Standard installation
7.9”
(200)
or more
59.1”
(1500)
or more
78.7”
(2000)
or more
39.4”
(1000)
or more
11.8”
(300) or
more
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Installation Manual
Outdoor Unit
3) Place unit on stand. Make sure it is level and
• When water is to be drained through the drain hose,
attach the following drain nipple and waterproof
rubber cap, and use the drain hose (Inner diameter:
0.6” (16 mm)) sold on the market. Also seal the
screws securely with silicone material, etc., to
prevent water from leaking.
Some conditions may cause condensation or
dripping of water.
• When collectively draining discharged water
completely, use a drain pan.
fasten securely to the stand.
•
As shown in the figure below, install the
foundation and vibration-proof rubber pads to
directly support the bottom surface of the fixing
leg that is in contact with the bottom plate of the
outdoor unit.
•
When installing the foundation for an outdoor
unit with downward piping, consider the piping
work.
GOOD
Mounting leg
Waterproof rubber cap
(5pcs.)
Drain nipple
Foundation
GOOD
Bottom plate
of outdoor unit
Drain nipple
Waterproof rubber cap
Foundation
Support the bottom surface of the
mounting leg that is in contact with
and underneath the bottom plate of
the outdoor unit.
„For Reference
Do not support
NO GOOD
the outdoor unit
only with the
If only the end of the
mounting leg is
supported, it may
deform.
If a heating operation is to be continuously performed
for a long time under the condition that the outdoor
temperature is 32 °F (0 °C) or lower, draining defrosted
water may be difficult due to the bottom plate freezing,
resulting in trouble with the cabinet or fan.
mounting leg.
Foundation
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Installation Manual
Outdoor Unit
6 REFRIGERANT PIPING
Piping connections are inside the front panel of the unit
and the front panel and pipe cover needs to be
removed before piping and wiring connections are
made.
Flaring
1. Cut the pipe with a pipe cutter.
Be sure to remove burrs that may cause a gas
leak.
2. Insert the supplied flare nut into the pipe, and then
flare the pipe.
Piping can enter the outdoor unit from the back, from
the side or from the bottom as shown
As the flaring sizes of R410A differ from those of
refrigerant R22, the flare tools newly manufactured
for R410A are recommended.
Front panel
Pipe cover
However, the conventional tools
B
can be used by adjusting the
projection margin of the copper
pipe.
Rear
Rearward
Pipe cover
▼ Projection margin in flaring : B (Unit : in (mm))
Rigid (Clutch type)
Side
Sideward
R410A tool
used
Conventional
tool used
Downward
Bottom
Outer diameter of
copper pipe
1. Remove the front panel of the unit.
2. Remove the pipe cover.
R410A
0.04” - 0.06”
(1.0 - 1.5)
3/8” (9.5)
0 - 0.02” (0 - 0.5)
3. Remove the appropriate knockout depending
on the orientation of the piping.
5/8” (15.9)
▼ Flaring diameter size : A (Unit : in (mm))
The pipe cover is easily mounted by cutting off
the slit at the lower part of the pipe cover.
+0
Outer diameter of copper pipe
3/8” (9.5)
A
-0.02" (–0.4)
0.52” (13.2)
0.78” (19.7)
5/8” (15.9)
* In case of flaring for R410A with the
conventional flare tool, pull the tool out
approx. 0.02” (0.5 mm) more than that for
R22 to adjust it to the specified flare size.
The copper pipe gauge is useful for
adjusting the projection margin size.
A
* Be sure to wear heavy work gloves while working.
4. Remove the burrs from the knockout opening
and use the factory supplied protective edge
guard material around the opening to protect the
piping and the wiring.
5. Remove the flare nut from the service valve on
outdoor unit. Insert the flare nut into the field
piping, and flare the pipe.
Bend the pipe approx. 90 degree with a pipe
bender for side and rear piping.
6. When the piping connections are complete re-
install the pipe cover.
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Installation Manual
Outdoor Unit
• After the installation work, be sure to check for gas
leaks of the pipe connections with nitrogen.
„Tightening of Flare
Connections
NO GOOD
1. Align the centers of the flare connections and fully
tighten the flare nuts with your fingers.
Cover
Valve at liquid side
Cap
Charge orifice
Piping valve
Tightened
Loosened
Flare nut
CAUTION
2. Use two wrenches to loosen or tighten the flare nut
on the gas service valve as shown in the figure.
Use only one wrench to loosen or tighten the flare
not on the liquid service valve.
1. Do not put the crescent wrench on the charge
orifice or cover.
The valve may be broken.
2. If applying excessive torque, the nut may break
according to some installation conditions.
The final tightening with a torque wrench should be
to the specifications shown in table below.
Unit : ft•lbs (N•m)
• Pressure of R410A is higher than that of R22
(Approx. 1.6 times).
Outer diameter of copper pipe
3/8” (9.5 mm)
Tightening torque
24 - 31 (33 - 42)
50 - 60 (68 - 82)
Therefore, using a torque wrench, tighten the flare
pipe connecting sections that connect the indoor/
outdoor units at the specified tightening torque.
Incomplete connections may cause not only a gas
leak, but also trouble with the refrigeration cycle.
5/8” (15.9 mm)
Valve at gas side
Cover
Do not apply refrigerant oil to the flared
surface.
Piping valve
Cap
Charge orifice
Flare nut
Tightened
Loosened
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Installation Manual
Outdoor Unit
7 ELECTRICAL CONNECTIONS
„Field wiring
WARNING
The dashed lines show field wiring.
ELECTRICAL SHOCK HAZARD
(Field power
supply)
(System
interconnection wires)
Failure to follow this warning could result in
personal injury or death.
L
1
2
L
1
2
L
L
1
2
Input
power
• The unit cabinet must have an uninterrupted or
unbroken ground to minimize personal injury if an
electrical fault should occur. The ground may consist
of electrical wire or metal conduit when installed in
accordance with existing electrical codes.
• Before performing service or maintenance, be sure
main power switch is turned OFF.
L
L
208/230 V~,
60 Hz
Remote
controller
S
S
circuit breaker
Outdoor unit
Indoor unit
ground
• System interconnection wire size must be AWG12.
• Breaker must have a capacity specified in the
following table.
CAUTION
• All wiring must comply with local electric codes and
NEC (National Electric Code) or CEC (Canadian
Electric Code).
All wiring and connections must comply with NEC, CEC,
local codes.
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage
or improper operation.
• Unit failure as a result of operation on improper line
voltage or excessive phase imbalance constitutes
abuse and may cause damage to electrical
components.
• Wrong wiring may cause a burn-out of some electrical
parts.
• Do not damage or scratch the conductive core or inner
insulator of the power and inter-connecting wires
when peeling them.
Model RAV-
SP240
208/230 V, 60 Hz
24 A
Power supply
MCA
MOCP (MAX Fuse/CB)
Breaker
40 A
25 A
System interconnection wires
MCA = Minimum Circuit Amps
AWG12
MOCP =Maximum Over Protection Device Amps.
• Connect the system interconnection wires (indoor to
outdoor) to the identical terminal numbers on the
terminal block of each unit.
Electric parts box
Electric control box
Incorrect connection may cause a failure.
Front panel
Front pane
1. With the front panel removed the electrical control
box is exposed at the top right corner of the unit.
2. Terminate the field wiring conduit (if used) at the
conduit connection holes provided.
Field wiring
terminal
blocks
3. Route the field power wires and the system
interconnection wires as shown on the following
pages. Terminate the wires at field wiring terminal
blocks located immediately below the electrical
control box.
Valve mounting
bracket
Conduit connection
Conduit connection
holes
holes
Pipe cover
Front Pipe cover
Piping knockout
Piping knockout
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Installation Manual
Outdoor Unit
2. Remove the wire cover from back of the front pipe
cover.
Field power supply
terminal block
System
interconncection
terminal block
Wire cover
Cable cover
L1
L2
S
L
1
L2
Ground screw
Ground screw
System
interconnection
wires
Field power
supply wires
Banding band
3. Pass the wires through the conduit connection holes
and attach the conduit connecters.
„Wiring
1. Remove the front panel and remove the front pipe
cover.
Remove the 4
screws.
Conduit connector
4. Connect the wires to the terminal blocks and fix the
wires to the wiring guide with the 2 included banding
band.
Front pipe cover
Terminal block
Do not make the
wires slack in this
section.
Wire guide
Fix with the 2
banding band.
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Installation Manual
Outdoor Unit
5. Pass the wires through the wiring guide of the front
pipe cover and adjust the wire lengths.
8. Connect 2 conduits.
Wiring guide
conduit
6. Attach the wire cover and hold the wires with the
wiring guide hooks.
Do not clip or damage the wires with the cover.
Fix with a screw.
Hook
Wire cover
7. Attach the front pipe cover with 4 screws.
Fix with 4
screws
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Installation Manual
Outdoor Unit
8 EVACUATE AND DEHYDRATE THE
SYSTEM
6. After evacuation is complete, fully close the low side
of manifold gage and stop operation of vacuum
pump.
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Never use the system compressor as a vacuum pump.
Deep Vacuum Method
The deep vacuum method requires a vacuum pump
capable of pulling a vacuum of 500 microns and a
vacuum gage capable of accurately measuring this
vacuum depth. The deep vacuum method is the most
positive way of assuring a system is free of air and
liquid water.
Refrigerant tubes and indoor heat exchanger should
be evacuated using the recommended deep vacuum
method of 500 microns. The alternate triple evacuation
method may be used if the procedure outlined below is
followed. Always break a vacuum with dry nitrogen.
Deep Vacuum Graph
5000
4500
4000
„SYSTEM VACUUM AND
CHARGE
LEAK IN
3500
SYSTEM
3000
2500
2000
Using Vacuum Pump
1. Completely tighten flare nuts A, B, C, D, connect
manifold gage charge hose to a charge port of the
low side service valve.
VACUUM TIGHT
1500
TOO WET
1000
TIGHT DRY
500
SYSTEM
Service Valve
Refrigerant
Low Side
Indoor Unit
0
1
2
3
4
5
6
7
Outdoor Unit
C
D
A
B
MINUTES
High Side
Triple Evacuation Method
Service Valve
The triple evacuation method should only be used
when vacuum pump is only capable of pumping down
to 28 in. of mercury vacuum and system does not
contain any liquid water.
Refer to “Triple Evacuation Method chart” and proceed
as follows:
2. Connect charge hose to vacuum pump.
3. Fully open the low side of manifold gage.
Manifold
Manifold Gage
500 microns
1. Pump system down to 28 in. of mercury and allow
pump to continue operating for an additional 15
minutes.
Low side valve
High side valve
Charge hose
2. Close service valves and shut off vacuum pump.
3. Connect a nitrogen cylinder and regulator to system
and open until system pressure is 2 psig.
4. Close service valve and allow system to stand for 1
hr. During this time, dry nitrogen will be able to
diffuse throughout the system absorbing moisture.
5. Repeat this procedure as indicated in the chart.
System will then be free of any cotaminants and
water vapor.
Charge hose
Vacuum pump
Low side valve
4. Start vacuum pump.
5. Evacuate using either deep vacuum or triple
evacuation method.
17-EN
– 17 –
Installation Manual
Outdoor Unit
Triple Evacuation Method chart
Open service valves
EVACUATE
Open or close the valve.
▼
▼ Liquid side
BREAK VACUUM WITH DRY NITROGEN
Open the valve with a 4 mm hexagon wrench.
▼
WAIT
▼ Gas side
▼
Valve unit
EVACUATE
▼
BREAK VACUUM WITH DRY NITROGEN
▼
WAIT
Using a straight blade
▼
EVACUATE
▼
screwdriver, turn it 90°
counter clockwise until
the valve is fully open
(against the stop).
Charge orifice
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACCUM)
▼
Flare nut
RELEASE CHARGE INTO SYSTEM
Final Tubing Check
Handle position
Fully closed
Fully opened
IMPORTANT:
Check to be certain factory tubing on both indoor and
outdoor unit has not shifted during shipment. Ensure
tubes are not rubbing against each other or any sheet
metal. Pay close attention to feeder rubes, making sure
wire ties on feeder tubes are secure and tight.
Stop pin
Main stopper
• While the valve is fully opened, after the screwdriver
has reached the stopper, do not apply torque
exceeding 4 ft•lbs (5 N•m). Applying excessive
torque may damage the valve.
Valve handling precautions
• Open the valve stem until it reaches the stop.
It is unnecessary to apply further force.
• Securely tighten the cap with a torque wrench.
• Cap tightening torque
Ø3/8” (9.5 mm)
24 - 31 ft•lbs (33 - 42 N•m)
Valve size
Ø5/8” (15.9 mm) 15 - 18 ft•lbs (20 - 25 N•m)
10 - 13 ft•lbs (14 - 18 N•m)
Charge port
EN
– 18 –
18-EN
Installation Manual
Outdoor Unit
9 FINISHING
After the refrigerant pipe, inter-unit wires, and drain pipe have been connected, make sure they are supported and
fixed in place for the entire length.
Keep the power wires and system interconnection wires away from all factory wiring and piping.
10TEST RUN
• Turn on the circuit breaker at least 12 hours before starting the system to preheat the compressor and
prevent damage.
To protect the compressor, power is supplied from the 208/230 VAC input to the unit to preheat the compressor.
• Check the following before starting a test run:
• That all pipes are connected securely without leaks.
• That the valve is open.
If the compressor is operated with the valve closed, the outdoor unit will become over pressurized, which may
damage the compressor or other components.
If there is a leak at a connection, air can be sucked in and the internal pressure further increases, which may
cause a burst or injury.
• Operate the air conditioner using the correct procedure as specified in the Owner’s Manual.
11PERIODIC MAINTENANCE
• For an air conditioning system that is operated on a regular basis, cleaning and maintenance of the indoor/
outdoor units are strongly recommended.
As a general rule, if an indoor unit is operated for about 8 hours daily, the indoor/outdoor units will need to be
cleaned at least once every 3 months. This cleaning and maintenance should be carried out by a qualified
service person.
Failure to clean the indoor/outdoor units regularly will result in poor performance, icing, water leaking and even
compressor failure.
19-EN
– 19 –
Installation Manual
Outdoor Unit
12TROUBLESHOOTING
You can perform fault diagnosis of the outdoor unit with the LEDs on the P.C. board of the outdoor unit in addition
to using the check codes displayed on the wired remote controller of the indoor unit.
Use the LEDs and check codes for various checks. Details of the check codes displayed on the wired remote
controller of the indoor unit are described in the Installation Manual of the indoor unit.
Verifying Fault code status (Outdoor control
board)
Verifying Fault code status stored in
memory (Outdoor control board)
1. Check that DIP switch SW803 is set to off.
2. Record the states (on or off) of LED 800 to LED 804
(Display mode 1).
1. Check that DIP switch SW803 is set to on.
2. Record the states (on or off) of LED 800 to LED 804
(Display mode 1).
3. Press SW800 for at least 1 second. The LED status
changes to display mode 2.
3. Press SW800 for at least 1 second. The LED status
changes to display mode 2.
4. Since display mode 1 covers multiple faults with the
same code display, mode 2 must also be used to
determine the final fault. Use the status recorded for
LED 800 to LED 804 in display mode 1 (Item 2
above) and combine it with the status for the same
LED’s in display mode 2 (Item 3 above) to determine
the complete fault code using the chart below.
4. Since display mode 1 covers multiple faults with the
same code display, mode 2 must also be used to
determine the final fault. Use the status recorded for
LED 800 to LED 804 in display mode 1 (Item 2
above) and combine it with the status for the same
LED’s in display mode 2 (Item 3 above) to determine
the complete fault code using the chart below.
NOTE
An outside air temperature (TO) sensor error can be
checked only when an error occurs.
Display mode 1
Display mode 2
No.
Cause
D800 D801 D802 D803 D804 D800 D801 D802 D803 D804
1
2
3
4
5
6
7
Normal
●
{
{
{
{
{
{
●
{
{
{
{
{
{
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
{
{
{
{
{
{
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
●
Discharge (TD) sensor error
Heat exchanger (TE) sensor error
Heat exchanger (TL) sensor error
Outside air temperature (TO) sensor error
Suction (TS) sensor error
●
●
●
●
●
Heat sink (TH) sensor error
Outdoor temperature sensor (TE/TS) connection
error
8
9
{
{
●
●
{
●
Outdoor EEPROM error
{
●
●
●
●
{
●
●
●
●
●
{
{
{
{
●
●
●
●
●
{
{
{
{
{
10 Compressor lock
●
●
●
●
●
●
●
●
●
●
●
●
●
11 Compressor lock
●
12 Current detection circuit error
13 Thermostat for compressor activated
●
●
Model data not set
14
●
{
{
●
{
●
●
●
(on the service P.C. board)
15 MCU-MCU communication error
16 Discharge temperature error
●
{
{
{
{
●
●
{
{
●
●
{
●
●
●
●
●
Abnormal power
(open phase detected or abnormal voltage)
17
{
{
{
●
{
EN
18 Heat sink overheat
19 Gas leak detected
{
{
{
{
{
{
{
{
{
●
●
●
{
{
{
●
●
20 4-way valve reverse error
●
●
(●:OFF {:ON :Flashing)
– 20 –
20-EN
Installation Manual
Outdoor Unit
Display mode 1
Display mode 2
No.
Cause
D800 D801 D802 D803 D804 D800 D801 D802 D803 D804
21 High pressure release operation
{
{
{
{
{
{
{
{
{
{
{
{
●
●
●
●
{
{
{
{
●
●
●
●
●
●
22 Outdoor fan motor error
23 Compressor driver short-circuit protection
24 Position detection circuit error in one-line display
●
●
(●:OFF {:ON :Flashing)
* The LEDs and DIP switches are located on the lower left of the P.C. board of the outdoor unit.
SW801
SW800
Enlargedview
of LEDs
D800
LED
D800
D801
D802
D803
D804
D805
SW804
D801
D802
D803
D804
D805
SW803
SW802
21-EN
– 21 –
Installation Manual
Outdoor Unit
13UNIT PUMP DOWN
• Use the pump down switch SW801 on the P.C. board of the outdoor unit to pump down the unit.
Procedure
1. Turn on the power of the air conditioner.
2. Select the FAN mode for indoor unit operation with the remote controller.
3. Set SW804 on the P.C. board of the outdoor unit to all OFF, and then press SW801 for 1 second or more. The
air conditioner enters the forced cooling mode for up to 10 minutes.
Pump down the unit during this 10 minutes.
4. Upon completion of pump down the unit, close the valve and press SW801 for at least 1 second to stop
operation.
5. Turn off the power.
Refrigerant
Pump down
recovery switch
SW801
SW801
P.C. board
P.C. board
switch
Optional
Optional connector
connector CN610
CN610
Special operation
Special operation
select switch
select switch
SW804
SW804
Existing pipe
Power save switch
s
S
w
W
it SW802
8
c
0
h
2
DANGER
Be careful of electric shock because the P.C. board has an electrical current running through it.
14POWER SAVE
• Power save can be set by setting SW802 dip switch.
Procedure
1. Turn on the SW802 dip switch 2 to activate Power save.
Power save controls reducing compressor periodicity (by approx. 10%) depending on the indoor unit heat
exchanger temperature in heating operation
SW802
... Power save setting
* All switches are OFF as factory default.
CAUTION
EN
Do not touch SW802 dip switch 1, 3 and 4.
If any changes are made, the unit may not work properly.
22-EN
– 22 –
EH99865401
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