Kelvinator KSV25CRJ, KSV35CRJ, KSV71CRJ, KSV71HWJ, KSV90HWJ Installation Manual

Inverter Air Conditioner

Installation Manual

KSV25CRJ, KSV35CRJ, KSV71CRJ,

KSV25HWJ, KSV35HWJ, KSV50HWJ,

KSV71HWJ, KSV90HWJ,

KSD25HWJ, KSD35HWJ, KSD50HWJ,

KSD71HWJ, KSD90HWJ

ENVIRONMENTAL TIPS

R300 refrigerant warning

Congratulations Contents

Congratulations and thank you for choosing our Inverter split
system room air conditioner. We are sure you will nd
your new air conditioner a pleasure to use. Before you use the air
conditioner, we recommend that you read through
the entire user manual, which provides the description of
the air conditioner and its functions.

To avoid the risks that are always present when you use an electrical
appliance, it is important that the air conditioner
is installed correctly and that you read the safety instructions
carefully to avoid misuse and hazards.

We recommend that you keep this instruction booklet
for future reference and pass it on to any future owner

After unpacking the air conditioner please check it is not damaged.
If in doubt, do not use the air conditioner but
contact your local Electrolux Customer Care Centre.

s.

Conditions of use

This appliance is intended to be used in household and similar
applications such as :

• staff kitchen areas in shops, ofces and other working
environments.

• farm houses.

• by clients in hotels, motels and other residential type

environments.

• bed and breakfast type environments.

This air conditioner is designed for and intended to be used in
normal domestic applications only.

Record model and serial number here:

Important Safety Instructions .................................................3

Installation instructions

Choosing a location to mount unit ...............................................4

Installation drawing .........................................................................5

Indoor unit installation

Installation plate mounting ............................................................6

Drilling the wall ................................................................................7

Connective pipe installation ..........................................................7

Drain piping ........................

.............................................................8

Outdoor unit installation

Location of outdoor unit ..............................................................10

Drain elbow installation ................................................................10

Refrigerant pipe connection ........................................................11

Flaring work ...................................................................................12

Test running

Air purging .....................................................................................15

Information servicing

Information servicing ....................................................................18

Warranty ......................................................................................23

Model number: ..................................................................................

Serial number: ..

.................................................................................

environment

Information on disposal for users

• Most of the packing materials are recyclable.
Please dispose of those materials through your local
recycling depot or by placing them in appropriate collection
containers.

• If you wish to discard this air conditioner, please contact your
local authorities and ask for the correct method
of disposal.

R32 refrigerant warning

This product uses R32 diuoromethane refrigerant, which is
a mildly ammable gas class 2.2 according according to
AS/NZS 5149 and must be handled by a refrigeration
mechanic with appropriate Australian refrigerant handling
licence.

2 Contents Kelvinator Air Conditioning

WARNING

WARNING

WARNING

WARNING

TIPS & INFORMATION

ENVIRONMENTAL TIPS

Important safety instructions Notice for installation

Please read this installation manual and the user manual before
installation and carefully store in a handy place for later reference.
Inside you will find many helpful hints on how to install and test the
air conditioner properly.

Incorrect installation due to ignoring this instruction may cause
harm or damage, which may not be covered by warranty.

warning

This symbol indicates information concerning your personal safety

caution

This symbol indicates information on how to avoid damaging
the appliance

important

This symbol indicates tips and information about use of the
appliance

environment

This symbol indicates tips and information about economical and
ecological use of the appliance

caution

1 The unit must only be installed by a qualified refrigeration

mechanic and electrical work carried out by a qualified
electrician according to AS/NZS 3000 electrical installation
standard and in accordance with all local and national
regulations.

2 If the installation is not completed by a suitably licensed

person, any faults resulting from poor installation may not be
covered under warranty.

3 Means for disconnection must be provided in the fixed wiring

according to AS/NZS 3000 and local wiring regulations, install
a suitable isolation switch in an accessible location adjacent to
this air conditioner.

4 The temperature of the refrigerant circuit will be high, please

keep the interconnection cable away from the copper tube.

5 This appliance is not intended for use by persons (including

children) with reduced physical, sensory or mental capabilities,
or lack of experience and knowledge, unless they have
been given supervision or instruction concerning use of the
appliance by a person responsible for their safety.

Children should be supervised to ensure that they do not play

with the appliance.

caution

• Contact an authorised installer for installation of this unit.

• Contact an authorised service technician for repair or
maintenance of this unit.

• Installation work must be performed in accordance with the
national wiring standards by authorised personnel only.

warning

Before obtaining access to terminals, all supply circuits must be
disconnected.

Kelvinator Air Conditioning Important safety instructions 3

Choosing a location to mount unit

Indoor unit

• Do not install the unit near any heat source, ammable gas or
steam.

• Choose a location where the air circulation is good, and where
there are no obstacles blocking the air ow.

• Select a place that will be convenient to run a drain to suitable
location outside.

• A place where noise prevention is taken into consideration.

• Do not install the unit near the door way.

• Ensure the restrictions on installation sp

unit installation drawings are met.

• Select a location which is
the device is not subjected to vibrations.

• The device should be installed at a distance of at least 1m
from all other electrical devices and installations, e.g. TV,
radio,computer, etc.

• Avoid installing in direct sunlight, if it's unavoidable consider
installing something to protect from direct sunlight.

enough for installation so that

ed in the indoor

reas

Your air conditioner is designed to condition the air for a certain
range of room size, please ensure the selection of your air
conditioner complies with the Kelvinator selection tool available
from www.kelvinator.com.au

This product uses mildly
of refrigerant require minimum room sizes. Please ensure that these
minimum room sizes are adhered to for standard installations (up
to 5m pipe length). If larger refrigerant charges than standard are
used then please consult AS/NZS 60335.2.40 to determine the safe
minimu

oor area for the installation.

ammable R32 refrigerant. Certain levels

Outdoor unit

• If an awning is built over the unit to prevent direct sunlight or
rain, be careful that heat radiation from the condenser is not
obstructed.

• Do not install outdoor unit in a location where the air outlet will
be directed on plants or animals as it may harm them.

• Make sure that there is suf
installation drawings.

• Do not place any obstacles which may cause a restriction of
the discharged air.

• Select a location which avoids causing a nuisance to
neighbours from noise and air emissions from device.

• Select a location which is suf

• Never cover the air inlets and outlets.

• The location must be suf

prevention of vibrations.

• There must be no risk presented by combustible gas or gas
escaping as a result of corrosion.

• Avoid a location where there is a high salt content.

• Avoid a location which is heavily exposed to dust.

• Avoid a location to which the general public have access.

nt space as spe ed in the

ntly well ventilated.

e r installation and the

Model Charge of R32 (g)

KSV25CRJ
KSV25HWJ
KSD25HWJ

KSV35CRJ
KSV35HWJ
KSD35HWJ

KSV50HWJ
KSD50HWJ

KSV71CRJ
KSV71HWJ
KSD71HWJ

KSV90HWJ
KSD90HWJ

800

850

1200

1300

2700

Minimum r area (m2)

N/A

N/A

2.00

2.44

6.95

4 Choosing a location Kelvinator Air Conditioning

Installation drawing

Fig. 1

Before screwing the remote
controller holder to the wall,
make sure that control signals
are properly received by
indoor unit.

4

Installation plate ng screw
ST3.9x25(5)

Remote
control

5

6

2x AAA batteries

7

12cm or more

30cm or more

A

3

15cm or more

1

12cm or more

Air

2

ter

Air outlet

200cm
or more

Additional drain pipe

Wrapping tape (wrap the
insulation pipe with the tape
from bottom to top)

60cm
or more

30cm or more

200cm or more

60cm or more

B

In sites with poor drainage, use block bases
for outdoor unit. Adjust its height until the
unit is leveled. Otherwise, water leakage or
pooling of water may occur.

Where there is a danger of the
unit falling, use foot bolts to

.

Allow two of A, B and
C directions to be free

C

from obstructions.

8 9

Seal

Drain elbow

Flare nuts

Air conditioner Qty. Qty.

1

Indoor unit

2

Outdoor unit

3

Indoor unit mounting plate

4

Mounting plate g screws, ST3.9x25 5 or 8*

7

1

1

1

Battery (AAA 1.5V)

8

Drain elbow & seal 1

9

Flare nuts 2

10

Installation Manual 1

2

5

Remote controller 1

6

Remote controller holder

11

User manual 1

1

* 9kW models have 8 screws, other models have 5 screws.

NOTE: Appearance of outdoor unit and indoor unit may differ from some models. The actual shape shall prevail.

Kelvinator Air Conditioning Installation drawing 5

Indoor unit installation

Remove the installation plate from the indoor unit. The installation
plate should be installed on a wall which can support the weight of
the indoor unit.

Indoor unit

Model

KSV25CRJ
KSV25HWJ
KSD25HWJ
KSV35CRJ
KSV35HWJ
KSD35HWJ

KSV50HWJ
KSD50HWJ
KSV71CRJ
KSV71HWJ
KSD71HWJ

KSV90HWJ
KSD90HWJ

dimensions
W x H x D (mm)

802 x 297 x 189

1080 x 335 x 226

1259 x 362 x 282

Weight (kg)

9.3

14.5

19.5

Installation plate mounting

ht tiF .1 e installation plate horizontally on structural parts of
the wall with suf
to accommodate the indoor unit and meet the clearance
requirements as per the assembly diagram, see

rppa esU .2 opriate w

d to which is suf nt to support the full weight of the

indoor unit.

3. Secure the installation plate to the wall with screws.

NOTE: Mount the installation plate and drill holes in the wall
according to the wall structure and corresponding mounting points
on the installation plate. The installation plate provided with the
machine differ from appliance to appliance. (Dimensions are in mm
unless otherwise stated).

Fig. 1

Correct orientation
of Installation Plate

nt space around the installation plate

ure 1.

gs suitable for the wall type being

Fig. 2

Left rear side
refrigerant
pipe hole

Left rear side
refrigerant
pipe hole

Ø65

Indoor unit
outline

Right rear side

232

192

297

Ø65

232

128

refrigerant

802

pipe hole

KSV25CRJ, KSV25HWJ, KSD25HWJ,
KSV35CRJ, KSV35HWJ, KSD35HWJ,

221

138

336

Ø75

298

149

578

Indoor unit
outline

Ø75

Right rear side
refrigerant

1080

pipe hole

KSV50HWJ, KSD50HWJ,
KSV71CRJ, KSV71HWJ, KSD71HWJ,

643.6

172

389

332

257

Indoor unit
outline

362

Left rear side
refrigerant
pipe hole

Ø90

1259

KSV90HWJ, KSD90HWJ,

6 Indoor unit installation Kelvinator Air Conditioning

Ø90

Right rear side
refrigerant
pipe hole

Indoor unit installation

WARNING

Drilling the wall

1. Choose the hole position to be either on the left or right side
of the installation plate and mark the position according to the
dimensions shown in

gure 2. Note most simple installation is

with hole on the right side.

2. Drill the piping hole with a hole core drill of the following
size: 65mm for models: KSV25CRJ, KSV25HWJ,
KSD25HWJ, KSV35CRJ, KSV35HWJ, KSD35HWJ,.
75mm for models: KSV50HWJ, KSD50HWJ, KSV71CRJ,
KSV71HWJ, KSD71HWJ.
90mm for models: KSV90HWJ, KSD90HWJ.

3. Drill the hole with slight (5-10mm) downward angle from indoor
to outdoor side so that the outside end is lower than the inside
end to help drainage, see

ure 3.

4. Insert a wall pipe or other means of protection to prevent the
pipes and electrical wires from toughing sharp edges within
the wall.

Connective pipe installation

1. For the left-hand and right-hand piping, remove the pipe
cover from the side panel.

2. For the right back and left back piping, install the piping
as shown.

NOTE: Bundle the pipes, connecting cable, and drain hose

with tape securely, evenly as shown in

gure 4 on the right.
The drain connection can be on the right side, left side or
both. If choosing to drain from both sides, another drain pipe
will need to be supplied by the installer. If choosing one side
drainage connection, make sure the drain hole on the other
side is well plugged. For 2.5kW & 3.5kW models, if choosing
left-hand or left-back piping, please choosing left side
drainage connection. The connection of t
must be connected by a qua

d installer in accordance with

he drain pipe hose

these instructions to prevent leakage.

3. Attach the drain hose to the underside of the refrigerant pipes
with adhesive vinyl tape.

4. Bundle the pipes, connecting cable, and drain hose with tape
securely, evenly as shown in Fig. 4.

5. Pass them through the wall hole.

6. Ensure that the drain hose has a continual downward fall from
the indoor side to the outdoor side to ensure the wat

e s
out smoothly. Failure to do this can result in water gathering in
and leaking from the indoor unit.

caution

• Do not put anything inside the condensate drain pan (refer to
ure 5), as this space is required to collect the condensate

prior to draining out of the indoor unit.

Fig. 3

Fig. 4

Fig. 5

Wall OutdoorIndoor

Move and tape
the drain hose
with piping in
a position as
mentioned in
Fig. below

Cover for
the piping

Cover for
the piping

Right piping

Left piping Left back

Indoor unit

Connective
cable

Drain hose

5-10mm

Cover for
the left piping

Rubber plug

piping

Condensate
drain pan

Pipe room

Connective
pipe

Wrapping
belt

Kelvinator Air Conditioning Indoor unit installation 7

Indoor unit installation

W ARNING

Drain piping

1. Run the drain hose as shown ure 6, ensuring it has a
constant downward fall.

2. The installer must supply a suitable drain hose extension to run
from the indoor unit drain hose to the desired drain location.
The drain hose extension should be
with the indoor unit drain hose, and secured in place with vinyl
tape. Ensure that the drain hose extension also has a continual
downward fall with an air gap at the bottom, and is drained to
a suitable location which will not cause damage to people or
property.

3. Remove the air
check the water

Fig 6.

Right Wrong

ter and pour some water into the drain pan to
ows smoothly.

No trap is permitted

tted and sealed tightly

Do not put the end of
drain hose into water

Connect the cable to the indoor unit

caution

Electrical installation must be completed by suitably quali d
electrician

Electric safety regulations for the initial installation

1. If there is serious safety problem about the power supply,
the technician should refuse to install the air conditioner and
explain to the client until the problem is solved.

2. Power voltage should be in the range of 90%–110%
of rated voltage.

3. The surge protector and main power switch with a 1.5 times
capacity of maximum. Current of the unit should be installed in
power circuit. Ensure the air conditioner is grounded well.

4. The appliance shall be installed in accordance with national
wiring regulations.

5. An all-pole disconnection device which has at least 3mm
clearances in all poles, the residual current device (RCD)
having a rated residual operating current not exceeding 30mA,
and disconnection must be incorporated in the
in accordance with the wiring rules. Refer to the table for
recommended circuit breaker rating for normal installation,
however national and local wiring regulations will prevail.

7. According to the attached electrical connection diagram
located on the panel of the indoor and outdoor unit to
connect the wire.

8. All wiring must comply with local and national electrical codes
and be installed by qua

9. Every wire must be connected
allowed to touch refrigerant tubing, the compressor, or any
moving parts.

10. Loose wiring will cause the terminal to overheat or result in
unit malfunction. A
sure all wiring is tightly connected.

This air conditioner will need to be installed on its own

11.
separate circuit, please refer to AS/NZS 3000 and local wiring
regulations for requirements.

12. For this air conditioner, the main power supply is fed to the
outdoor unit terminal block, ensure that the main power supply
wires running to the outdoor unit can carry the full current
of the air conditioner, which is stated on the rating label,
according
cable that connects from outdoor unit to indoor unit do not
carry the full compressor current, therefore 1.0mm
suitable for this application.

to national wiring regulations. The power and signal

d and skilled electricians.

rmly. No wire should be

re hazard may also exist. Therefore, be

d wiring

2

(or larger) is

8 Indoor unit installation Kelvinator Air Conditioning

Indoor unit installation

Recommended circuit breaker rating

Model Circut breaker rating (Amps)

KSV25CRJ, KSV25HWJ,
KSD25HWJ

15

Fig 7.

active
brown

) 2(SN)L(1

neutral

blue

signal
white

earth (yellow
and green)

Terminal block

KSV35CRJ, KSV35HWJ,
KSD35HWJ

KSV50HWJ, KSD50HWJ

KSV71CRJ, KSV71HWJ,
KSD71HWJ

KSV80HRG, KSD80HRG xxA

KSV90HWJ, KSD90HWJ

15

20

25

25

NOTE: The wire size of power supply cord and interconnected
wire and the current of the fuse or switch are determined by the
maximum current indicated on the nameplate which located on
the side panel of the unit. Please refer to the nameplate before
selecting the wire size, fuse or switch.

important

The air conditioners circuit board (PCB) is designed with a fuse to
provide over current protection. The spe
printed on the circuit board, such as:

Indoor unit: T3.15A/250VAC, T5A/250VAC (applicable for unit
adopts R32 refrigerant).

Outdoor unit: T20A/250VAC (for < 5.0kW unit), T30A/250VAC
(for > 5.0kW unit)

NOTE: Ceramic body fuse.

Connect the cable to the indoor unit

NOTE: Before performing any electrical work, turn off the main
power to the system.

1. Use suitably rated power cable to connect to the indoor unit.
Note the
indoor unit does not carry full compressor current, therefore
1mm
unit and outdoor unit accordingly.

2. Lift the indoor unit panel up, remove the wire box cover by
loosening the screw.

3. Feed in the active, neutral, earth and signal wires from the
outside until the wires are visible in the indoor u
block area.

4. Remove the cable clamp. Match wire colours with terminal
numbers on indoor and outdoor unit terminal blocks an
screw wires to the corresponding terminals. It is recommended
to use the following wire colour sequence:
1(L) = Brown;
2(N) = Blue;
S = White;
(Earth) = Yellow & Green.

5. Connect the end of the connection cable fully inserting into
the terminal block. Tighten the terminal block screws, then
gently pull on the wires to con

6. Fasten the connection cable with a cable clamp.

7.
the indoor unit cover.

main power supply goes to the outdoor unit and the

2

(or larger) wire is suitable for connecting between indoor

re box cover and secure with the screw, then close

tions of the fuse are

nit terminal

hey are securely attached.

Terminal block

Screw

Cable clamp

1. Use vinyl tape to tape the power cables to the drain pipe and
hose assembly with drain hose at the bottom.

2. Carefully pass the piping and wiring assembly through the
hole, taking care to ensure that no pipe or cable touches any
sharp edge within the cut wall.

3. Hook the indoor unit onto the upper portion of installation
plate (Engage the indoor unit with the upper edge of the
installation p

late). Ensure the hooks are properly seated on the

installation plate by moving it in left and right.

4. Piping can easily be made by lifting the indoor unit with a
cushioning material between the indoor unit and the wall.
Get it out after

h piping. When using a wall embedded pipe,
the indoor unit can be moved to the left or right for 30–50mm
(model dependent), which offers suf

t space to arrange
the pipes and ensure the indoor unit fully close to the wall
after installation.

rP .5 ess the lower left and right side of the unit against the

installation plate until hooks engages with the their slots.

Fig 8.

Wall embedded
pipe

Upper hook

Lower hook

Cushioning
material

y

30°

Move to left or right

30-50mm 30-50mm

Kelvinator Air Conditioning Indoor unit installation 9

150mm

Wire cover

Screw

Outdoor unit installation

WARNING

caution

• Install the outdoor unit on a rigid base to prevent excessive
noise level and vibration.

• Choose an outdoor unit location where the air outlet direction
is not blocked, and the clearances as per the assembly
diagra

• In the case that the installation location is exposed to strong
wind such as a seaside, make sure the fan can operate properly
by putting the unit lengthwise along the wall or using a dust
or shield plates. If installing on a wall bracket, the installer
must supply a suitable mounting bracket that can hold the full
weight of the product, use suitable
and must follow the installation instructions of the wall bracket
accordingly.

• The installation wall should be solid brick, concrete or the
same intensity construction, or take actions to reinforce,
support and add vibration dampening material as required.
The connection between the wall, bracket and the air
conditioner should be

• Be sure there is no obstacle which blocks the

Fig. 9

Strong
wind

ure 1) are followed.

Incorrect

gs to attach to the wall

rm, stable and reliable.

Correct

Barrier

Strong
wind

w.

Drain elbow installation

NOTE: The drain elbow is slightly different according to the
different outdoor unit. For the drain elbow with the seal (Fig.11
(A)),
elbow into the base pan hole of outdoor unit, rotate 90° to securely
assemble them. To install drain elbow as shown in Fig.11 (B), insert
the drain elbow into the base pan hole of outdoor unit until it
remain

The installer may supply and connect a drain hose to the drain
elbow to direct the condensed water to a suitable location that will
not cause damage to people or property."

In cold areas that can drop below 0°C, it is not recommended to
install a drain hose as it may be subject to freezing

t the seal onto the drain elbow, then insert the drain

ed with a clicking sound.

Fig. 10

H

W

A

Air inlet

Location of outdoor unit

• Anchor the outdoor unit with a 8 or 10 diameter bolt and nut
tightly and horizontally on a concrete or rigid mount.

Outdoor
unit
weight

Dimensions
A (mm)

(kg)

27.1

28.3

38.3

43.7

64.5

Dimensions
B (mm)

452 286

452 286

663 354

663 354

673 403

Model

KSV25CRJ
KSV25HWJ
KSD25HWJ

KSV35CRJ
KSV35HWJ
KSD35HWJ

KSV50HWJ
KSD50HWJ

KSV71CRJ
KSV71HWJ
KSD71HWJ

KSV90HWJ
KSD90HWJ

Outdoor unit
dimensions
W x H x D (mm)

765 x 555 x 303

765 x 555 x 303

890 x 673 x 342

890 x 673 x 342

1040 x 810 x 455

Fig. 11

Air inlet

D B

Air outlet

Seal Drain elbow Base pan hole

(A)

Seal

Drain pipe

of outdoor unit

(B)

10 Outdoor unit installation Kelvinator Air Conditioning

Outdoor unit installation

Refrigerant pipe connection

NOTE:

• The connectors used to join the indoor and outdoor
refrigeration pipes must be located outside. They cannot be
located inside or within a wall cavity where refrigerant may
build up in the case of a leak.

• Refrigeration pipe length will affect the capacity and energy
ef
the pipe length of 5 meters.

• If the installation requires pipe length greater than the
standard 5m, then add additional refrigerant according to the
below table, which also indicates the maximum pipe length
and maximum height difference between indoor and outdoor
units.

• Please also refer to the below table for discharge and suction
pipe diameter.

of the unit. The nominal ef ency is tested based on

Model

KSV25CRJ
KSV25HWJ
KSD25HWJ

KSV35CRJ
KSV35HWJ
KSD35HWJ

KSV50HWJ
KSD50HWJ

KSV71CRJ
KSV71HWJ
KSD71HWJ

KSV90HWJ
KSD90HWJ

Discharge
pipe
diameter

ø 6.35 (1/4") ø 9.52 (3/8")

ø 6.35 (1/4") ø 12.7 (1/2")

ø 6.35 (1/4") ø 12.7 (1/2")

ø 9.52 (3/8") ø 15.9 (5/8")

ø 9.52 (3/8") ø 15.9 (5/8")

Suction pipe
diameter

Standard
length
(m)

5 25 10 15

5 25 10 15

5 30 20 15

5 50 25 30

5 50 25 30

Maximum
length
(m)

Maximum
height
(m)

Additonal
refrigerant
(g/m)

Kelvinator Air Conditioning Outdoor unit installation 11

TIPS & INFORMATION

WARNING

Outdoor unit installation

Flaring work

important

For installer

It is critical that the installer follows the correct flaring procedure
using the right tools to produce good quality flares in order to
ensure installation without refrigerant gas leaks.

Service calls caused by poor installation are the responsibility of
the installer, and these service calls will be referred back to the
installer accordingly.

Please take care to make the flare connection carefully and test for
refrigerant leaks before commissioning the air conditioner.

Main cause for refrigerant leakage is due to defect in the flaring
work. Carry out correct flaring work using the following procedure:

Cut the pipes and the cable

1. Purchase the appropriate pipe size locally according to the
table on page 11.

2. Measure the distance between the indoor and the
outdoor unit.

3. Cut the pipes a little longer than the measured distance.

4. Cut the cable 1.5m longer than the pipe length.

5. Cut pipes must follow the requirements shown in figure 12.

Burr removal

1. Completely remove all burrs from the cut cross section
of the pipe.

2. Put the end of the copper pipe in a downward direction as you
remove burrs in order to avoid dropping burrs into
the the pipe, as shown in figure 13.

Fig. 12

Fig. 13

Fig. 14

"

90°

Point down

Copper tube

✗ ✗ ✗✓

Oblique

Flare nut

Roughness Burr

Pipe

Reamer

Checking flare work

Compare the flare work with the adjacent diagram. If the pipe has
any defect, cut off the flared section and redo the flare until it meets
the requirements.

caution

Putting nut on

Remove flare nuts attached to indoor and outdoor unit, then put
them on pipe/tube having completed burr removal (not possible to
put them on after flaring work).

Flaring work

Carry out flaring work using a flaring tool as shown in figure 15, and
ensure dimension A is maintained within the tolerance as indicated
in the table below.

Outer diameter (mm)

ø 6.35 (1/4") 1.3 0.7

ø 9.52 (3/8") 1.6 1.0

ø 12.7 (1/2") 1.8 1.0

ø 15.9 (5/8") 2.4 2.2

Dimension A (mm) as per

Max. Min.

g. 15

Fig. 15

Bar

A

Copper
pipe

Bar

Clamp
handle

Handle

Yoke

Cone

Red arrow mark

12 Outdoor unit installation Kelvinator Air Conditioning

Outdoor unit installation

WARNING

Tightening Connection

• Align the center of the pipes.

• Sufficiently tighten the flare nut with fingers, and then tighten it
with a spanner and torque wrench as shown in Fig.16 & 17.

Outer diameter (mm)

Torque (Nm)

ø 6.35 (1/4") 15-20

ø 9.52 (3/8") 35-40

ø 12.7 (1/2") 50-55

ø 15.9 (5/8") 60-65

caution

• Excessive torque can break the nut or flared pipe and cause
a leak, and too low torque can also cause a leak. Follow the
specified torque and use a torque wrench as required.

• When flared joints are reused, the flare part shall be
re-fabricated.

• Neatly run the refrigeration pipe from the indoor unit
connection to the outdoor unit suction and discharge
connections. Follow the same flaring procedure outlined
above to flare and connect the suction and discharge pipes to
the outdoor unit accordingly.

Insulating the pipes

Wrap suitable insulation material (supplied by the installer) separately
around each individual refrigeration pipe, the suction and discharge
pipes must not be in direct contact. Ensure that the flare connections
are covered, then wrap the insulated pipes with vinyl tape.

Attach the interconnecting electrical cable and drain pipe to
the pipe assembly with narrow vinyl tape, then wrap the whole
assembly with wide vinyl tape starting from top to bottom, as
pictured in the diagram below.

Finally plug the hole in the wall using gum type sealer.

heat insulation

Fig. 16

Indoor unit tubing Flare nut Pipings

Fig. 17

Outdoor unit electrical connection

1. Check that power supply to the air conditioner circuit is off

2. Confirm that power cable with suitable rating for the air
conditioner current rating has been run from the circuit breaker
to the isolation switch, according to AS/NZS 3000 & local
wiring rules.

3. Run power supply cable from the isolation switch to the
outdoor unit terminal block area. Also run the interconnecting
cables from the indoor unit to the outdoor unit terminal
block area. All exposed power cables must be protected, for
example in conduit.

4. Remove the terminal block cover and loosen the cable clamp
as shown in figure 18.

Fig. 18

Terminal block

Cover

Screw (1–2 model
dependant)

Cable clamp

connection
cable

suction line pipe liquid line pipe

pipe

vinyl tape
(narrow)

connection pipe

vinyl tape (wide)

drain hose

connection
power cable

incorrect

wrap with vinyl tape

pipe

vinyl tape
(narrow)

wrap with vinyl
tape (wide)

indoor pipe unit

5. Connect the interconnecting cable from the indoor unit to the
terminal block following the below wiring diagram, ensuring
that the colours match between indoor unit and outdoor unit.

6. Connect the main power supply cables from the isolation
switch to the outdoor unit terminal block following the wiring
diagram.

7. Ensure that the terminal block screws are secure by gently
pulling the wires.

8. Fit the cable clamp over the incoming wires to protect from
strain, then fit the cover and fix in place with the screw.

Kelvinator Air Conditioning Outdoor unit installation 13

Electrical connection

Wiring diagram

Indoor unit terminal block

1(L)

2(N)

Outdoor unit terminal block

1(L)

2(N)SS L N

(3)

Power supply

Key:
1(L) = Live (Brown)
2(N) = Neutral (Blue)
S = Signal (White)

= Earth (Yellow & Green)

Installation of DRED network cable

The following models are equipped with a RJ45 Demand Response
connection socket to facilitate demand response control by your
electricity provider:

KSD25HWJ, KSD35HWJ, KSD50HWJ, KSD71HWJ, KSD90HWJ

Please refer to your electricity provider for more information about
DRED.

The DRED socket is located inside the outdoor unit near the
terminal block, and is labelled "DR", refer to

Connect the demand response cable into the DRED socket labelled
DR, ensure that a click is heard to con

Secure the demand response cable in the cable clamp, then
terminal block cover and secure with screws.

re 19.

t has locked into place.

the

Fig. 19

Y/G

DR

2(N)

1(L)

INDOOR UNIT

L

S

POWE R SU PP LY

N

14 Outdoor unit installation Kelvinator Air Conditioning

Test running

W ARNING

W ARNING

Air purging

Air and other foreign matter in the refrigerant circuit causes
abnormal pressure rise, which may result in equipment damage
and even injury. Therefore, the indoor unit and tubing between
the indoor and outdoor unit must be leak tested and evacuated to
remove any non condensable and moisture from the system.

NOTE: Any brazed connections must be completed before
e

vacuation and prior to release of any refrigerant into the

refrigeration system. Low temperature solder must not be used.

Air purging with vacuum pump

• Preparation
Check that each tube (both liquid and gas side tubes) between
the indoor and outdoor units have been properly connected
and all wiring for the test run has been completed. Remove
the service valve caps from both the gas and the liquid side on
the outdoor unit. Note that both the liquid and the gas side
service valves on the outdoor unit are kept closed at this stage.

• Pipe length and refrigerant amount:

caution

R32 is a mildly able refrigerant. Make sure that the area has
been made safe by having suitable ventilation and is free from
ignition sources before charging or releasing the charge of R32.

warning

If additional refrigerant charge is added, please check the
minimum indoor room size for the complete air conditioner
R32 charge has been checked and complied with against the
requirements of AS/NZS 60335.2.40

Standard

Model

KSV25CRJ
KSV25HWJ
KSD25HWJ

KSV35CRJ
KSV35HWJ
KSD35HWJ

KSV50HWJ
KSD50HWJ

KSV71CRJ
KSV71HWJ
KSD71HWJ

KSV90HWJ
KSD90HWJ

Minimum length: 3m

Additional refrigerant required for pipe length greater than
standard 5m installation can be calculated using the following
equation:
M = (L - 5) x A
Where:
M = Mass of additional refrigerant (g)
L = Actual installed connecting pipe length (m)
A = Additional refrigerant
(g/m) (refer to the above table)

length
(m)

Maximum
length
(m)

5 25 10 15

5 25 10 15

5 30 20 15

5 50 25 30

5 50 25 30

required p

Maximum
height
(m)

er meter of connecting pipe

Additonal
refrigerant
(g/m)

Kelvinator Air Conditioning Test running 15

Outdoor unit installation

• Make sure the refrigerant added into the air conditioner is

liquid form.

Caution in handling the service valve

• To open the service valve, remove the cap then open the valve
stem using an Allen key until it hits the stopper, do not try to
open it further.

• To close the service valve, securely tighten the valve stem
using an Allen key, then t and tighten the cap with a spanner.

When Using the Vacuum Pump

(For method of using a manifold valve, refer to its operation
manual.)

Completely tighten the are nuts, A, B, C, D (as shown in

1.
Fig. 20) connect the manifold valve charge hose to a
charge port of the low-pressure valve on the gas pipe side.

2. Connect the charge hose connection to the vacuum pump.

3. Fully open the handle Lo of the manifold valve.

4. Operate the vacuum pump to evacuate. After starting
evacuation, slightly loose the
gas pipe side and check that the air is entering (Operation
noise of the vacuum pump changes and a compound meter
indicates 0 instead of minus). Then retighten the

5. Keep the vacuum pump running for more than 15 minutes and
make sure the pressure reading is -76cm.Hg or lower. Now
fully close the low handle of the manifold valve and stop the
operation of the vacuum pump.

6. Turn the stem of the packed valve B about 45 counterclockwise
for 6–7 seconds after the gas coming out, then tighten the

re nut again. Make sure the pressure display in the pressure

indicator is a little higher than the atmosphere pressure.

7. Remove the charge hose from the Low pressure charge hose.

8. Fully open the service valve stems B and A.

9. Securely tighten the cap of the service valve.

are nut of the Lo valve on the

re nut.

Fig. 20

Fig. 21

unit

Service valve

-76cmHg

Handle Lo

Charge hose

A. Low pressure
valve (3-way) ­gas side.

B. High pressure valve
(2-way) - liquid side

Valve body

Manifold valve

Pressure gaugeCompound meter

RefrigerantOutdoor

Flare nut

Valve stem

Handle Hi

Charge hose

Gas side

Liquid side

Stopper

Vacuum pump

C

D

Half union

Cap

Indoor
unit

16 Outdoor unit installation Kelvinator Air Conditioning

Low pressure valve

Electrical and gas leak check

Electrical safety check

Perform the electric safe check after completing installation:

1. Earth connection - Check the earth connection visually and
with a multi meter following national wiring rules to conrm
good earth connection of both the indoor unit and the
outdoor unit.

2. Earth leakage test - While the unit is running, conduct earth
leakage test with a multi meter. If high leakage current is
detected immediately switch off the unit and solve the
problem before proceeding. Follow earth leakage test
procedure as per national wiring rules.

Gas leak check

1. Soap water method: Apply a soap water or a liquid neutral
detergent on the indoor unit connections and outdoor unit
connections by a soft brush to check for leakage of the
connecting points of the piping. If bubbles come out, it
indicates that the pipes have leakage.

2. Leak detector method: Use a leak detector to check near
connections A, B, C & D for refrigerant leakage.

Fig. 22

Indoor unit
check point

Cover

Outdoor unit
check point

D C

B

A

Operation test

After conrming the electrical safety has passed and conrmed
there are no gas leaks, follow the below steps to complete an
operation test:

Check that all tubing and wiring have been properly connected.

Check that the gas and liquid side service valves are fully open.

1. Connect the power, press the ON/OFF button on the remote
controller to turn the unit on.

2. Use the MODE button to select COOL, HEAT, AUTO and FAN
to check if all the functions work well.

3. When the ambient temperature is too low (lower than 17°C),
the unit cannot be controlled by the remote controller to run in
cooling mode. Force the unit into cooling mode by using the
manual control button on the indoor unit as per

• Hold the panel sides and lift the panel up to an angle until it
remains xed with a clicking sound.

• Pressing the button once will put the unit into AUTO mode,
and the unit will automatically select heating or cooling based
on the ambient room conditions. Pressing the button twice
within 5 seconds will put the air conditioner into forced
cooling mode and “FC” will be shown on the display. After
about 30 minutes operation in forced cooling mode, the air
conditioner will switch to AUTO mode and “FC” will be
replaced with AUTO mode set temperature of “24” on the
display. Pressing the button again while the air conditioner
is operating will switch off the air conditioner.

4. The test operation should last about 30 minutes.

below.

Auto/Cool
Manual control

button

Kelvinator Air Conditioning Electrical and gas leak check 17

Information servicing

Checks to the area

Prior to beginning work on systems containing ammable
refrigerants, safety checks are necessary to ensure that the risk of
ignition is minimised. For repair to the refrigerating system, the
following precautions shall be complied with prior to conducting
work on the system.

Work procedure

Work shall be undertaken under a controlled procedure so as to
minimise the risk of a ammable gas or vapour being present while
the work is being performed.

General work area

All maintenance staff and others working in the local area shall
be instructed on the nature of work being carried out. Work in
conned spaces shall be avoided. The area around the work space
shall be sectioned
have been made safe by control of ammable material.

off. Ensure that the conditions within the area

Checking for presence of refrigerant

The area shall be checked with an appropriate refrigerant
detector prior to and during work, to ensure the technician is
aware of potentially ammable atmospheres. Ensure that the leak
detection equipment being used is suitable for use with ammable
refrigerants, i.e. no sparking, adequately sealed or intrinsically safe.

Presence of re extinguisher

If any hot work is to be conducted on the refrigeration equipment
or any associated parts, appropriate re extinguishing equipment
shall be available to hand. Have a dry powder or CO2 re
extinguisher adjacent to the charging area.

No ignition sources

No person carrying out work in relation to a refrigeration system
which involves exposing any pipe work that contains or has
contained ammable refrigerant shall use any sources of ignition
in such a manner that it may lead to the risk of re or explosion.
All possible ignition sources, including cigarette smoking, should
be kept sufciently far away from the site of installation, repairing,
removing and disposal, during which ammable refrigerant can
possibly be released to the surrounding space. Prior to work taking
place, the area around the equipment is to be surveyed to make
sure that there are no ammable hazards or ignition risks. NO
SMOKING signs shall be displayed.

Checks to the refrigeration equipment

Where electrical components are being changed, they shall be
t for the purpose and to the correct specication. At all times
the manufacturer's maintenance and service guidelines shall
be followed. If in doubt consult the manufacturer's technical
department for assistance.

• The following checks shall be applied to installations using
ammable refrigerants: the char
the room size within which the refrigerant containing parts are
installed;

• The ventilation machinery and outlets are operating
adequately and are not obstructed;

• If an indirect refrigerating circuit is being used, the secondary
circuit shall be checked for the presence of refrigerant; marking
to the equipment continues to be visible and legible.

• Markings and signs that are illegible shall be corrected;
refrigeration pipe or components are installed in a position
where they are unlikely to be exposed to any substance which
may corrode refrigerant containing components, unless the
components are
resistant to being corroded or are suitably protected against
being so corroded.

constructed of materials which are inherently

ge size is in accordance with

Checks to electrical devices

Repair and maintenance to electrical components shall include
initial safety checks and component inspection procedures. If a
fault exists that could compromise safety, then no electrical supply
shall be connected to the circuit until it is satisfactorily dealt with.
If the fault cannot be corrected immediately but it is necessary to
continue operation, an adequate temporary solution shall be used.
This shall be reported to the owner of the equipment so all parties
are advised.

Initial safety check

• That capacitors are discharged: this shall be done in a safe
manner to avoid possibility of sparking;

• That there is no live electrical components and wiring are
exposed while charging, recovering or purging the system;

• That there is continuity of earth bonding.

s shall include:

Ventilated area

Ensure that the area is in the open or that it is adequately ventilated
before breaking into the system or conducting any hot work.
A degree of ventilation shall continue during the period that the
work is carried out. The ventilation should safely disperse any
released refrigerant and preferably expel it externally into the
atmosphere.

18 Information ser vicing Kelvinator Air Conditioning

Information servicing

Repairs to sealed components

1. During repairs to sealed components, all electrical supplies
shall be disconnected from the equipment being worked upon
prior to any removal of sealed covers, etc. If it is absolutely
necessary to have an electrical supply to equipment during
servicing, then a permanently operating form of leak detection
shall be located at the most critical point to warn of a
potentially hazardous situation.

2. Particular attention shall be paid to the following to ensure that
by working on electrical components, the casing is not altered
in such a way that the level of protection is affected. This shall
include damage to cables, excessive number of connections,
terminals not made to original specification, damage to seals,
incorrect fitting of glands, etc.

• Ensure that apparatus is mounted securely.

• Ensure that seals or sealing materials have not degraded
such that they no longer serve the purpose of preventing the
ingress of flammable atmospheres. Replacement parts shall be
in accordance with the manufacturer's specifications.

NOTE: The use of silicon sealant may inhibit the effectiveness
of some types of leak detection equipment. Intrinsically safe
components do not have to be isolated prior to working on them.

Repair to intrinsically safe components

Do not apply any permanent inductive or capacitance loads to the
circuit without ensuring that this will not exceed the permissible
voltage and current permitted for the equipment in use. Intrinsically
safe components are the only types that can be worked on while
live in the presence of a flammable atmosphere. The test apparatus
shall be at the correct rating. Replace components only with parts
specified by the manufacturer. Other parts may result in the ignition
of refrigerant in the atmosphere from a leak.

Removal and evacuation

When breaking into the refrigerant circuit to make repairs or for any
other purpose conventional procedures shall be used. However,
it is important that best practice is followed since flammability is a
consideration. The following procedure shall be adhered to

• Remove refrigerant;

• Purge the circuit with inert gas;

• Evacuate;

• Purge again with inert gas;

• Open the circuit by cutting or brazing.

The refrigerant charge shall be recovered into the correct recovery
cylinders. The system shall be flushed with OFN to render the
unit safe. This process may need to be repeated several times.
Compressed air or oxygen shall not be used for this task. Flushing
shall be achieved by breaking the vacuum in the system with OFN
and continuing to fill until the working pressure is achieved, then
venting to atmosphere, and finally pulling down to a vacuum. This
process shall be repeated until no refrigerant is within the system.
When the final OFN charge is used, the system shall be vented
down to atmospheric pressure to enable work to take place. This
operation is absolutely vital if brazing operations on the pipe-work
are to take place. Ensure that the outlet for the vacuum pump is not
close to any ignition sources and there is ventilation available.

Cabling

Check that cabling will not be subject to wear, corrosion,
excessive pressure, vibration, sharp edges or any other adverse
environmental effects. The check shall also take into account
the effects of aging or continual vibration from sources such as
compressors or fans.

Leak detection methods

The following leak detection methods are deemed acceptable
for systems containing flammable refrigerants. Electronic leak
detectors shall be used to detect flammable refrigerants, but
the sensitivity may not be adequate, or may need re-calibration.
(Detection equipment shall be calibrated in a refrigerant-free
area.) Ensure that the detector is not a potential source of ignition
and is suitable for the refrigerant used. Leak detection equipment
shall be set at a percentage of the LFL of the refrigerant and shall
be calibrated to the refrigerant employed and the appropriate
percentage of gas (25 % maximum) is confirmed. Leak detection
fluids are suitable for use with most refrigerants but the use of
detergents containing chlorine shall be avoided as the chlorine
may react with the refrigerant and corrode the copper pipe­work. If a leak is suspected, all naked flames shall be removed or
extinguished. If a leakage of refrigerant is found which requires
brazing, all of the refrigerant shall be recovered from the system, or
isolated (by means of shut off valves) in a part of the system remote
from the leak. Oxygen free nitrogen (OFN) shall then be purged
through the system both before and during the brazing process.

Kelvinator Air Conditioning Information servicing 19

Information servicing

Charging procedures

In addition to conventional charging procedures, the following
requirements shall be followed:

• Ensure that contamination of different refrigerants does not
occur when using charging equipment. Hoses or lines shall
be as short as possible to minimize the amount of refrigerant
contained in them.

• Cylinders shall be kept upright.

• Ensure that the refrigeration system is earthed prior to

charging the system with refrigerant.

• Label the system when charging is complete (if not already).

• Extreme care shall be taken not to overll the refrigeratio

system.

• Prior to recharging the system it shall be pressure tested
with OFN. The system shall be leak tested on completion of
charging but prior to commissioning. A follow up leak test shall
be carried out prior to leaving the site.

n

Decommissioning

Before carrying out this procedure, it is essential that the technician
is completely familiar with the equipment and all its detail. It is
recommended good practice that all refrigerants are recovered
safely. Prior to the task being carried out, an oil and refrigerant
sample shall be taken.

In case analysis is required prior to re-use of reclaimed refrigerant.
It is essential that electrical power is available before the task is
commenced.

a) Become

b) Isolate system electrically.

c) Before attempting the procedure ensure that:

• Mechanical handling equipment is available, if required,

• All personal protective equipment is available and being

• All times by a competent person.

• Recovery equipment and cylinders conform to the

d) Pump down refrigerant system, if possible.

e) If a vacuum is not possible, make a manifold so that refrigerant

can be removed from various parts of the system.

f) Make sure

recovery takes place.

g) Start the recovery machine and operate in accordance with

manufacturer's instructions.

h) Do not overll cylinders. (No more than 80 % volume liquid

charge).

i) Do not exceed the maximum working pressure of the cylinder,

even temporarily.

j) When the cylinders have been lled correctly and the process

completed, make sure that the cylinders and the equipment
are removed from site promptly and all isolation valves on the
equipment are closed off.

familiar with the equipment and its operation.

for handling refrigerant cylinders;

used correctly; the recovery process is supervised at

appropriate standards.

that cylinder is situated on the scales before

k) Recovered refrigerant shall not be charged into another

refrigeration system unless it has been cleaned and checked.

Labelling

Equipment shall be labelled stating that it has been
de-commissioned and emptied of refrigerant. The label shall be
dated and signed. Ensure that there are labels on the equipment
stating the equipment contains ammable refrigerant.

Recovery

• When removing refrigerant from a system, either for servicing
or decommissioning, it is recommended good practice that all
refrigerants are removed safely.

• When transferring refrigerant into cylinders, ensure that only
appropriate refrigerant recovery cylinders are employed.
Ensure that the correct numbers of cylinders for holding the
total system charge are available. All cylinders to be used are
designated for the
refrigerant (i.e. special cylinders for the recovery of refrigerant).
Cylinders shall be complete with pressure relief valve and
associated shut-off valves in good working order.

• Empty recovery cylinders are evacuated and, if possible,
cooled before recovery occurs.

• The recovery equipment shall be in good working order with
a set of instructions concerning the equipment that is at hand
and shall be suitable for the recovery inammable refrigerants.
In addition, a set of calibrated weighing scales shall be
available and in good working order.

• Hoses shall be complete with leak-free disconnect couplings
and in good cond
check that it is in satisfactory working order, has been properly
maintained and that any associated electrical components are
sealed to prevent ignition in the event of a refrigerant release.
Consult manufacturer if in doubt.

• The recovered refrigerant shall be returned to the refrigerant
supplier in the correct recovery cylinder, and the relevant
Waste Transfer Note arranged. Do not mix refrigerants in
recovery units and especially not in cylinders. If compressors
or compressor oils are to be removed, ensure that they have
been evacuated to an acceptable level to make certain that
ammable refrigerant does not
The evacuation process shall be carried out prior to returning
the compressor to the suppliers. Only electric heating to the
compressor body shall be employed to accelerate this process.
When oil is drained from a system, it shall be carried out safely.

recovered refrigerant and labelled for that

ition. Before using the recovery machine,

remain within the lubricant.

Transportation, marking and storage for units

1. Transport of equipment containing ammable refrigerants
compliance with the transport regulations.

2. Marking of equipment using signs compliance with local
regulations.

3. Disposal of equipment using ammable refrigerants
Compliance with national regulations.

4. Storage of equipment/appliances The storage of equipment
should be in accordance with the manufacturers instructions.

. Storage of packed (unsold) equipment

5

Storage package protection should be constructed such that
mechanical damage to the equipment inside the package
will not cause a leak of the refrigerant charge. The maximum
number of pieces of equipment permitted to be stored
together will be determined by local regulations.

20 Information ser vicing Kelvinator Air Conditioning

Notes

Kelvinator Air Conditioning Notes 21

Notes

22 Notes Kelvinator Air Conditioning

Kelvinator Air Conditioning Warranty 23

For more information on all Kelvinator
appliances, or for dimension and installation
information, call into your retailer, phone or email
our customer care team or visit our website:

AUSTRALIA

phone: [phone]
fax: [phone]
email: [e-mail]
web: kelvinator.com.au

NEW ZEALAND

phone: [phone]
fax: [phone]
email: [e-mail]
web: kelvinator.co.nz

Kelvinator. We are part of the Electrolux Family.
To add a touch of professional inspiration to
your home, visit electrolux.com.au

© 2018 Electrolux Home Products Pty Ltd.
ABN 51 004 762 341
June20_KMAN_AIRCARE_IM