LG ARUN40GS2A INSTALLATION MANUAL

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INSTALLATION MANUAL

AIR CONDITIONER

ÅPlease read this installation manual completely before installing the product.

ÅInstallation work must be performed in accordance with the national wiring standards by authorized personnel only.

ÅPlease retain this installation manual for future reference after reading it thoroughly.

TYPE :

www.lg.com

ARUN/ARUV Series Outdoor Unit Installation Manual

TABLE OF CONTENTS

Safety Precautions.......................................................................................................	3
Installation Process .....................................................................................................	7
Outdoor Units Information ..........................................................................................	8
Before installation......................................................................................................	10
Select the Best Location............................................................................................	11
Installation Space.......................................................................................................	12
Installation ..................................................................................................................	16
Refrigerant piping ......................................................................................................	20
Electrical Wiring .........................................................................................................	40
Test Run ......................................................................................................................	58
Caution For Refrigerant Leak....................................................................................	70
Installation guide at the seaside...............................................................................	72

2 Outdoor Unit

Safety Precautions

Safety Precautions

To prevent injury to the user or other people and property damage, the following instructions must be followed.

νIncorrect operation due to ignoring instruction will cause harm or damage. The seriousness is classified by the following indications.

This symbol indicates the possibility of death or serious injury.

This symbol indicates the possibility of injury or damage to properties only.

ν Meanings of symbols used in this manual are as shown below.

Be sure not to do.

Be sure to follow the instruction.

ν Installation

Have all electric work done by a licensed electrician according to "Electric Facility Engineering Standard" and "Interior Wire Regulations" and the instructions given in this manual and always use a special circuit.

•If the power source capacity is inadequate or electric work is performed improperly, electric shock or fire may result.

Always ground the product.

•There is risk of fire or electric shock.

For re-installation of the installed product, always contact a dealer or an Authorized Service Center.

•There is risk of fire, electric shock, explosion, or injury.

Do not store or use flammable gas or combustibles near the air conditioner.

•There is risk of fire or failure of product.

Prepare for strong wind or earthquake and install the unit at the specified place.

•Improper installation may cause the unit to topple and result in injury.

Ask the dealer or an authorized technician to install the air conditioner.

•Improper installation by the user may result in water leakage, electric shock, or fire.

Always intstall a dedicated circuit and breaker.

•Improper wiring or installation may cause fire or electric shock.

Do not install, remove, or re-install the unit by yourself (customer).

•There is risk of fire, electric shock, explosion, or injury.

Use the correctly rated breaker or fuse.

•There is risk of fire or electric shock.

Do not install the product on a defective installation stand.

•It may cause injury, accident, or damage to the product.

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Installation Manual 3

Safety Precautions

When installing and moving the air conditioner to another site, do not charge it with a different refrigerant from the refrigerant specified on the unit.

•If a different refrigerant or air is mixed with the original refrigerant, the refrigerant cycle may malfunction and the unit may be damaged.

Ventilate before operating air conditioner when gas leaked out.

•It may cause explosion, fire, and burn.

Do not reconstruct to change the settings of the protection devices.

•If the pressure switch, thermal switch, or other protection device is shorted and operated forcibly, or parts other than those specified by LGE are used, fire or explosion may result.

Securely install the cover of control box and the panel.

•If the cover and panel are not installed securely, dust or water may enter the outdoor unit and fire or electric shock may result.

If the air conditioner is installed in a small room, measures must be taken to prevent the refrigerant concentration from exceeding the safety limit when the refrigerant leaks.

•Consult the dealer regarding the appropriate measures to prevent the safety limit from being exceeded. Should the refrigerant leak and cause the safety limit to be exceeded, harzards due to lack of oxygen in the room could result.

ν Operation

Do not damage or use an unspecified power cord.

•There is risk of fire, electric shock, explosion, or injury.

Be cautious that water could not enter the product.

•There is risk of fire, electric shock, or product damage.

When the product is soaked (flooded or submerged), contact an Authorized Service Center.

•There is risk of fire or electric shock.

Take care to ensure that nobody could step on or fall onto the outdoor unit.

•This could result in personal injury and product damage.

Use a dedicated outlet for this appliance.

•There is risk of fire or electrical shock.

Do not touch the power switch with wet hands.

•There is risk of fire, electric shock, explosion, or injury.

Be cautious not to touch the sharp edges when installing.

•It may cause injury.

Do not open the inlet grille of the product during operation. (Do not touch the electrostatic filter, if the unit is so equipped.)

•There is risk of physical injury, electric shock, or product failure.

4 Outdoor Unit

Safety Precautions

ν Installation

Always check for gas (refrigerant) leakage after installation or repair of product.

•Low refrigerant levels may cause failure of product.

Keep level even when installing the product.

•To avoid vibration or water leakage.

Use power lines of sufficient current carrying capacity and rating.

•Cables that are too small may leak, generate heat, and cause a fire.

Do not install the product where the noise or hot air from the outdoor unit could damage the neighborhoods.

•It may cause a problem for your neighbors.

Do not install the unit where combustible gas may leak.

•If the gas leaks and accumulates around the unit, an explosion may result.

Do not use the product for special purposes, such as preserving foods, works of art, etc. It is a consumer air conditioner, not a precision refrigeration system.

•There is risk of damage or loss of property.

Keep the unit away from children. The heat exchanger is very sharp.

•It can cause the injury, such as cutting the finger. Also the damaged fin may result in degradation of capacity.

When installting the unit in a hospital, communication station, or similar place, provide sufficient protection against noise.

•The inverter equipment, private power generator, high-frequency medical equipment, or radio communication equipment may cause the air conditioner to operate erroneously, or fail to operate. On the other hand, the air conditioner may affect such equipment by creating noise that disturbs medical treatment or image broadcasting.

Do not install the product where it is exposed to sea wind (salt spray) directly.

•It may cause corrosion on the product. Corrosion, particularly on the condenser and evaporator fins, could cause product malfunction or inefficient operation.

ν Operation

Do not use the air conditioner in special environments.

•Oil, steam, sulfuric smoke, etc. can significantly reduce the performance of the air conditioner or damage its parts.

Make the connections securely so that the outside force of the cable may not be applied to the terminals.

•Inadequate connection and fastening may generate heat and cause a fire.

Do not block the inlet or outlet.

•It may cause failure of appliance or accident.

Be sure the installation area does not deteriorate with age.

•If the base collapses, the air conditioner could fall with it, causing property damage, product failure, or personal injury.

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Installation Manual 5

Safety Precautions

Install and insulate the drain hose to ensure that water is drained away properly based on the installation manual.

•A bad connection may cause water leakage.

Be very careful about product transportation.

•Only one person should not carry the product if it weighs more than 20 kg.

•Some products use PP bands for packaging. Do not use any PP bands for a means of transportation. It is dangerous.

•Do not touch the heat exchanger fins. Doing so may cut your fingers.

•When transporting the outdoor unit, suspending it at the specified positions on the unit base. Also support the outdoor unit at four points so that it cannot slip sideways.

Safely dispose of the packing materials.

Turn on the power at least 6 hours before starting operation.

•Packing materials, such as nails and other metal or wooden parts, may cause stabs or other injuries.

•Tear apart and throw away plastic packaging bags so that children may not play with them. If children play with a plastic bag which was not torn apart, they face the risk of suffocation.

•Starting operation immediately after turning on the main power switch can result in severe damage to internal parts. Keep the power switch turned on during the operational season.

Do not touch any of the refrigerant piping during and after operation.

•It can cause a burn or frostbite.

Do not directly turn off the main power switch after stopping operation.

•Wait at least 5 minutes before turning off the main power switch. Otherwise it may result in water leakage or other problems.

Use a firm stool or ladder when cleaning or maintaining the air conditioner.

•Be careful and avoid personal injury.

Do not operate the air conditioner with the panels or guards removed.

•Rotating, hot, or high-voltage parts can cause injuries.

Auto-addressing should be done in condition of connecting the power of all indoor and outdoour units. Auto-addressing should also be done in case of changing the indoor unit PCB.

Do not insert hands or other objects through the air inlet or outlet while the air conditioner is plugged in.

•There are sharp and moving parts that could cause personal injury.

6 Outdoor Unit

Installation Process

Installation Process

Determination of division work

Indicate clearly who is to be responsible for switch settings

Make relationship between outdoor, indoor, remote controller, and option connections clear.

Preparation of contract drawings

(Prepare control circuit diagram)

Sleeve and insert work

Installation of indoor unit

Refrigerant piping work

Drain pipe work

Duct work

Heat insulation work

Electrical work

(connection circuits and drive circuits)

Take account of gradient of drain piping

Check model name to make sure the fitting is made correctly

Special attention to dryness, cleanness and tightness

Adjust to downward gradient

Make sure airflow is sufficient

Make sure no gaps are left where the insulating materials are joined

Multiple core cable must not be used. (suitable cable should be selected)

Outdoor unit foundation work

The foundation must be level even

Installation of outdoor unit

Avoid short circuits and ensure sufficient space is allowed for service

Airtight test

Vacuum drying

Additional charge of refrigerant

Fit facing panels

Automatic addressing of indoor unit

Test run adjustment

Transfer to customer with explanation

In the final check for 24hours at 3.8 MPa(38.7 kgf/cm2) there must be no drop in pressure.

The vacuum pump used must have a capacity of reaching at least 5 torr, more than 1 hour

Recharge correctly as calculated in this manual. and record the amount of added refrigerant

Make sure there are no gaps left between the facing materials used on the ceiling

Refer to automatic addressing flowchart

Preheat the crank case with the electrical heater for more than 6 hours. (In case of outdoor temperature below 10)

Run each indoor unit in turn to make sure the pipe work has been fitted correctly

Explain the use of the system as clearly as possible to your customer and make sure all relevant documentation is in order

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•The above list indicates the order in which the individual work operations are normally carried out but this order may be varied where local conditions warrants such change.

•The wall thickness of the piping should comply with the relevant local and national regulations for the designed pressure 3.8MPa.

•Since R410A is a mixed refrigerant, the required additional refrigerant must be charged in its liquid state.(If the refrigerant is charged in its gaseous state, its composition changes and the system will not work properly.)

Installation Manual 7

Outdoor Units Information

Outdoor Units Information

	Chassis	External Apperance	Outdoor	Phase	PFC	Model
			Fan			Heat Pump	Cooling Only
				1Ø	PFC	ARUN50GS2A	ARUV60GS2A
						ARUN60GS2A
						ARUN40LS2A	ARUV40LS2A
	U3		2 FAN		PFC	ARUN50LS2A	ARUV50LS2A
				3Ø		ARUN60LS2A	ARUV60LS2A
						ARUN40LS2B	ARUV40LS2B
					Active Filter	ARUN50LS2B	ARUV50LS2B
						ARUN60LS2B	ARUV60LS2B
	U4		1 FAN	1Ø	PFC	ARUN40GS2A	ARUV50GS2A
							ARUV40GS2A

CAUTION

Ratio of the connectable Indoor Units to the Outdoor: Within 50 ~ 130% Ratio of running Indoor Units to the Outdoor: Within 10 ~ 100%

A combination operation over 100% cause to reduce each indoor unit capacity.

Power Supply : 1Ø, 220~240V, 50Hz / 1Ø, 220V, 60Hz

ν Heat Pump Model

Chassis			U4	U3	U3
System(HP)			4	5	6
Model			ARUN40GS2A	ARUN50GS2A	ARUN60GS2A
Refrigerant	Product charge	kg	1.8	3.0	3.0
	CF(Correction Factor)	kg	0	0	0
Max. Connectable No. of Indoor Units			6	8	9
Net Weight(Gross Weight)		kg	77	106	106
Dimensions (WxHxD)		mm	950×834×330	950×1380×330	950×1380×330
		inch	37.4×32.8×13.0	37.4×54.3×13.0	37.4×54.3×13.0
Connecting Pipes	Liquid Pipes	mm	9.52	9.52	9.52
		inch	3/8	3/8	3/8
	Gas Pipes	mm	15.88	15.88	19.05
		inch	5/8	5/8	3/4
	Connection Type		FLARE	BRAZING	BRAZING

8 Outdoor Unit

Outdoor Units Information

ν Cooling Only Model

Chassis			U4	U4	U3
System(HP)			4	5	6
Model			ARUV40GS2A	ARUV50GS2A	ARUN60GS2A
Refrigerant	Product charge	kg	1.95	1.95	3.0
	CF(Correction Factor)	kg	0	0	0
Max. Connectable No. of Indoor Units			6	8	9
Net Weight(Gross Weight)		kg	78	78	106
Dimensions (WxHxD)		mm	950×834×330	950×834×330	950×1380×330
		inch	37.4×32.8×13.0	37.4×32.8×13.0	37.4×54.3×13.0
Connecting Pipes	Liquid Pipes	mm	9.52	9.52	9.52
		inch	3/8	3/8	3/8
	Gas Pipes	mm	15.88	15.88	19.05
		inch	5/8	5/8	3/4
	Connection Type		FLARE	FLARE	BRAZING

Power Supply : 3Ø, 380~415V, 50Hz/ 3Ø, 380V, 60Hz

*A:PFC model, B:Active Filter model

	Chassis			U3	U3	U3
	System(HP)			4	5	6
	Model			ARUN40LS2*	ARUN50LS2*	ARUN60LS2*
				ARUV40LS2*	ARUV50LS2*	ARUV60LS2*
	Refrigerant	Product charge	kg	3.0	3.0	3.0
		CF(Correction Factor)	kg	-0.5	0	0
	Max. Connectable No. of Indoor Units			6	8	9
	Net Weight		kg	107	107	107
	Dimensions (WxHxD)		mm	950 x 1,380 x 330	950 x 1,380 x 330	950 x 1,380 x 330
			inch	37.4 x 54.3 x 13.0	37.4 x 54.3 x 13.0	37.4 x 54.3 x 13.0
		Liquid Pipes	mm	Ø9.52	Ø9.52	Ø9.52
	Connecting Pipes		inch	3/8	3/8	3/8
		Gas Pipes	mm	Ø15.88	Ø15.88	Ø19.05
			inch	5/8	5/8	3/4

Connectable Indoor Unit

should be connected with "2 series" indoor unit only.

Ex) ARNU07GSEA2

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Installation Manual 9

Before Installation

Before Installation

Environment-friendly Alternative Refrigerant R410A

•The refrigerant R410A has the property of higher operating pressure in comparison with R22. Therefore, all materials have the characteristics of higher resisting pressure than R22 ones and this characteristic should be also considered during the installation.

R410A is an azeotrope of R32 and R125 mixed at 50:50, so the ozone depletion potential (ODP) of R410A is 0. These days the developed countries have approved it as the environment-friendly refrigerant and encouraged to use it widely to prevent environment pollution.

CAUTION:

•The wall thickness of the piping should comply with the relevant local and national regulations for the designed pressure 3.8MPa

•Since R410A is a mixed refrigerant, the required additional refrigerant must be charged in its liquid state.

•If the refrigerant is charged in its gaseous state, its composition changes and the system will not work properly.

•Do not place the refrigerant container under the direct rays of the sun to prevent it from exploding.

•For high-pressure refrigerant, any unapproved pipe must not be used.

•Do not heat pipes more than necessary to prevent them from softening.

•Be careful not to install wrongly to minimize economic loss because it is expensive in comparison with R22.

Transporting the Unit

•When carrying the suspended, unit pass the ropes between legs of base panel under the unit.

•Always lift the unit with ropes attached at four points so that impact is not applied to the unit.

•Attach the ropes to the unit at an angle of 40° or less.

•Use only accessories and parts which are of the designated specification when installing.

Air outlet grille	Corner	Intake hole

Sub line

Handle

Always hold the unit by the corners, as holding			A 40° or less
it by the side intake holes on the casing may
cause them to deform.

WARNING

* Product appearance may be different depending on model.

CAUTION:

Be very careful while carrying the product.

-Do not have only one person carry product if it is more than 20 kg.

-PP bands are used to pack some products. Do not use them as a mean for transportation because they are dangerous.

-Do not touch heat exchanger fins with your bare hands. Otherwise you may get a cut in your hands.

-Tear plastic packaging bag and scrap it so that children cannot play with it Otherwise plastic packaging bag may suffocate children to death.

-When carrying in Outdoor Unit, be sure to support it at four points. Carrying in and lifting with 3-point support may make Outdoor Unit unstable, resulting in a fall.

10 Outdoor Unit

Select the Best Location

Select the Best Location

	1. Select space for installing outdoor unit, which will meet the following conditions:
	• No direct thermal radiation from other heat sources
	• No possibility of annoying neighbors by noise from unit
	• No exposition to strong wind
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	• Because of the possibility of fire, do not install unit to the space where generation, inflow, stagnation, and
	• With strength which bears weight of unit
	• Note that drain flows out of unit when heating
	• With space for air passage and service work shown next
	leakage of combustible gas is expected.
	• Avoid unit installation in a place where acidic solution and spray (sulfur) are often used.
	• Do not use unit under any special environment where oil, steam and sulfuric gas exist.
	• It is recommended to fence round the outdoor unit in order to prevent any person or animal from accessing
	the outdoor unit.
	• If installation site is area of heavy snowfall, then the following directions should be observed.
	- Make the foundation as high as possible.
	- Fit a snow protection hood.
	2. Select installation location considering following conditions to avoid bad condition when additionally
	performing defrost operation.
	• Install the outdoor unit at a place well ventilated and having a lot of sunshine in case of installing the product
	at a place with a high humidity in winter (near beach, coast, lake, etc).
	(Ex) Rooftop where sunshine always shines.
	• Performance of heating will be reduced and preheat time of the indoor unit may be lengthened in case of
	installing the outdoor unit in winter at following location:
	- Shade position with a narrow space
	- Location with much moisture in neighboring floor.
	- Location with much humidity around.
	- Location where ventilation is good.
	It is recommended to install the outdoor unit at a place with a lot of sunshine as possible as.
	- Location where water gathers since the floor is not even.
	3. When installing the outdoor unit in a place that is constantly exposed to a strong wind like a coast or on a
	high story of a building, secure a normal fan operation by using a duct or a wind shield.
	• Install the unit so that its discharge port faces to the wall of the building.
	Keep a distance 500mm or more between the unit and the wall surface.
	• Supposing the wind direction during the operation season of the air conditioner, install the unit so that the
	discharge port is set at right angle to the wind direction.

Strong wind

Strong wind

Blown air

500

Air inlet grille

Turn the air outlet side toward the building's wall, fence or windbreak screen.

Set the outlet side at a right angle to the direction of the wind.

Installation Manual 11

Installation Space

Installation Space

•The following values are the least space for installation.

If any service area is needed for service according to field circumstance, obtain enough service space.

•The unit of values is mm.

νIn case of obstacles on the suction side

1.Stand alone installation

or 100more

orless 500

<![if ! IE]>

<![endif]>or1000more

or 100 more

100
more
	or
		100				or
					100
		more
					more
				or
				less
				or	<![if ! IE]> <![endif]>1000 or more
			500
150 or
more		150			or
			or
					150
		more			more	[Unit:mm]

2. Collective installation

orless 500

1000	or				1000	or
more		100			more		100
			or					or
		more					more
			200	or	or			200
					300
			more		more			more	or

<![if ! IE]>

<![endif]>1000 or more

or 300 more

[Unit:mm]

12 Outdoor Unit

νIn case of obstacles on the discharge side

1.Stand alone installation

ormore 500

2. Collective installation

Installation Space

orless 500

<![if ! IE]>

<![endif]>1000 or more

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ormore 500

orless 500 moreor

<![if ! IE]>

<![endif]>1000

100	or	100	or
more		more
	more		more
			or
	or		1000	[Unit:mm]
	1000

νIn case of obstacles on the suction and the discharge sideObstacle height of discharge side is higher than the unit

1. Stand alone installation
L > H	L > H
	<![if ! IE]> <![endif]>H
<![if ! IE]> <![endif]>L
	or
	100
or	more
more
500

<![if ! IE]>

<![endif]>H

orless 500

<![if ! IE]>

<![endif]>or1000more

	<![if ! IE]> <![endif]>L
	or
	250
or	more
1000	[Unit:mm]
more

Installation Manual 13

Installation Space

2. Collective installation

L > H				L > H
				<![if ! IE]> <![endif]>H
<![if ! IE]> <![endif]>L
	100	or	more
				or
				300
				more
				or
				1000
				more

less

or

500

<![if ! IE]>

<![endif]>1000 or more

100				<![if ! IE]> <![endif]>L
	or	more
				or
				300
			more	more
			or	[Unit:mm]
			1250

Obstacle height of discharge side is lower than the unit

1. Stand alone installation

L ≤ H
	<![if ! IE]> <![endif]>H
<![if ! IE]> <![endif]>L
	or
	100
or	more
500
more

L ≤ H

<![if ! IE]>

<![endif]>L

less
or	<![if ! IE]> <![endif]>1000 or more
500
	<![if ! IE]> <![endif]>H
	or
	300
or	more
1000
more

2. Collective installation

L ≤ H

orless 500

L ≤ H

<![if ! IE]>

<![endif]>1000 or more

<![if ! IE]> <![endif]>H

<![if ! IE]> <![endif]>H

<![if ! IE]> <![endif]>L					<![if ! IE]> <![endif]>L
100	or	more			100	or	more
				or				or
				300				300
			or	more			or	more
			1500				more	[Unit:mm]
			more				1500

14 Outdoor Unit

Installation Space

Collective / Continuous Installation for roof top use

Space required for collective installation and continuous installation: When installing several units, leave space between each block as shown below considering passage for air and people.

1. One row of stand alone installation

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	or
	200
or	more
1000
more

	or
	100
or	more
2000
more

[Unit:mm]

2. Rows of collective installation (2 or more)

• L should be smaller than H

L ≤ H
	100	or
	more
<![if ! IE]> <![endif]>H	or
or	600
	more
1500
more

Seasonal wind and cautions in winter

	<![if ! IE]> <![endif]>L
	or
	300
or	more
3000
more
	[Unit:mm]

•Sufficient measures are required in a snow area or severe cold area in winter so that product can be operated well.

•Get ready for seasonal wind or snow in winter even in other areas.

•Install a suction and discharge duct not to let in snow or rain.

•Install the outdoor unit not to come in contact with snow directly. If snow piles up and freezes on the air suction hole, the system may malfunction. If it is installed at snowy area, attach the hood to the system.

•Install the outdoor unit at the higher installation console by 50cm than the average snowfall (annual average snowfall) if it is installed at the area with much snowfall.

1.The height of H frame must be more than 2 times the snowfall and its width shall not exceed the width of the product. (If width of the frame is wider than that of the product, snow may accumulate)

2.Don't install the suction hole and discharge hole of the Outdoor Unit facing the seasonal wind.

Installation Manual 15

Installation

Installation

Foundation for Installation

•Check the strength and level of the installation ground so that the unit will not cause any operating vibration or noise after installation.

•Fix the unit securely by means of the foundation bolts. (Prepare 4sets of M12 foundation bolts, nuts and washers each which are available on the market.)

•It is best to screw in the foundation bolts until their length are 20mm from the foundation surface.

	Spring washer		Anti-vibration
			materials
				Four bolt are
	Frame	Nut	Concrete
			base	required
H-Beam
				3 thread ridges
			<![if ! IE]> <![endif]>75
<![if ! IE]> <![endif]>100	<![if ! IE]> <![endif]>75		<![if ! IE]> <![endif]>200	<![if ! IE]> <![endif]>200

[Unit:mm]

Foundation bolt executing method

16 Outdoor Unit

Installation

Preparation of Piping

Main cause of gas leakage is defect in flaring work. Carry out correct flaring work in the following procedure.

1)Cut the pipes and the cable.

νUse the accessory piping kit or the pipes purchased locally.

νMeasure the distance between the indoor and the outdoor unit.

νCut the pipes a little longer than measured distance.

νCut the cable 1.5m longer than the pipe length.

2)Burrs removal

νCompletely remove all burrs from the cut cross section of pipe/tube.

νPut the end of the copper tube/pipe to downward direction as you remove burrs in order to avoid to let burrs drop in the tubing.

Copper		Slanted Uneven Rough
tube	90°

Pipe

Reamer

Point down

3)Flaring work

νCarry out flaring work using flaring tool as shown right.

Unit : mm(inch)

Indoor unit	Pipe		" A "
[kW(Btu/h]	Gas	Liquid	Gas	Liquid
<5.6(19,100)	12.7(1/2)	6.35(1/4)	1.6~1.8	1.1~1.3
			(0.63~0.71)	(0.43~0.51)
<16.0(54,600)	15.88(5/8)	9.52(3/8)	1.6~1.8	1.5~1.7
			(0.63~0.71)	(0.59~0.67)
<22.4(76,400)	19.05(3/4)	9.52(3/8)	1.9~2.1	1.5~1.7
			(0.75~0.83)	(0.59~0.67)

	Handle
Bar	Bar
"A"	Yoke
	Cone

Copper pipe

Clamp handle

Red arrow mark

Firmly hold copper tube in a bar(or die) as indicated dimension in the table above.

4)Check

νCompare the flared work with figure right.

νIf flare is noted to be defective, cut off the flared section and do flaring work again.

Inside is shining without scratches.

= Improper flaring =

Inclined Surface Cracked Uneven

damaged thickness

Even length all round

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Installation Manual 17

Installation

Flare shape and flare nut tightening torque

Precautions when connecting pipes

•See the following table for flare part machining dimensions.

•When connecting the flare nuts, apply refrigerant oil to the inside and outside of the flares and turn them three or four times at first. (Use ester oil or ether oil.)

•See the following table for tightening torque.(Applying too much torque may cause the flares to crack.)

•After all the piping has been connected, use nitrogen to perform a gas leak check.

pipe size	tightenig torque	A	flare shape
mm	N.m(kgf.cm)	mm	90° ±2
Ø9.52	32.7-39.9(327~399)	12.8-13.2	45°±2
			A
Ø12.7	49.5-60.3(495~603)	16.2-16.6
			R=0.4~0.8
Ø15.88	61.8-75.4(618~754)	19.3-19.7

CAUTION
• Always use a charge hose for service port connection.
• After tightening the cap, check that no refrigerant leaks are	Union
present.
• When loosening a flare nut, always use two wrenches in
combination, When connecting the piping, always use a spanner
and torque wrench in combination to tighten the flare nut.

•When connecting a flare nut, coat the flare(inner and outer faces) with oil for R410A(PVE) and hand tighten the nut 3 to 4 turns as the initial tightening.

Opening shutoff valve

1.Remove the cap and turn the valve counter clockwise with the hexagon wrench.

2.Turn it until the shaft stops.

Do not apply excessive force to the shutoff valve. Doing so may break the valve body, as the valve is not a backseat type. Always use the special tool.

3.Make sure to tighten the cap securely.

Closing shutoff valve

1.Remove the cap and turn the valve clockwise with the hexagon wrench.

2.Securely tighten the valve until the shaft contacts the main body seal.

3.Make sure to tighten the cap securely.

* For the tightening torque, refer to the table on the below.

Tightening torque

	Outside diameter		Torque
mm		inch	N.m(kgf•cm)
Ø6.35		1/4	18~25(180~250)
Ø9.52		3/8	34~42(340~420)
Ø12.7		1/2	55~66(550~660)
Ø15.88		5/8	63~82(630~820)
Ø19.05		3/4	99~121(990~1210)

18 Outdoor Unit

Installation

Heat insulation

1.Use the heat insulation material for the refrigerant piping which has an excellent heat-resistance (over 120°C).

2.Precautions in high humidity circumstance:

This air conditioner has been tested according to the

"KS Standard Conditions with Mist" and confirmed that there is not any default. However, if it is operated for a long time in high humid atmosphere (dew point

temperature: more than 23°C), water drops are liable

Indoor unit

to fall. In this case, add heat insulation material according to the following procedure:

Fastening band (accessory)

Refrigerant piping

Thermal insulator (accessory)

•Heat insulation material to be prepared... Adiabatic glass wool with thickness 10 to 20mm.

•Stick glass wool on all air conditioners that are located in ceiling atmosphere.

•In addition to the normal heat insulation (thickness: more than 8mm) for refrigerant piping (gas piping: thick piping) and drain piping, add further 10mm to 30mm thickness material.

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Installation Manual 19

Refrigerant Piping

Refrigerant Piping

U3 Chassis (2 Fan Model)

ν Connecting the pipes to the outdoor unit

• Braze suitable field piping with service valve of gas pipe.

CAUTION
Take care so that there is no thermal damage on the
service valves of the outdoor unit.	Wet towel
(Especially packing part of service port.) Wrap the
service valve with a wet towel when brazing it as
shown figure above.	<Liquid pipe> <Gas pipe>

ν Possible direction for field piping

•The installation piping is connectable in four directions.(refer to figure 1)

•When connecting in a downward direction, knock out the knockout hole of the base pan.

(refer to figure2, figure3)

<Figure 1>

Backward

	Downward
Forward	Sideways
<Figure 2>
Knock-out	Base pan

ν Preventing foreign objects from entering (Figure 4)

•Plug the pipe through-holes with putty or insulation material(procured locally)to stop up all gaps,as shown in the figure 3.

•Insects or small animals entering the outdoor unit may cause a short circuit in the electrical box.

<Figure 4>

Liquid side piping (Smaller Dia.)

Gas side piping (Bigger Dia.)

Connecting wire

Drain hose

Connection pipe

Putty or insulating material (produced locally)

CAUTION

• You should not dame pipe/base during the work of

pipe knock out.

• Operate piping work removing burr after pipe knock out.

Pipe knock <Figure 3> out during the

ground piping.

20 Outdoor Unit

Refrigerant Piping

CAUTION

•Make sure that pipe doesn't contact with the compressor terminal cover and comp bolt.

•Always insulate the liquid and gas-side field piping and branch.

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U4 Chassis (1Fan Model)

νAfter connecting the refrigerant pipe and checking the refrigerant leakage, cover it with heat insulator and roll around it with vinyl tape.

Tighten up the flare nut fitting on regulated torque. (Until “clatter” sounds is made at torque wrench part.)

The centers correspond with each other		Flare nut
	Socket flare
	Screw wrench	Torque wrench
Refrigerant pipe	Flare nut
Cap		Pipe
Pipe	Pipe

νDo not bend the pipe more than twice and work on it making it a big half circle.

If it is folded over, cooling/heating capacity may decrease and it could be the reason of malfunction. Do not remove the cap on flare side until the connection.

Dust and sand inside pipes can be the reason of malfunction.

νBend it following the wall and connect to outdoor unit valve.

Refrigerant pipe connection torque

Pipe external	6.35mm	9.52mm	12.7mm	15.88mm
diameter	(1/4")	(3/8")	(1/2")	(5/8")
Torque	180~250kgf.cm	340~420kgf.cm	550~660kgf.cm	630~820kgf.cm

Installation Manual 21

Refrigerant Piping

Cautions for Handling Service Valve

•The service valves are closed at shipment from the factory

CAUTION

Make sure to keep the valve open during operation

The names of parts of the service valve are shown in the figure.

1	1.	Service point
	2.	Shut-off Valve

3. Filed piping connection

2	4. Valve cover

3

4

•Since the side boards may be deformed if only a torque wrench is used when loosening or tightening flare nuts, always lock the shut-off valve with a wrench and then use a torque wrench.

Do not place wrenches on the valve cover.

1. Spanner

2. Torque wrench

1

2

Do not apply force on the valve cover, this may result in a refrigerant leak.

How to Use the Shut-Off Valve

Use hexagonal wrenches 4mm or 6mm

•Opening the valve

1.Place the hexagon wrench on the valve bar and turn counter-clockwise.

2.Stop when the valve bar no longer turns. It is now open.

•Closing the valve

1.Place the hexagon wrench on the valve bar and turn clockwise.

2.Stop when the valve bar no longer turns. It is now closed.

Direction to open					Direction to open

<Liquid pipe>

<Gas pipe>

22 Outdoor Unit

Refrigerant Piping

Caution

1.Use the following materials for refrigerant piping.

•Material: Seamless phosphorous deoxidized copper pipe

•Wall thickness : Comply with the relevant local and national regulations for the designed pressure

3.8MPa. We recommend the following table as the minimum wall thickness.

	Outer diameter	6.35	9.52	12.7	15.88	19.05	22.2	25.4	28.58	31.8	34.9	38.1	41.3
	[mm]
	Minimum	0.8	0.8	0.8	0.99	0.99	0.99	0.99	0.99	1.1	1.21	1.35	1.43
	thickness [mm]

2.Commercially available piping often contains dust and other materials. Always blow it clean with a dry inert gas.

3.Use care to prevent dust, water or other contaminants from entering the piping during installation.

4.Reduce the number of bending portions as much as possible, and make bending radius as big as possible.

5.Always use the branch piping set shown below, which are sold separately.

	Y branch			Header
			4 branch	7 branch	10 branch
ARBLN01621		ARBLN03321	ARBL054	ARBL057	ARBL1010
ARBLN07121		ARBLN14521	ARBL104	ARBL107	ARBL2010

6.If the diameters of the branch piping of the designated refrigerant piping differs, use a pipe cutter to cut the connecting section and then use an adapter for connecting different diameters to connect the piping.

7.Always observe the restrictions on the refrigerant piping (such as rated length, difference in height, and piping diameter).

Failure to do so can result in equipment failure or a decline in heating/cooling performance.

8. A second branch cannot be made after a header. (These are shown by.)

A

A

B

A To Outdoor Unit

BSealed Piping

9.The Multi V will stop due to an abnormality like excessive or insufficient refrigerant. At such a time, always properly charge the unit. When servicing, always check the notes concerning both the piping length and the amount of additional refrigerant.

10.Never use refrigerant to perform an air purge. Always evacuate using a vacuum pump.

11.Always insulate the piping properly. Insufficient insulation will result in a decline in heating/cooling performance, drip of condensate and other such problems.

12.When connecting the refrigerant piping, make sure the service valves of the Outdoor Unit is completely closed (the factory setting) and do not operate it until the refrigerant piping for the Outdoor and Indoor Units has been connected, a refrigerant leakage test has been performed and the evacuation process has been completed.

13.Always blow nitrogen into pipe which is brazed. Always use a non-oxidizing brazing material for brazing the parts and do not use flux. If not, oxidized film can cause clogging or damage to the compressor unit and flux can harm the copper piping or refrigerant oil.

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Installation Manual 23