LG ARWB80LA2, ARWB100LA2, ARWB500LA2, ARWB600LA2, ARWB400LA2 Installation Manual

...

ENGLISH

System

Outside Unit

INSTALLATION MANUAL

MODELS: ARWB Series

website http://www.lgservice.com

IMPORTANT

• Please read this installation manual completely before installing the product.

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

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

R410A

2 Outside Unit

ARWN Series Outside unit Installation Manual

TABLE OF CONTENTS

Safety Precautions ...........................................................................................................3

Installation Process ..........................................................................................................7

Outside units Information .................................................................................................8

Environment-friendly Alternative Refrigerant R410A .......................................................9

Select the Best Location...................................................................................................9

Installation space ...........................................................................................................11

Water control .................................................................................................................13

Lifting method.................................................................................................................15

Installation ......................................................................................................................16

Refrigerant piping installation.........................................................................................20

Device protection unit.....................................................................................................30

Refrigerant piping system ..............................................................................................32

Y branch pipe and header branch pipe type ..................................................................41

Leakage test and vacuum .............................................................................................42

Electrical Wiring..............................................................................................................44

HR Unit PCB ..................................................................................................................56

Test Run .........................................................................................................................73

Cooling tower applied method .......................................................................................82

Caution For Refrigerant Leak.........................................................................................83

Water Solenoid Valve Control........................................................................................85

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Installation Manual 3

Safety Precautions

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

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

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

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

Be sure not to do.

Be sure to follow the instruction.

■ 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.

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 ground the product.

• There is risk of fire or electric shock.

Always intstall a dedicated circuit and breaker.

• Improper wiring or installation may cause 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 install, remove, or re-install the unit by yourself (customer).

• 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.

Use the correctly rated breaker or fuse.

• There is risk of fire or electric shock.

Do not install the unit outdoor.

• Otherwise it may cause fire, electric shock and trouble

Do not install the product on a defective installation stand.

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

4 Outside Unit

Safety Precautions

Ventilate before operating air conditioner when gas leaked out.

• It may cause explosion, fire, and burn.

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 outside 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.

■ Operation Do not damage or use an unspecified power

cord.

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

Use a dedicated outlet for this appliance.

• There is risk of fire or electrical shock.

Be cautious that water could not enter the product.

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

Do not touch the power switch with wet hands.

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

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.

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.

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

• There is risk of fire or electric shock.

Be cautious not to touch the sharp edges when installing.

• It may cause injury.

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

• This could result in personal injury and product damage.

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.

■ Installation Always check for gas (refrigerant) leakage

after installation or repair of product.

• Low refrigerant levels may cause failure of product.

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

• It may cause a problem for your neighbors.

Installation Manual 5

ENGLISH

Safety Precautions

Keep level even when installing the product.

• To avoid vibration or water leakage.

Do not install the unit where combustible gas may leak.

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

Use power cables of sufficient current carrying capacity and rating.

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

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.

■ 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.

Do not block the inlet or outlet.

• It may cause failure of appliance or accident.

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.

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.

6 Outside Unit

Safety Precautions

Safely dispose of the packing materials.

•

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.

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

• 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.

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

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

• It can cause a burn or frostbite.

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

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

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.

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.

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

• Be careful and avoid personal injury.

Select Installation Location

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Installation Manual 7

Installation Process

The foundation must be level even

Outside unit foundation work

Avoid short circuits and ensure sufficient space is allowed for service

Installation of outside unit

Refer to automatic addressing flowchart

Automatic addressing of indoor unit

In the final check for 24hours at 3.8 MPa(38.7 kgf/cm

) there must be no drop in pressure.

Airtight test

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

Electrical work

(connection circuits and drive circuits)

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

Heat insulation work

Make sure airflow is sufficient

Duct work

Adjust to downward gradient

Drain pipe work

Special attention to dryness, cleanness and tightness

Refrigerant piping work

Check model name to make sure the fitting is made correctly

Installation of indoor unit

Take account of gradient of drain piping

Sleeve and insert work

Make relationship between outside, indoor, remote controller, and option connections clear. (Prepare control circuit diagram)

Preparation of contract drawings

Indicate clearly who is to be responsible for switch settings

Determination of division work

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

Vacuum drying

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

Additional charge of refrigerant

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

Fit facing panels

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

Test run adjustment

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

Transfer to customer with explanation

Preheat the crank case with the electrical heater for more than 6 hours.

• 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.)

Outside units Information

8 Outside Unit

Outside units Information

Power Supply: Outside Unit (3Ø, 380 ~ 415V, 50Hz)

■ Heat pump

Unit System(HP) Model

Product Charge kg CF(Correction Factor) kg Max. Connectable No. of Indoor Units Net Weight kg Dimension(W x H x D) mm

inch Refrigerant Liquid(mm/inch) Connecting Pipes Gas(mm/inch) Water Inlet Connecting Pipes Outlet

Drain Outlet Range of Operation Cooling(°C) Water Temp. Heating(°C)

1 Unit 2 Unit

08 10 20 30 ARWB80LA2 ARWB100LA2 ARWB200LA2 ARWB300LA2 ARWB80LA2 ARWB100LA2 ARWB200LA2 ARWB200LA2

ARWB100LA2

7.3 7.3 8.8 7.3+8.8

1.5 1.5 3 4.5 13 16 32 49

170 170 238 170 + 238

772 x 1,120 x 547 772 x 1,120 x 547 772 x 1,120 x 547 (772 x 1,120 x 547) x 2

30.4 x 44.1 x 21.5 30.4 x 44.1 x 21.5 30.4 x 44.1 x 21.5 (30.4 x 44.1 x 21.5) x 2

9.52(3/8) 9.52(3/8) 12.7(1/2) 19.05(3/4)

22.2(7/8) 22.2(7/8) 28.58(1 1/8) 34.9(1 3/8)

PT32A (internal thread) PT32A (internal thread) PT40A (internal thread)

PT32A + PT40A (internal thread)

PT32A (internal thread) PT32A (internal thread) PT40A (internal thread)

PT32A + PT40A (internal thread)

20mm (internal thread) 20mm (internal thread) 20mm (internal thread) 20mm (internal thread)

10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45

Unit System(HP) Model

Product Charge kg CF(Correction Factor) kg Max. Connectable No. of Indoor Units Net Weight kg Dimension(W x H x D) mm

inch Refrigerant Liquid(mm/inch) Connecting Pipes Gas(mm/inch) Water Inlet Connecting Pipes Outlet

Drain Outlet Range of Operation Cooling(°C) Water Temp. Heating(°C)

2 Unit 3 Unit

40 50 60 ARWB400LA2 ARWB500LA2 ARWB600LA2 ARWB200LA2 ARWB200LA2 ARWB200LA2 ARWB200LA2 ARWB200LA2 ARWB200LA2

ARWB100LA2 ARWB200LA2

8.8+8.8 7.3+8.8+8.8 8.8+8.8+8.8 6 7.5 9

64 64 64

(238) x 2 170 + (238) x 2 (238) x 3 (772 x 1,120 x 547) x 2 (772 x 1,120 x 547) x 3 (772 x 1,120 x 547) x 3 (30.4 x 44.1 x 21.5) x 2 (30.4 x 44.1 x 21.5) x 3 (30.4 x 44.1 x 21.5) x 3

19.05(3/4) 19.05(3/4) 19.05(3/4)

41.3(1 5/8) 41.3(1 5/8) 41.3(1 5/8)

PT40A + PT40A (internal thread)

PT32A + PT40A + PT40A (internal thread) PT40A + PT40A + PT40A (internal thread)

PT40A + PT40A (internal thread)

PT32A + PT40A + PT40A (internal thread) PT40A + PT40A + PT40A (internal thread)

20mm (internal thread) 20mm (internal thread) 20mm (internal thread)

10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45 10 ~ 45

• Ratio of the running Indoor Units to the Outside: Within 10 ~ 100%

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

■ Combination Ration(50~200%)

Notes: * We can guarantee the operation only within 130% Combination.

If you want to connect more than 130% combination, please contact us and discuss the requirement like below.

1) If the operation of indoor unit is more than 130%, low airflow operation is recommended in all the indoor units.

2) If the operation of indoor unit is more than 130%, additional refrigerant is needed according to the Äheadquarter guidance.

3)Over 130%, capacity is same as capacity of 130%, Same remark is valid for power input.

Outside Number Connection Capacity

Single outside units 200%

Double outside units 160%

Triple outside units 130%

Environment-friendly Alternative Refrigerant R410A

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Installation Manual 9

Select the Best Location

Select space for installing outside 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

• 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

• Because of the possibility of fire, do not install unit to the space where generation, inflow, stagnation, and

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 outside unit in order to prevent any person or animal from accessing the

outside unit.

• This product is prohibited for outdoor installation.

• Select installation location considering following conditions to avoid bad condition when additionally performing

defrost operation.

1. Install the outside 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 (neare beach, coast, lake, etc). (Ex) Rooftop where sunshine always shines.

2. Performance of heating will be reduced and preheat time of the indoor unit may be lengthened in case of installing the outside unit in winter at following location: (1) Shade position with a narrow space (2) Location with much moisture in neighboring floor. (3) Location with much humidity around. (4) Location where water gathers since the floor is not even.

• 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.

Environment-friendly Alternative Refrigerant R410A

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.

Environment-friendly Alternative Refrigerant R410A

10 Outside Unit

■ Select installation location of the HR unit suitable for following conditions

• Avoid a place where rain may enter since the HR unit is for indoor.

• Sufficient service space must be obtained.

• Refrigerant pipe must not exceed limited length.

• Avoid a place subject to a strong radiation heat from other heat source.

• Avoid a place where oil spattering, vapor spray or high frequency electric noise is expected.

• Install the unit at a place in which it is not affected by operation noise. (Installation within cell such as meeting

room etc. may disturb business due to noise.)

• Place where refrigerant piping, drain piping and electrical wiring works are easy.

Inspection door(NOTICE 1) (servicing space)

481

345

100 more

(Serviceing space)

300more

(Servicing space)

300more

(Servicing space)

300more

(Servicing space)

450more

(Servicing space)

1 2

453(174)

(174)

182

218

41961 (137)

124

128

30 60

(NOTICE 2)

450

100 more (Serviceing space)

100 more

(Serviceing space)

100 more (Serviceing space)

Description

PRHR040/030 PRHR020

1 Low pressure Gas pipe connection port Ø28.58 Brazing connection Ø22.2 Brazing connection 2 High pressure Gas pipe connection port Ø22.2 Brazing connection Ø19.05 Brazing connection 3 Liquid pipe connection port Ø12.7 Brazing connection Ø9.52 Brazing connection 4 Indoor unit Gas pipe connection port Ø15.88 Brazing connection Ø15.88 Brazing connection 5 Indoor unit Liquid pipe connection port Ø9.52 Brazing connection Ø9.52 Brazing connection 6 Control box - 7 Hanger metal M10 or M8 M10 or M8

Part NameNo.

1. Be sure to install the inspection door at the control box side.

2. If reducers are used, servicing space must be increased equal to reducer's dimension.

NOTICE

(Unit: mm)

Installation space

Individual Installation

Collective / Continuous Installation

Required the minimum space as shown below for installation and check. If the space is not fit on this drawing, consult with LG.

Space required for collective installation and continuous installation as shown below considering passage for air and people.

: Service area

* In case of the water pipe passing side product, please make sufficient service place to avoid occurring

between water pipe and product side.

: Service area

H-Beam Support

(unit : mm)

1120 100100

20 100

350

772

Water pipe installation space

600 547 20

Product

(Outdoor unit)

Service area

(Front)

Product

(Outdoor unit)

Product

(Outdoor unit)

(Unit : mm)

350

772

100

772 100

600 547

Product

(Outdoor unit)

Product

(Outdoor unit)

350

772

100

772

Product

(Outdoor unit)

(Unit : mm)

350

100

772 100

600 547

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Installation Manual 11

12 Outside Unit

Installation space

Two Layer Installation

Space required for two layer installation as shown below considering passage for air and people.

: Service area

H-Beam Support

1120 100

100

(unit : mm)

1120

100

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Installation Manual 13

Water control

• Keep the water temperature between 10~45°C. Other it may cause the breakdown.

- Standard water supply temperature is 30°C for Cooling and 20°C for heating.

• Properly control the water velocity. Otherwise it may cause the noise, pipe vibration or pipe contraction, expansion according to the temperature. Use the same water pipe size connected with the product or more.

• Refer to the water source pipe diameter and water velocity table below. As the water velocity is fast, air bubble will increase.

• Be careful of the water purity control. Otherwise it may cause the breakdown due to water pipe corrosion. (Refer to 'Standard Table for Water Purity Control')

• In case the water temperature is above 40°C, it is good to prevent the corrosion by adding the anticorrosive agent.

• Install the pipe, valve and gauge sensor in the space where it is easy to maintain. Install the water valve in the low

position for drain, if required.

• Be careful not to let air in. If so, the water velocity will be unstable in the circulation, pump efficiency will also decrease and may cause the piping vibration. Therefore, install the air purge where it may generate the air.

• Choose the following anti freezing methods. Otherwise, it will be dangerous for the pipe to break in the winter.

- Circulate the water with the pump before dropping the temperature.

- Keep the normal temperature by boiler.

- When the cooling tower is not operated for a long time, drain the water in the cooling tower.

- Use an anti-freeze.

- Refer to the additive amount about freezing temperature as in the table given below.

• In addition to anti freeze, it may cause the change of the pressure in the water system and the low performance of the product.

• Make sure to use the closed cooling type tower. When applying the open type cooling tower, use a 2ndheat exchanger to make the water supply system a closed type system.

Diameter (mm) Velocity range (m/s)

< 50 0.6 ~ 1.2

50 ~ 100 1.2 ~ 2.1

100 < 2.1 ~ 2.7

Minimum temperature for anti freezing (°C)

0 -5 -10 -15 -20 -25

Ethylene glycol (%) 0 12 20 30 - -

Propylene glycol (%) 0 17 25 33 - -

Methanol (%) 0 6 12 16 24 30

Anti freeze type

Water control

14 Outside Unit

Water control

Standard table for water purity control

The water may contain many foreign substances and hence may influence the performance and lifetime of the product due to the corrosion of the condenser and water pipe. (Use water source that complies with the below standard table for water purity control.)

If you use water supply other than the tap water to supply the water for the cooling tower, you must do a water quality inspection.

• If you use the closed cooling tower, the water quality must be controlled in accordance with the following standard table. If you do not control the water quality in accordance with the following standard water quality table, it can cause performance deterioration to the air conditioner and severe problem to the product

[Reference]

(1) The "O" mark for corrosion and scale means that there is possibility of occurrence. (2) When the water temperature is 40°C or above or when uncoated iron is exposed to the water, it can result in corro-

sion. Therefore adding anti-corrosion agent or removing the air can be very effective.

(3) In case of using the closed type cooling tower, the cooling water and supplementing water must satisfy the water quali-

ty criteria of closed type system in the table.

(4) Supplementing water and supplied water must be supplied with tap water, industrial water and underground water

excluding filtered water, neutral water, soft water etc.

(5) 15 items in the table are general causes of corrosion and scale.

Items

pH(25°C)

Conductivity[25°C](mS/m)

Chlorine ion(mg CI-/l)

Sulfuric acid ion(mg SO

/l)

Acid demand[pH 4.8] (mg SiO

2/l)

Total hardness(mg SiO2/l) Ca hardness(mg CaCO3/l)

Ion silica(mg SiO2/l)

Fe(mg Fe/l)

Copper(mg Cu/l)

Sulfuric acid ion(mg S

/l)

Ammonium ion(mg NH

4/l)

Residual chlorine(mg Cl/l)

Free carbon dioxide(mg CO2/l)

Stability index

7.0~8.0 Below 30 Below 50 Below 50 Below 50 Below 70 Below 50 Below 30

Below 1.0 Below 1.0

Must not be detected

Below 0.3

Below 0.25

Below 0.4

Below 0.3 Below 0.1

Must not be detected

Below 0.1 Below 0.3 Below 4.0

7.0~8.0 Below 30 Below 50 Below 50 Below 50 Below 70 Below 50 Below 30

O O O O

O O O O O O O

O O

O O O O O

Closed type

Basic Item

Reference Item

Effect

Circulating water Supplemented water Corrosion Scale

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Installation Manual 15

Lifting method

• When carrying the suspended, unit pass the ropes under the unit and use the two suspension points each at the front and rear.

• 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.

40° or less Rope supporter

A B

Sub line

CAUTION

Be very careful while carrying the product.

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

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

• Use 2 belts of at least 8 m long.

• Place extra cloth or boards in the locations where the casing comes in contact with the sling to prevent

damage.

• Hoist the unit making sure it is being lifted at its center of gravity.

16 Outside Unit

Installation

Location of anchor bolt

The location of anchor bolt

59 50

599

658

(Unit: mm)

WARNING

• Be sure to install unit in a place strong enough to withstand its weight. Any lack of strength may cause unit to fall down, resulting in a personal injury.

• Have installation work in order to protect against a strong wind and earthquake. Any installation deficiency may cause unit to fall down, resulting in a personal injury.

• Especially take care for support strength of the floor surface, water drain processing (processing of water flown out from the outside unit during operation) and paths of the pipe and wiring when making a base support.

ENGLISH

Installation Manual 17

Installation

Preparation of Piping

1) Cut the pipes and the cable.

■ Use the accessory piping kit or the pipes purchased locally.

■ Measure the distance between the indoor and the outside unit.

■ Cut the pipes a little longer than measured distance.

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

2) Burrs removal

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

■ Put 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.

3) Flaring work

■ Carry out flaring work using flaring tool as shown below.

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

4) Check

■ Compare the flared work with figure below.

■ If flare is noted to be defective, cut off the flared section

and do flaring work again.

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

Pipe "A "

Gas Liquid Gas

Liquid

<5.6(19,100) 1/2" 1/4" 0.5~0.8 0~0.5 <16.0(54,600) 5/8" 3/8" 0.8~1.0 0.5~0.8 <22.4(76,400) 3/4" 3/8" 1.0~1.3 0.5~0.8

Indoor unit [kW(Btu/h]

Copper

tube

90°

Slanted Uneven Rough

Pipe

Reamer

Point down

Bar

Copper pipe

Clamp handle

Red arrow mark

Cone

Yoke

Handle

Bar

"A"

Inclined

Inside is shining without scratches.

Smooth all round

Even length

all round

Surface

damaged

Cracked Uneven

thickness

= Improper flaring =

18 Outside Unit

Installation

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.

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.

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.

Tightening torque

Union

CAUTION

• Always use a charge hose for service port connection.

• After tightening the cap, check that no refrigerant leaks are

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

Closing shutoff valve

FLARE SHAPE and FLARE NUT TIGHTENING TORQUE

Shutoff

valve size

Ø6.4 Ø9.5

Ø12.7 Ø15.9 Ø22.2

Ø25.4

13.5-16.5 18-22

14-17 33-39 50-60

62-75

23-27

13.5-16.5

5.4-6.6

Hexagonal

wrench 4mm

Hexagonal

wrench 6mm

Hexagonal

wrench 10mm

8.1-9.9

27-33 36-44

11.5-13.9

22-28-

Tightening torque N-m(Turn clockwise to close)

Shaft(valve body)

Gas line piping attached to unit

Cap(Valve lid) Service port Flare nut

90°

±2

45°

±2

R=0.4~0.8

pipe size tightening torque(Ncm) A(mm) flare shape

Ø9.5 3270-3990 12.8-13.2

Ø12.7 4950-6030 16.2-16.6

Ø15.9 6180-7540 19.3-19.7

ENGLISH

Installation Manual 19

Installation

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

• Heat insulation material to be prepared... EPDM (Ethylene Propylene Diene Methylene)-over 120°C the heat-resistance temperature.

• Add the insulation over 10mm thickness at high humidity environment.

Indoor unit

Thermal insulator (accessory)

Fastening band (accessory)

Refrigerant piping

HEAT INSULATION

20 Outside Unit

Refrigerant piping installation

WARNING

After completing work, securely tighten both service ports and caps so that gas does not leak.

Refrigerant piping installation

WARNING

Always use extreme care to prevent the refrigerant gas (R410A) from leakage while using fire or flame. If the refrigerant gas comes in contact with the flame from any source, such as a gas stove, it breaks down and generates a poisonous gas which can cause gas poisoning. Never perform brazing in an unventilated room. Always conduct an inspection for gas leakage after installation of the refrigerant piping has been completed.

Pipe joint (auxiliary parts): Securely perform brazing with a nitrogen blow into the service valve port.(Releasing pressure : 0.02 MPa or less)

Flare nut: Loose or tighten flare nut by using the wrench with both ends. Coat the flare connection part with oil for the compressor.

Cap: Remove caps and operate valve, etc. After operation, always reattach caps (tightening torque of valve cap: 25Nm (250kg-cm) or more). (Don't remove the internal part of the port)

Service port: Make the refrigerant pipe vacuum and charge it using the service port. Always reattach caps after completing work (tightening torque of service cap: 14Nm (140kg-cm) or more).

Liquid pipe Gas pipe Elbow joint (field supply)

Cautions in pipe connection/valve operation

Open status when both the pipe and the valve are in a straight line.

Cut both the pipe and the valve with a cutter to suit the length (Don't cut the length of less than 70mm)

CLOSE OPEN

Elbow

Ball Valv e(Gas Pipe)

Ball Valv e(Liquid Pipe)

ENGLISH

Installation Manual 21

Refrigerant piping installation

Slave Outside Unit

Master Outside Unit

Slave1 Outside Unit

Slave2 Outside Unit

Main Outside Unit

1) For the high/low pressure common pipe, connect both master outside unit and slave outside units to the pipe by using elbows.

2) For cutting the pipe, connect the high/low pressure common pipe after removing burrs, dusts and foreign material within the pipe. Otherwise, the product may not operate due to sludge within the pipe.

3) For the working part leakage test, apply the nitrogen gas pressure of 3.8MPa (38.7kgf/cm

4) The vacuum criteria is to maintain the vacuum level to less than 5 Torr 1 hour after reaching 5 Torr. (Execute the vacuum work again when it is below the criteria.)

5) Open the valve with the hexagon wrench.

Connecting

branch pipe

Combination specification Gas pipe Liquid pipe

Do not cut for 70mm or less

Execute the welding while pouring nitrogen

Master Outside unit pipe

Main pipe

ARCNN20

(unit : mm)

2 Outside Units 3 Outside Units

Connection of High/Low Pressure Common pipe

2 outside units

Connection of Outside units

22 Outside Unit

Refrigerant piping installation

3 Outside Units

Connecting branch pipe

Combination specification Gas pipe Liquid pipe

ARCNN20

ARCNN30

Slave1 Outside unit gas pipe

Ø 31.8

Ø 28.58

Ø 19.05

Ø 22.2

Ø 28.58

Ø 34.9

Don't cut the pipe less than 70mm

Blow nitrogen while brazing

OD28.58

Ø19.05

Ø22.2

Ø38.1

OD34.9

Ø15.88

OD19.05

Slave1 Outside unit pipe

Ø 12.7

Ø 9.52

Ø 12.7

Ø 15.88

Ø 19.05

Ø 12.7

Ø22.2

OD19.05

Ø9.52

OD12.7

Main pipe

Master Outside unit gas pipe

Ø 38.1

Ø 34.9

Ø 28.58

Ø 41.3

Don't cut the pipe less than 70mm

Blow nitrogen while brazing

OD28.58

Ø19.05

Ø22.2

Main pipe

Master Outside unit pipe

Ø 12.7

Ø 19.05

Ø 12.7

Ø 15.88

Ø 22.2

Ø 19.05

Ø9.52

OD12.7

(unit : mm)

Y branch

To outdoor unit To branch piping or indoor unit

A B

Facing

upwards

Facing

downwards

Within ± 3° Within ± 3°

Viewed from point A in direction of arrow

Within +/- 10°

ENGLISH

Installation Manual 23

Installation of Outdoor Unit, HR Unit, Indoor Unit Refrigerant Pipe

3 pipes are connected to the HR unit from the outdoor unit, classified into liquid pipe, low pressure gas pipe and high pressure gas pipe depending on status of refrigerant passing through the pipe.

You must connect 3 pipes from outdoor unit to HR unit. For connection between indoor unit and HR unit, you must connect both liquid pipe and gas pipe from the HR

unit to the indoor unit. In this case, connect them to the indoor unit starting from No.1 connection port of the HR unit (the port number is displayed on ports of the HR unit). Use auxiliary flare as annexed parts in connection to the indoor unit.

Low pressure

Gas pipe

High pressure

Gas pipe

Liquid pipe

HR Unit

CAUTION:

Whenever connecting the indoor units with the HR unit, install the indoor units in numerical order from No.1. Ex) In case of installing 3 indoor units : No. 1, 2, 3 (O), No. 1, 2, 4 (X), No.1, 3, 4 (X), No.2, 3, 4 (X).

Installation procedure for HR unit

Six-sided Nut (M10 or M8)

Hanger metal

Flat washer

Flat washer (M10)

Hanging bolt

Hanging bolt (M10 or M8)

Insulation

1. Using an insert-hole-in- anchor, hang the hanging bolt.

2. Install a hexagon nut and a flat washer (locally-procured)to the hanging bolt as shown in the figure in the bottom, and fit the main unit to hang on the hanger metal.

3. After checking with a level that the unit is level, tighten the hexagon nut. * The tilt of the unit should be within ±5° in front/back and left/right.

4. This unit should be installed suspended from ceiling and side A should always be facing up.

5. Insulate not used pipes completely as shown in the figure.

24 Outside Unit

Select an HR unit according to the number of the indoor units to be installed. HR units are classified into 3 types by the number of connectable indoor units.

Ex) Installation of 6 indoor units

Consists of HR unit for 4 rooms and HR unit for 2 rooms.

Type of HR Unit

PRHR030(3 rooms)PRHR020(2 rooms) PRHR040(4 rooms)

WARNING

• 1 port of HR unit allows up to 14.1kW based on cooling capacity of the indoor unit (up to 14.1kW (48kBtu/hr) for max installation).

• The maximum total capacity of the indoor units connected to one PRHR040 HR unit is 47kW (160kBtu/hr). In case of installation of four indoor units of 14.1kW (48kBtu/hr), use two PRHR020's rather than one PRHR040.

Gas pipe Ø15.88 Liquid pipe Ø9.52 Brazing Type

Remove caps on The brazing part.

Liquid pipe

Low pressure gas pipe

High pressure gas pipe

HR unit PRHR020 PRHR030 PRHR040

Low pressure gas pipe Ø22.2 Ø28.58 Ø28.58

High pressure gas pipe Ø19.05 Ø22.2 Ø22.2

Liquid pipe Ø9.52 Ø12.7 Ø12.7

(Unit: mm)

Joint Method of HR Unit (Big Duct : URNU76GB8-, URNU96GB8-)

Joint Method is required when B5/B8 chassis is installed. In Joint Method, two neighboring outlets of one HR unit are linked by Y branch pipe and connected to one indoor unit.

1st HR Unit 2nd HR Unit

1 2 3 4

(96k) (28k)

1 2 3 4

(76k)(21k)

ENGLISH

Installation Manual 25

[ Reducers for indoor unit and HR unit ]

Models

High pressure

Gas pipe

Low pressure

Liquid pipe

Indoor unit

reducer

HR unit reducer

PRHR020

OD22.2 Ø19.05 Ø15.88

OD15.88 Ø

12.7

Ø6.35OD9.52

OD19.05 Ø15.88 Ø12.7

OD22.2 Ø19.05 Ø15.88

OD15.88 Ø12.7

PRHR030/ PRHR040

OD19.05 Ø15.88

OD28.58 Ø22.2 Ø19.05

OD12.7 Ø9.52

OD15.88 Ø12.7

(Unit: mm)

26 Outside Unit

0.99

22.2

1.1

31.8

1.21

34.9

1.35

38.1

1.43

41.3

0.99

28.58

0.99

25.4

0.99

19.05

0.99

15.88

0.8

12.7

0.8

9.52

0.8

6.35

Minimum

thickness [mm]

Outer diameter

[mm]

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.

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.

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. The system 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 pipe length and the amount of additional refrigerant.

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

10. Always insulate the piping properly. Insufficient insulation will result in a decline in heating/cooling perfor-

mance, drip of condensate and other such problems.

11. 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.

12. 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 compressors and flux can harm the copper piping or refrigerant oil.

13. Diameter of the refrigerant pipe from the HR unit to the indoor unit is determined by capacity of the

indoor unit. The pipe port is installed to suit a large capacity of the indoor unit for the connection flare of the HR unit. It is sufficient to cut, connect and install the subsidiary flare to suit the pipe of the indoor unit connected.

14. Take care so that there is no thermal damage on the service valves of the outdoor unit.

(Especially packing part of service port.) Wrap the service valve with a wet towel when brazing it.

Caution

ARBLB01620 ARBLB03320 ARBLB07120 ARBLB14520

Y branch

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