LG ARWN038GA2 INSTALLATION MANUAL

INSTALLATION MANUAL

AIR CONDITIONER

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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.

Water Mini series

www.lg.com

P/NO : MFL63748905

Copyright © 2013 - 2018 LG Electronics Inc. All Rights Reserved.

ARWN Series Outside unit Installation Manual

TABLE OF CONTENTS

Safety Precautions .........................................................................................................	3
Installation Process .......................................................................................................	7
Outside units Information..............................................................................................	8
Alternative Refrigerant R410A ......................................................................................	9
Select the Best Location................................................................................................	9
Installation space ........................................................................................................	10
Water control ................................................................................................................	11
Lifting method ..............................................................................................................	13
Installation ....................................................................................................................	14
Refrigerant piping installation ....................................................................................	18
Device protection unit..................................................................................................	21
Refrigerant piping system ..........................................................................................	23
Y branch pipe and header branch pipe type .............................................................	37
Leakage test and vacuum ...........................................................................................	39
Electrical Wiring ...........................................................................................................	41
Test Run ........................................................................................................................	55
Cooling tower applied method ...................................................................................	62
Caution For Refrigerant Leak......................................................................................	63
Water Solenoid Valve Control .....................................................................................	65
Variable Water Flow Control KIT(Accessory) ............................................................	66

2 Outside 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.

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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 install 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 outside.

-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.

•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.

•Ventilate before operating air conditioner when gas leaked out.

Installation Manual 3

Safety Precautions

-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.

•Use a vacuum pump or Inert (nitrogen) gas when doing leakage test or air purge. Do not compress air or Oxygen and Do not use Flammable gases. Otherwise, it may cause fire or explosion.

-There is the risk of death, injury, fire or explosion.

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 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.

•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.

4 Outside Unit

Safety Precautions
- There is risk of damage or loss of property.
• Keep the unit away from children. The heat exchanger is very sharp.		<![if ! IE]> <![endif]>ENGLISH
noise.
- It can cause the injury, such as cutting the finger. Also the damaged fin may result in degradation of capacity.
• When installing the unit in a hospital, communication station, or similar place, provide sufficient protection against
- 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 con-
ditioner 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.

•Be very careful about product transportation.

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

-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.

•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 6hours 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.

•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 5minutes 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. Autoaddressing 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.

Installation Manual 5

Safety Precautions

WARNING

• Refer to local code for all wiring size.

•Installation or repairs made by unqualified persons can result in hazards to you and others.

Installation of all field wiring and components MUST conform with local building codes or, in the absence of local codes, with the National Electrical Code 70 and the National Building Construction and Safety Code or Canadian Electrical code and National Building Code of Canada.

•The information contained in the manual is intended for use by a qualified service technician familiar with safety procedures and equipped with the proper tools and test instruments.

•Failure to carefully read and follow all instructions in this manual can result in equipment malfunction, property damage, personal injury and/or death.

WARNING

When wiring:

Electrical shock can cause severe personal injury or death. Only a qualified, experienced electrician should attempt to wire this system.

•Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

•Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.

•Ground the unit following local electrical codes.

•Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

• The choice of materials and installations must comply with the applicable local/national or international standards.

When transporting:

Be careful when picking up and moving the indoor and outside units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your finger.

When installing...

... in a wall: Make sure the wall is strong enough to hold the unit's weight.

It may be necessary to construct a strong wood or metal frame to provide added support.

... in a room: Properly insulate any tubing run inside a room to prevent "sweating" that can cause dripping and water damage to wall and floors.

... in moist or uneven locations: Use a raised concrete pad or concrete blocks provide a solid, level foundation for the outside unit. This prevents water damage and abnormal vibration.

... in an area with high winds: Securely anchor the outside unit down with bolts and a metal frame. Provide a suitable air baffle.

... in a snowy area(for Heat Pump Model): Install the outside unit on a raised platform that is higher than drifting snow. Provide snow vents.

When connecting refrigerant tubing

•Keep all tubing runs as short as possible.

•Use the flare method for connecting tubing.

•Check carefully for leaks before starting the test run.

When servicing

•Turn the power OFF at the main power box(mains) before opening the unit to check or repair electrical parts and wiring.

•Keep your fingers and clothing away from any moving parts.

•Clean up the site after you finish, remember to check that no metal scraps or bits of wiring have been left inside the unit being serviced.

6 Outside Unit

Installation Process

Installation Process

	Determination of division work		Indicate clearly who is to be responsible for switch settings
	Preparation of contract drawings		Make relationship between outside, indoor, remote controller, and option connections clear.
			(Prepare control circuit diagram)

Sleeve and insert work

Installation of indoor unit

Refrigerant piping 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

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)

Outside unit foundation work The foundation must be level even

Installation of outside 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 3.8MPa (38.7kgf/cm2) there must be no drop in pressure.

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

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 6hours.

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

Outside units Information

Outside units Information

Ratio of the connectable Indoor Units to the Outside: Within 50 ~ 130%

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

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

Power Supply: Outside Unit (1Ø, 208/230V, 60Hz)

	Model (HP)			4	5	6
	Model			ARWN038GA2	ARWN048GA2	ARWN053GA2
	Refrigerant	Product charge	kg (lbs)	1.0 (2.2)	1.0 (2.2)	1.0 (2.2)
		CF (Correction Factoer)	kg (lbs)	-	-	-
	Number of maxmum connectable indoor units			6	8	9
	Net Weight	kg (lbs)		76 (168)	76 (168)	76 (168)
	Dimensions	mm		520 X 1,080 X 330	520 X 1,080 X 330	520 X 1,080 X 330
	(WxHxD)	inch		201/2 × 421/2 × 13	201/2 × 421/2 × 13	201/2 × 421/2 × 13
	Connecting	Liquid	Ø, mm(inch)	9.52 (3/8)	9.52 (3/8)	9.52 (3/8)
	Pipes	Gas	Ø, mm(inch)	19.05 (3/4)	19.05 (3/4)	19.05 (3/4)

For Mexico:

Model ARWN~~~GA2: Nominal voltage: 220 V~ 60 Hz

8 Outside Unit

Alternative Refrigerant R410A

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.

•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.

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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 page.

•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 outside 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 (near 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 high moisture level in neighboring floor.

(3)Location with high humidity around.

(4)Location where water gathers since the floor is not even.

Installation Manual 9

Installation space

Installation space

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

: Service area

	<![if ! IE]> <![endif]>20 (25/32)
	<![if ! IE]> <![endif]>(14-29/32)	Product
		(Outside unit)
	<![if ! IE]> <![endif]>379
Water pipe	<![if ! IE]> <![endif]>(23-5/8)
installation		Service area
space		(Front)
	<![if ! IE]> <![endif]>600
	193 (7-19/32)
	100 (3-15/16)	523 (20-19/32)	20 (25/32)
		<Top View>

[Unit : mm(inch)]

<![if ! IE]>

<![endif]>100 (3-15/16)

	<![if ! IE]> <![endif]>(42-17/32)
	<![if ! IE]> <![endif]>1,080
H-Beam Support	<![if ! IE]> <![endif]>(3-15/16)
	<![if ! IE]> <![endif]>100

<Front View>

10 Outside Unit

Water control

Water control

Water control

•Keep the water temperature between 10~45°C (50~113°F). Other it may cause the breakdown. - Standard water supply temperature is 30°C (86°F) for Cooling and 20°C (68°F) 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.

Diameter [mm(inch)]	Velocity range (m/s)
< 50 (1-31/32)	0.6 ~ 1.2
50 (1-31/32) ~ 100 (5-7/8)	1.2 ~ 2.1
100100 (5-7/8) <	2.1 ~ 2.7

•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 (104°F), 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. (For using an anti freeze, change the DIP switch on main PCB in outside unit.)

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

	Anti freeze type		Minimum temperature for anti freezing [°C (°F)]
		0	-5 (23)	-10 (14)	-15 (5)	-20 (-4)	-25
	Ethylene glycol (%)	0	12	20	30	-	-
	Propylene glycol (%)	0	17	25	33	-	-
	Methanol (%)	0	6	12	16	24	30

•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 2nd heat exchanger to make the water supply system a closed type system.

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Installation Manual 11

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

Items	Closed type			Effect
	Circulating water	Supplemented water	Corrosion		Scale
	Basic Item
pH(25C)	7.0~8.0	7.0~8.0	O		O
Conductivity[25C](mS/m)	Below 30	Below 30	O		O
Chlorine ion(mg CI-/l)	Below 50	Below 50	O		-
Sulfuric acid ion(mg SO42-/l)	Below 50	Below 50	O		O
Acid demand[pH 4.8] (mg SiO2/l)	Below 50	Below 50	-		O
Total hardness(mg SiO2/l)	Below 70	Below 70	-		O
Ca hardness(mg CaCO3/l)	Below 50	Below 50	-		O
Ion silica(mg SiO2/l)	Below 30	Below 30	-		O
	Reference Item
Fe(mg Fe/l)	Below 1.0	Below 0.3	O		O
Copper(mg Cu/l)	Below 1.0	Below 0.1	O		-
Sulfuric acid ion(mg S2/l)	Must not be detected	Must not be detected	O		-
+	Below 0.3	Below 0.1	O		-
Ammonium ion(mg NH4/l)
Residual chlorine(mg Cl/l)	Below 0.25	Below 0.3	O		-
Free carbon dioxide(mg CO2/l)	Below 0.4	Below 4.0	O		-
Stability index	-	-	O		O

[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 corrosion. 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 quality 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.

12 Outside Unit

Lifting method

Lifting method

•When carrying the unit suspended, 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 fours points so that impact is not applied to the unit.

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

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Sub line

A40° or less

BRope supporter

WARNING

CAUTION

•Do not have only one person carry product if it is more than 20kg (44.1lbs).

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

•Tear the plastic packaging bag and scrap it so that children cannot play with it. Otherwise plastic packaging bag may suffocate children.

•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 of it.

•When carrying with the forklift, be careful not to drop the product.

Installation Manual 13

Installation

Installation

Location of anchor bolt

[Unit : mm(inch)]

392 (15-7/16)

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The location of anchor bolt

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.

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 (25/32inch) from the foundation surface.

			Spring washer
	Frame							Nut
H-Beam
<![if ! IE]> <![endif]>100 (3-15/16)	<![if ! IE]> <![endif]>75 (2-31/32)									<![if ! IE]> <![endif]>200 (7-7/8)

Anti-vibration
materials									Four bolt are
Concrete
base									required
<![if ! IE]> <![endif]>75 (2-31/32)									3 thread ridges
								<![if ! IE]> <![endif]>200 (7-7/8)

[Unit:mm(inch)]

Foundation bolt executing method

14 Outside 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 outside 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.

3)Flaring work

νCarry out flaring work using flaring tool as shown below.

	Pipe diameter	A inch (mm)
	Inch (mm)	Wing nut type	Clutch type
	Ø1/4 (Ø6.35)
	Ø3/8 (Ø9.52)	0.04~0.07 (1.1~1.8)	0~0.02 (0~0.5)
	Ø1/2 (Ø12.7)
	Ø5/8 (Ø15.88)

Copper		Slanted Uneven Rough
tube	90°

Pipe

Reamer

Point down

<Wing nut type>

Bar

"A"

Copper pipe

<Clutch type>

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

4) Check

ν Compare the flared work with figure below.

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

Smooth all round

Inside is shining without scratches.

= Improper flaring =

Inclined Surface Cracked Uneven

damaged thickness

Even length all round

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Installation Manual 15

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	tightening torque(Ncm)	A(mm)	flare shape
			±2
Ø9.5	3270-3990	12.8-13.2	90°
				45°±
			A	2
Ø12.7	4950-6030	16.2-16.6
				R=0.4~0.8
Ø15.9	6180-7540	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

Shutoff		Tightening torque N-m(Turn clockwise to close)
valve size	Shaft(valve body)		Cap(Valve lid)	Service port	Flare nut	Gas line piping attached to unit
Ø6.4	5.4-6.6	Hexagonal	13.5-16.5		14-17
Ø9.5					33-39
		wrench 4mm
Ø12.7	8.1-9.9		18-22		50-60	-
Ø15.9	13.5-16.5	Hexagonal	23-27	11.5-13.9	62-75
		wrench 6mm
Ø22.2	27-33	Hexagonal	36-44		-	22-28
Ø25.4		wrench 10mm

16 Outside Unit

Indoor 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 "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.

Fastening band (accessory)

Refrigerant piping

Thermal insulator (accessory)

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Installation Manual 17

Refrigerant piping installation

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.

Cautions in pipe connection/valve operation

Cut both the pipe and the valve with a cutter to suit the length

(Don't cut the length of less than 70mm)

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

CLOSE OPEN

WARNING

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

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

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)

	Ball Valve	Elbow	Ball Valve(Gas Pipe)
	(Liquid Pipe)

18 Outside Unit

Refrigerant piping installation

Installation of water pipe

1) Water pipe system diagram

•The water pressure resistance of the water pipe system of this product is 1.98MPa

•When the water pipe passes indoors, make sure to execute heat insulation on the pipe so that water drops do not form on the outer side of the water pipe.

•The size of the drain pipe must be equal to or larger than the diameter of the connecting product.

-Always install a trap so that the drained water does not back flush.

•Always install a strainer (50Mesh or above) at the entrance of the water pipe. (When sand, trash, rusted pieces get mixed into the water supply, it can cause problems to the product due to blocking)

-If On/Off valve is applied, by interlocking with outside unit, it can save the energy consumption of pump by blocking the water supply to the outside unit not operating. Select appropriate valve and install on site if necessary.

•Install a pressure gauge and temperature gauge at the inlet and outlet of the water pipe.

•Flexible joints must be installed not to cause any leakage from the vibration of pipes.

•Install a service port to clean the heat exchanger at the each end of the water inlet and outlet.

•For the components of the water pipe system, always use components above the designed water pressure.

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Water pipe

Pressure gauge

Temperature gauge

outlet

Gate valve

Service port

Water pipe

Inlet

Strainer

Gate valve

Service port

Drain line

Do not directly connect the drain outlet to the water pipe outlet. (It can cause problems to the product.)

2) Water pipe connection

•The water pipe should be the same size of the connection on the product or more.

•If necessary install the insulation material in the water pipe inlet/outlet to prevent water drop, freeze and to save energy. (Use the above 20mm thickness PE insulation material.)

•Tightly connect the socket to the water pipe refer to below table for recommended specification. (Too much torque may cause the damage of the facility.)

Installation Manual 19

Refrigerant piping installation

Pipe thickness			Shear stress		Tensile stress		Bending moment			Torque
mm	inch		(kN)	(kgf)	(kN)	(kgf)	(N.m)	(kgf.m)	(N.m)		(kgf.m)
12.7	1/2		3.5	350	2.5	250	20	2	35		3.5
19.05	3/4		12	1,200	2.5	250	20	2	115		11.5
25.4		1	1 1.2	1,120	4	400	45	4.5	155		15.5
31.8	1	1/4	14.5	1,450	6.5	650	87.5	8.75	265		26.5
38.1	1	1/2	16.5	1,700	9.5	950	155	16	350		35.5
50.8		2	21.5	2,200	13.5	1,400	255	26	600		61

Water pipe outlet

Water pipe connection

Water pipe inlet

20 Outside Unit

Device protection unit

Device protection unit

Strainer on water pipe

To protect the water cooling type product, you must install a strainer with 50mesh or more on the heat water supply pipe. If not installed, it can result in damage of heat exchanger by the following situation.

1.Heat water supply within the plate type heat exchanger is composed of multiple small paths.

2.If you do not use a strainer with 50mesh or more, alien particles can partially block the water paths.

3.When running the heater, the plate type heat exchanger plays the role of the evaporator, and at this time, the temperature of the coolant side drops to drop the temperature of the heat water supply, which can result in icing point in the water paths.

4.And as the heating process progresses, the water paths can be partially frozen to lead to damage in plate type heat exchanger.

5.As a result of the damage of the heat exchanger from the freezing, the coolant side and the heat water source side will be mixed to make the product unusable.

1. Pollution of	2. Partially frozen	3. Damage
Heat source
Heat Source	Refrigerant
(Water)

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Installation Manual 21