Panasonic CU-TZ20ZKE Serie Installationsanleitung

Air conditioner
MODEL NO. :-
CU-TZ20, TZ25, TZ35, TZ42, TZ50, TZ60, TZ71ZKE Series
Installation Instruction
CU-RZ25, RZ35, RZ50ZKE Series
QR code for
Web Manual
https://eu.datanavi.ac.smartcloud.panasonic.com/documents/index.htm?model=CU-TZ20ZKE
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Please scan the above matrix two-dimensional (2D) barcode and read thoroughly for the detailed instruction. Panasonic will
not be responsible for any accident or damage due to improper installation in anyway not described in the detailed manuals.
Malfunction caused by incorrect installation is also not covered by product warranty.
Required tools for Installation Works
1 Phillips screw driver 6 Pipe cutter 11 Thermometer 14 Torque wrench
100 N•m (10.2 kgf•m)
2 Level gauge 7 Reamer 12 Megameter 18 N•m (1.8 kgf•m) 15 Vacuum pump
3 Electric drill, hole core drill (ø70 mm) 8 Knife 13 Multimeter 42 N•m (4.3 kgf•m)
16 Gauge manifold
55 N•m (5.6 kgf•m)
4 Hexagonal wrench (4 mm) 9 Gas leak detector
65 N•m (6.6 kgf•m)
5 Spanner 10 Measuring tape
Explanation of symbols displayed on the indoor unit or outdoor unit.
WARNING
This symbol shows that this equipment uses a fl ammable refrigerant. If the refrigerant is leaked, together with an external ignition source, there is a possibility of ignition.
CAUTION
This symbol shows that the Installation Manual should be read carefully.
CAUTION
This symbol shows that a service personnel should be handling this equipment with reference to the Installation Manual.
CAUTION
This symbol shows that there is information included in the Operation Manual and/or Installation Manual.
SAFETY PRECAUTIONS
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Read the following "SAFETY PRECAUTIONS" carefully before installation.
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Electrical work must be installed by a licensed electrician. Be sure to use the correct rating of the power plug and main circuit for the model to be installed.
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The caution items stated here must be followed because these important contents are related to safety. The meaning of each indication used is as below.
Incorrect installation due to ignoring of the instruction will cause harm or damage, and the seriousness is classifi ed by the following indications.
WARNING This indication shows the possibility of causing death or serious injury.
CAUTION This indication shows the possibility of causing injury or damage to properties only.
The items to be followed are classifi ed by the symbols:
Symbol with white background denotes item that is PROHIBITED.
Symbol with dark background denotes item that must be carried out.
• Carry out test running to confi rm that no abnormality occurs after the installation. Then, explain to user the operation, care and maintenance as stated in instructions. Please remind the
customer to keep the operating instructions for future reference.
WARNING
Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. Any unfi t method or using incompatible material may cause product damage, burst and serious
injury.
Do not install outdoor unit near handrail of veranda. When installing air-conditioner unit on veranda of a high rise building, child may climb up to outdoor unit and cross over the handrail causing an accident.
Do not use unspecifi ed cord, modifi ed cord, joint cord or extension cord for power supply cord. Do not share the single outlet with other electrical appliances. Poor contact, poor insulation or over current will cause
electrical shock or fi re.
Do not tie up the power supply cord into a bundle by band. Abnormal temperature rise on power supply cord may happen.
Do not insert your fi ngers or other objects into the unit, high speed rotating fan may cause injury.
Do not sit or step on the unit, you may fall down accidentally.
Keep plastic bag (packaging material) away from small children, it may cling to nose and mouth and prevent breathing.
When installing or relocating air conditioner, do not let any substance other than the specifi ed refrigerant, eg. air etc mix into refrigeration cycle (piping).
Mixing of air etc. will cause abnormal high pressure in refrigeration cycle and result in explosion, injury etc.
Do not pierce or burn as the appliance is pressurized. Do not expose the appliance to heat, fl ame, sparks, or other sources of ignition.
Else, it may explode and cause injury or death.
Do not add or replace refrigerant other than specifi ed type. It may cause product damage, burst and injury etc.
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For R32/R410A model, use piping, fl are nut and tools which is specifi ed for R32/R410A refrigerant. Using of existing (R22) piping, fl are nut and tools may cause abnormally high pressure in the refrigerant cycle
(piping), and possibly result in explosion and injury.
For R32 and R410A, the same fl are nut on the outdoor unit side and pipe can be used.
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Since the working pressure for R32/R410A is higher than that of refrigerant R22 model, replacing conventional piping and fl are nuts on the outdoor unit side are recommended.
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If reuse piping is unavoidable, refer to instruction "IN CASE OF REUSING EXISTING REFRIGERANT PIPING"
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Thickness of copper pipes used with R32/R410A must be more than 0.8 mm. Never use copper pipes thinner than 0.8 mm.
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It is desirable that the amount of residual oil less than 40 mg/10 m.
Engage authorized dealer or specialist for installation. If installation done by the user is incorrect, it will cause water leakage, electrical shock or fi re.
For refrigeration system work, Install according to this installation instructions strictly. If installation is defective, it will cause water leakage, electrical shock or fi re.
Use the attached accessories parts and specifi ed parts for installation. Otherwise, it will cause the set to fall, water leakage, fi re or electrical shock.
Install at a strong and fi rm location which is able to withstand weight of the set. If the strength is not enough or installation is not properly done, the set will drop and cause injury.
For electrical work, follow the national regulation, legistration and this installation instructions. An independent circuit and single outlet must be used. If electrical circuit capacity is not enough or defect found in the
electrical work, it will cause electrical shock or fi re.
Do not use joint cable for indoor / outdoor connection cable. Use the specifi ed indoor/outdoor connection cable, refer to instruction 5 CONNECT THE CABLE TO THE OUTDOOR UNIT and connect tightly for indoor/
outdoor connection. Clamp the cable so that no external force will have impact on the terminal. If connection or fi xing is not perfect, it will cause heat up or fi re at the connection.
Wire routing must be properly arranged so that control board cover is fi xed properly. If control board cover is not fi xed perfectly, it will cause fi re or electrical shock.
This equipment is strongly recommended to be installed with Earth Leakage Circuit Breaker (ELCB) or Residual Current Device (RCD), with sensitivity of 30 mA at 0.1 sec or less. Otherwise, it may cause electrical
shock and fi re in case of equipment breakdown or insulation breakdown.
During installation, install the refrigerant piping properly before running the compressor. Operation of compressor without fi xing refrigeration piping and valves at opened position will cause suck-in of air, abnormal high
pressure in refrigeration cycle and result in explosion, injury etc.
During pump down operation, stop the compressor before removing the refrigeration piping. Removal of refrigeration piping while compressor is operating and valves are opened will cause suck-in of air, abnormal high
pressure in refrigeration cycle and result in explosion, injury etc.
Tighten the fl are nut with torque wrench according to specifi ed method. If the fl are nut is over-tightened, after a long period, the fl are may break and cause refrigerant gas leakage.
After completion of installation, confi rm there is no leakage of refrigerant gas. It may generate toxic gas when the refrigerant contacts with fi re.
Ventilate if there is refrigerant gas leakage during operation. It may cause toxic gas when the refrigerant contacts with fi re.
Be aware that refrigerants may not contain an odour.
This equipment must be properly earthed. Earth line must not be connected to gas pipe, water pipe, earth of lightning rod and telephone.
Otherwise, it may cause electrical shock in case of equipment breakdown or insulation breakdown.
CAUTION
Do not install the unit in a place where leakage of fl ammable gas may occur. In case gas leaks and accumulates at surrounding of the unit, it may cause fi re.
Prevent liquid or vapor from entering sumps or sewers since vapor is heavier than air and may form suffocating atmospheres.
Do not release refrigerant during piping work for installation, re-installation and during repairing refrigeration parts. Take care of the liquid refrigerant, it may cause frostbite.
Do not install this appliance in a laundry room or other location where water may drip from the ceiling, etc.
Do not touch the sharp aluminium fi n, sharp parts may cause injury.
Carry out drainage piping as mentioned in installation instructions. If drainage is not perfect, water may enter the room and damage the furniture.
Select an installation location which is easy for maintenance.
Incorrect installation, service or repair of this air conditioner may increase the risk of rupture and this may result in loss damage or injury and/or property.
Power supply connection to the room air conditioner.
Use power supply cord 3 x 1.5 mm² (3/4 ~ 1.75HP), 3 x 2.5 mm² (2.0 ~ 2.5HP) type designation 60245 IEC 57 or heavier cord.
Connect the power supply cord of the air conditioner to the mains using one of the following method.
Power supply point should be in easily accessible place for power disconnection in case of emergency.
In some countries, permanent connection of this air conditioner to the power supply is prohibited.
1) Power supply connection to the receptacle using power plug.
Use an approved 15/16 A (3/4 ~ 1.75HP), 16 A (2.0 ~ 2.25HP), 20 A (2.5HP) power plug with earth pin for the connection to the socket.
2) Power supply connection to a circuit breaker for the permanent connection.
Use an approved 16 A (3/4 ~ 2.25HP), 20 A (2.5HP) circuit breaker for the permanent connection. It must be a double pole switch with a minimum 3.0 mm contact gap.
Installation work.
It may need two people to carry out the installation work.
Keep any required ventilation openings clear of obstruction.
PRECAUTION FOR USING R32 REFRIGERANT
• Pay careful attention to the following precaution points and the installation work procedures.
WARNING
The appliance shall be stored, installed and operated in a well ventilated room with indoor fl oor area larger than A (m²) [refer Table A] and without any continuously operating ignition source. Keep away from open
min
fl ames, any operating gas appliances or any operating electric heater. Else, it may explode and cause injury or death.
The mixing of different refrigerants within a system is prohibited. Models that use refrigerant R32 and R410A have a different charging port thread diameter to prevent erroneous charging with refrigerant R22 and for safety.
Therefore, check beforehand. [The charging port thread diameter for R32 and R410A is 12.7 mm (1/2 inch).]
Ensure that foreign matter (oil, water, etc.) does not enter the piping.
Also, when storing the piping, securely seal the opening by pinching, taping, etc. (Handling of R32 is similar to R410A.)
Operation, maintenance, repairing and refrigerant recovery should be carried out by trained and certifi ed personnel in the use of fl ammable refrigerants and as recommended by the manufacturer. Any personnel
conducting an operation, servicing or maintenance on a system or associated parts of the equipment should be trained and certifi ed.
Any part of refrigerating circuit (evaporators, air coolers, AHU, condensers or liquid receivers) or piping should not be located in the proximity of heat sources, open fl ames, operating gas appliance or an operating
electric heater.
The user/owner or their authorized representative shall regularly check the alarms, mechanical ventilation and detectors, at least once a year, where as required by national regulations, to ensure their correct
functioning.
A logbook shall be maintained. The results of these checks shall be recorded in the logbook.
In case of ventilations in occupied spaces shall be checked to confi rm no obstruction.
Before a new refrigerating system is put into service, the person responsible for placing the system in operation should ensure that trained and certifi ed operating personnel are instructed on the basis of the instruction
manual about the construction, supervision, operation and maintenance of the refrigerating system, as well as the safety measures to be observed, and the properties and handling of the refrigerant used.
The general requirement of trained and certifi ed personnel are indicated as below:
a) Knowledge of legislation, regulations and standards relating to fl ammable refrigerants; and,
b)  D etailed knowledge of and skills in handling fl ammable refrigerants, personal protective equipment, refrigerant leakage prevention, handling of cylinders, charging, leak detection, recovery and disposal; and,
c) Able to understand and to apply in practice the requirements in the national legislation, regulations and Standards; and,
d) Continuously undergo regular and further training to maintain this expertise.
Air-conditioner piping in the occupied space shall be installed in such a way to protect against accidental damage in operation and service.
Precautions shall be taken to avoid excessive vibration or pulsation to refrigerating piping.
Ensure protection devices, refrigerating piping and fi ttings are well protected against adverse environmental effects (such as the danger of water collecting and freezing in relief pipes or the accumulation of dirt and debris).
Expansion and contraction of long runs piping in refrigerating systems shall be designed and installed securely (mounted and guarded) to minimize the likelihood hydraulic shock damaging the system.
Protect the refrigerating system from accidental rupture due to moving furniture or reconstruction activities.
To ensure no leaking, fi eld-made refrigerant joints indoors shall be tightness tested. The test method shall have a sensitivity of 5 grams per year of refrigerant or better under a pressure of at least 0,25 times the
maximum allowable pressure (>1.04 MPa, max 4.15 MPa). No leak shall be detected.
CAUTION
1. General
• Must ensure the installation of pipe-work shall be kept to a minimum. Avoid use dented pipe and do not allow acute bending.
R32
• Must ensure that pipe-work shall be protected from physical damage.
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Must comply with national gas regulations, state municipal rules and legislation. Notify relevant authorities in accordance with all applicable regulations.
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Must ensure mechanical connections be accessible for maintenance purposes.
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In cases that require mechanical ventilation, ventilation openings shall be kept clear of obstruction.
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REFRIGERANT When disposal of the product, do follow to the precautions in #11 and comply with national regulations.
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In case of fi eld charge, the effect on refrigerant charge caused by the different pipe length has to be quantifi ed, measured and labelled.
Always contact to local municipal offi ces for proper handling.
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Ensure the actual refrigerant charge is in accordance with the room size within which the refrigerant containing parts are installed.
This Air Conditioner contains and
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Ensure refrigerant charge not to leak.
operates with refrigerant R32.
• Wear appropriate protective equipment, including respiratory protection, as conditions warrant.
• Keep all sources of ignition and hot metal surfaces away.
THIS PRODUCT MUST ONLY BE INSTALLED OR SERVICED
BY QUALIFIED PERSONNEL. 2. Servicing
2-1. Qualifi cation of workers
Refer to National, State, Territory and local legislation,
regulations, codes, installation & operation manuals, before •
Any qualifi ed person who is involved with working on or breaking into a refrigerant circuit should hold a current valid certifi cate from an industry-accredited assessment authority, which authorizes their competence to
the installation, maintenance and/or service of this product.
handle refrigerants safely in accordance with an industry recognized assessment specifi cation.
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Servicing shall only be performed as recommended by the equipment manufacturer. Maintenance and repair requiring the assistance of other skilled personnel shall be carried out under the supervision of the person
competent in the use of fl ammable refrigerants.
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Servicing shall be performed only as recommended by the manufacturer.
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The system is inspected, regularly supervised and maintained by a trained and certifi ed service personnel who is employed by the person user or party responsible.
2-2. Checks to the area
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Prior to beginning work on systems containing fl ammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised.
For repair to the refrigerating system, the precautions in #2-3 to #2-7 must be followed before conducting work on the system.
2-3. Work procedure
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Work shall be undertaken under a controlled procedure so as to minimize the risk of a fl ammable gas or vapour being present while the work is being performed.
2-4. General work area
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All maintenance staff and others working in the local area shall be instructed and supervised on the nature of work being carried out.
• Avoid working in confi ned spaces. Always ensure away from source, at least 2 meter of safety distance, or zoning of free space area of at least 2 meter in radius.
2-5. Checking for presence of refrigerant
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The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially fl ammable atmospheres.
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Ensure that the leak detection equipment being used is suitable for use with fl ammable refrigerants, i.e. non sparking, adequately sealed or intrinsically safe.
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In case of leakage/spillage happened, immediately ventilate area and stay upwind and away from spill/release.
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In case of leakage/spillage happened, do notify persons down wind of the leaking/spill, isolate immediate hazard area and keep unauthorized personnel out.
2-6. Presence of fi re extinguisher
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If any hot work is to be conducted on the refrigerating equipment or any associated parts, appropriate fi re extinguishing equipment shall be available at hand.
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Have a dry powder or CO fi re extinguisher adjacent to the charging area.
2
2-7. No ignition sources
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No person carrying out work in relation to a refrigerating system which involves exposing any pipe work that contains or has contained fl ammable refrigerant shall use any sources of ignition in such a manner that it
may lead to the risk of fi re or explosion. He/She must not be smoking when carrying out such work.
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All possible ignition sources, including cigarette smoking, should be kept suffi ciently far away from the site of installation, repairing, removing and disposal, during which fl ammable refrigerant can possibly be released
to the surrounding space.
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Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no fl ammable hazards or ignition risks.
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"No Smoking" signs shall be displayed.
2-8. Ventilated area
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Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work.
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A degree of ventilation shall continue during the period that the work is carried out.
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The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.
2-9. Checks to the refrigerating equipment
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Where electrical components are being changed, they shall be fi t for the purpose and to the correct specifi cation.
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At all times the manufacturer's maintenance and service guidelines shall be followed.
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If in doubt consult the manufacturer's technical department for assistance.
• The following checks shall be applied to installations using fl ammable refrigerants.
- The actual refrigerant charge is in accordance with the room size within which the refrigerant containing parts are installed.
- The ventilation machinery and outlets are operating adequately and are not obstructed.
- If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant.
- Marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected.
- Refrigerating pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed
of materials which are inherently resistant to being corroded or are properly protected against being so corroded.
2-10. Checks to electrical devices
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Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures.
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Initial safety checks shall include but not limit to:-
- That capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking.
- That there is no live electrical components and wiring are exposed while charging, recovering or purging the system.
- That there is continuity of earth bonding.
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At all times the manufacturer's maintenance and service guidelines shall be followed.
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If in doubt consult the manufacturer's technical department for assistance.
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If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with.
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If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used.
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The owner of the equipment must be informed or reported so all parties are advised thereinafter.
3. Repairs to sealed components
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During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc.
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If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.
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Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables,
excessive number of connections, terminals not made to original specifi cation, damage to seals, incorrect fi tting of glands, etc.
• Ensure that apparatus is mounted securely.
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Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of
preventing the ingress of fl ammable atmospheres.
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Replacement parts shall be in accordance with the manufacturer's specifi cations.
4. Repair to intrinsically safe components
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Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use.
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Intrinsically safe components are the only types that can be worked on while live in the presence of a fl ammable atmosphere.
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The test apparatus shall be at the correct rating.
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Replace components only with parts specifi ed by the manufacturer. Unspecifi ed parts by manufacturer may result ignition of refrigerant in the atmosphere from a leak.
5. Cabling
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Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects.
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The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
6. Detection of fl ammable refrigerants
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Under no circumstances shall potential sources of ignition be used in the searching or detection of refrigerant leaks.
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A halide torch (or any other detector using a naked fl ame) shall not be used.
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The following leak detection methods are deemed acceptable for all refrigerant systems.
- No leaks shall be detected when using detection equipment with a sensitivity of 5 grams per year of refrigerant or better under a pressure of at least 0,25 times the maximum allowable pressure (>1.04 MPa, max
4.15 MPa) for example, a universal sniffer.
- Electronic leak detectors may be used to detect fl ammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration.
(Detection equipment shall be calibrated in a refrigerant-free area.)
- Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used.
- Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25 % maximum) is confi rmed.
- Leak detection fl uids are also suitable for use with most refrigerants, for example, bubble method and fl uorescent method agents. The use of detergents containing chlorine shall be avoided as the chlorine may
react with the refrigerant and corrode the copper pipe-work.
- If a leak is suspected, all naked fl ames shall be removed/extinguished.
- If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. The precautions
in #7 must be followed to remove the refrigerant.
7. Removal and evacuation
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When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures shall be used.
However, it is important that best practice is followed since fl ammability is a consideration.
The following procedure shall be adhered to:
• remove refrigerant -> • purge the circuit with inert gas -> • evacuate -> • purge with inert gas -> • open the circuit by cutting or brazing
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The refrigerant charge shall be recovered into the correct recovery cylinders.
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The system shall be purged with OFN to render the appliance safe. (remark: OFN = oxygen free nitrogen, type of inert gas)
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This process may need to be repeated several times.
• Compressed air or oxygen shall not be used for this task.
• Purging shall be achieved by breaking the vacuum in the system with OFN and continuing to fi ll until the working pressure is achieved, then venting to atmosphere, and fi nally pulling down to a vacuum.
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This process shall be repeated until no refrigerant is within the system.
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When the fi nal OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place.
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This operation is absolutely vital if brazing operations on the pipe work are to take place.
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Ensure that the outlet for the vacuum pump is not close to any potential ignition sources and there is ventilation available.
8. Charging procedures
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In addition to conventional charging procedures, the following requirements shall be followed.
- Ensure that contamination of different refrigerants does not occur when using charging equipment.
- Hoses or lines shall be as short as possible to minimize the amount of refrigerant contained in them.
- Cylinders shall be kept in an appropriate position according to the instructions.
- Ensure that the refrigerating system is earthed prior to charging the system with refrigerant.
- Label the system when charging is complete (if not already).
- Extreme care shall be taken not to over fi ll the refrigerating system.
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Prior to recharging the system it shall be pressure tested with OFN (refer to #7).
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The system shall be leak tested on completion of charging but prior to commissioning.
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A follow up leak test shall be carried out prior to leaving the site.
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Electrostatic charge may accumulate and create a hazardous condition when charging and discharging the refrigerant.
To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging.
9. Decommissioning
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Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its details.
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It is recommended good practice that all refrigerants are recovered safely.
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Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of recovered refrigerant.
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It is essential that electrical power is available before the task is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure ensure that:
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mechanical handling equipment is available, if required, for handling refrigerant cylinders;
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all personal protective equipment is available and being used correctly;
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the recovery process is supervised at all times by a competent person;
•
recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
•
Electrostatic charge may accumulate and create a hazardous condition when charging or discharging the refrigerant.
To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging.
10. Labelling
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Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant.
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The label shall be dated and signed.
•
Ensure that there are labels on the equipment stating the equipment contains fl ammable refrigerant.
11. Recovery
•
When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
•
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed.
•
Ensure that the correct number of cylinders for holding the total system charge are available.
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All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i.e. special cylinders for the recovery of refrigerant).
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Cylinders shall be complete with pressure relief valve and associated shut-off valves in good working order.
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Recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
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The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of concerning the equipment that is at hand and shall
be suitable for the recovery of fl ammable refrigerants.
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In addition, a set of calibrated weighing scales shall be available and in good working order.
• Hoses shall be complete with leak-free disconnect couplings and in good condition.
•
Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a
refrigerant release.
Consult manufacturer if in doubt.
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The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged.
•
Do not mix refrigerants in recovery units and especially not in cylinders.
•
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that fl ammable refrigerant does not remain within the lubricant.
•
The evacuation process shall be carried out prior to returning the compressor to the suppliers.
•
Only electric heating to the compressor body shall be employed to accelerate this process.
• When oil is drained from a system, it shall be carried out safely.
Attached accessories
No. Accessories part
Drain elbow
1
CAUTION
  If an awning is built over the unit to prevent direct sunlight or rain, be careful that heat radiation from the condenser is not obstructed.
  There should not be any animal or plant which could be affected by hot air discharged.
  Keep the spaces indicated by arrows from wall, ceiling, fence or other obstacles.
  Do not place any obstacles which may cause a short circuit of the discharged air.
  If piping length is over the [piping length for additional gas], additional refrigerant should be added as shown in the table.
Table A
Model
TZ20***
TZ25***, RZ25***
TZ35***, RZ35***
TZ42***
TZ50***, RZ50***
TZ60***
TZ71***
(*) Systems with total refrigerant charge, m
Example: For TZ20***
If the unit is installed at 10 m distance, the quantity of additional refrigerant should be 25 g .... (10-7.5) m x 10 g/m = 25 g.
1
SELECT THE BEST LOCATION
(Refer to "Select the best location" section)
2
INSTALL THE OUTDOOR UNIT
•
After selecting the best location, start installation to Indoor/Outdoor Unit Installation Diagram.
Fix the unit on concrete or rigid frame fi rmly and horizontally by bolt nut (ø10 mm).
1.
Make sure unit install in balance level to ensure that water fl ow out from unit drainage hole.
2. When installing at roof, please consider strong wind and earthquake.
Please fasten the installation stand fi rmly with bolt, screws or nails.
3
CONNECT THE PIPING
Connecting The Piping to Indoor
For connection joint location at outside building
Please make flare after inserting flare nut (locate
at joint portion of tube assembly) onto the copper
pipe. (In case of using long piping)
Connect the piping
•
Align the center of piping and suffi ciently tighten
the fl are nut with fi ngers.
• Further tighten the fl are nut with torque wrench in
NOTE:
specifi ed torque as stated in the table.
- The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment.
- Intrinsically safe components do not have to be isolated prior to working on them.
Spanner or
Wrench
Connecting The Piping to Outdoor
Decide piping length and then cut by using
pipe cutter.
Remove burrs from cut edge.
Make fl are after inserting the fl are nut (locate
at valve) onto the copper pipe. Align center of
piping to valve and then tighten with torque
wrench to the specifi ed torque as stated in
the table.
5
CONNECT THE CABLE TO THE OUTDOOR UNIT
1. Remove the control board cover from the unit by loosening the screw.
Connection cable between indoor unit and outdoor unit shall be approved polychloroprene
2.
sheathed 4 x 1.5 mm
60245 IEC 57 or heavier cord. Do not use joint connection cable. Replace the wire if the existing
wire (from concealed wiring, or otherwise) is too short.
Terminals on the outdoor unit
Colour of wires (connection cable)
Terminals on the indoor unit
3. Secure the cable onto the control board with the holder (clamper).
4. Attach the control board cover back to the original position with screw.
For wire stripping and connection requirement, refer to instruction CONNECT THE CABLE TO
5.
THE INDOOR UNIT.
This equipment must be properly earthed.
DISPOSAL OF OUTDOOR UNIT DRAIN WATER
•
If a drain elbow is used, the unit should be placed on a stand which
is taller than 3 cm.
f) Make sure that cylinder is situated on the scales before recovery takes place. • If the unit is used in an area where temperature falls below 0 °C
g) Start the recovery machine and operate in accordance with instructions.
for 2 or 3 days in succession, it is recommended not to use a drain
h) Do not over fi ll cylinders. (No more than 80 % volume liquid charge).
elbow, for the drain water freezes and the fan will not rotate.
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been fi lled correctly and the process completed, make sure
that the cylinders and the equipment are removed from site promptly and all isolation
valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigerating system unless it
has been cleaned and checked.
IN CASE OF REUSING EXISTING REFRIGERANT PIPING
Observe the followings to decide reusing the existing refrigerant piping.
Poor refrigerant piping could result in product failure.
•
In the circumstances listed below, do not reuse any refrigerant piping. Instead, make sure to install a
new piping.
- Heat insulation is not provided for either liquid-side or gas-side piping or both.
- The existing refrigerant pipe has been left in an open condition.
- The diameter and thickness of the existing refrigerant piping does not meet the requirement.
- The piping length and elevation does not meet the requirement.
Perform proper pump down before reuse piping.
• In the circumstances listed below, clean it thoroughly before reuse.
- Pump down operation cannot be performed for the existing air-conditioner.
- The compressor has a failure history.
- Oil color is darken. ( ASTM 4.0 and above ).
- The existing air-conditioner is gas/oil heat pump type.
• Do not reuse the fl are to prevent gas leak. Make sure to install a new fl are.
•
If there is a welded part on the existing refrigerant piping, conduct a gas leak check on the welded part.
•
Replace deteriorated heat insulating material with a new one.
Heat insulating material is required for both liquid-side and gas-side piping.
Qty. A = ( m
min
A = Required minimum room area, in m²
min
1
m = Refrigerant charge in appliance, in kg
c
LFL = Lower fl ammability limit (0.307 kg/m³)
h = Installation height of the appliance (1.8 m for wall mounted)
0
SELECT THE BEST LOCATION
SF = Safety factor with a value of 0.75
** The required minimum room area,
OUTDOOR UNIT
A
min
The higher value shall be taken when determining the room area.
Piping Max.
Piping size Std. Max. Min. Piping Max. Piping Additional
Capacity W Length for Refrigerant Indoor
Length Elevation Length Length Refrigerant
add. gas Charge A min (m²)
(HP)
(m) (m) (m) (m) (g/m)
(m) (kg)
Gas Liquid
3/4HP
15 3 15 10 7.5 0.60 Not applicable (*)
9.52 mm
1.0HP 15 3 15 10 7.5 0.69 Not applicable (*)
(3/8")
1.5HP 15 3 15 10 7.5 0.75 Not applicable (*)
1.75HP 6.35 mm
15 3 15 10 7.5 0.87 Not applicable (*) It is advisable to avoid more
5
12.7 mm
(1/4")
2.0HP 15 3 20 15 10 1.22 Not applicable (*) than 2 blockage directions.
(1/2")
For better ventilation &
2.25HP 15 3 30 15 10 1.52 Not applicable (*)
multiple-outdoor installation,
15.88 mm
2.5HP 20 3 30 25 10 1.85 4.46
(5/8") please consult authorized
dealer/specialist.
, lower than 1.84 kg are not subjected to any room area requirements.
c
• This illustration is for
explanation purposes only.
OUTDOOR UNIT
4
AIR TIGHTNESS TEST ON THE REFRIGERATING SYSTEM
Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.
There is no extra refrigerant in the outdoor unit for air purging.
•
Before system is charged with refrigerant and before the refrigerating system is put into operation, below site
test procedure and acceptance criteria shall be verifi ed by the certifi ed technicians, and/or the installer.
• Be sure to check whole system for gas leakage.
Model A B C D
A B
Preparation
TZ20***
(Step 1-2)
TZ25***, RZ25***
570 mm 105 mm 18.5 mm 320 mm
TZ35***, RZ35***
TZ42***
TZ50***, RZ50***
540 mm 160 mm 18.5 mm 330 mm
TZ60***
TZ71*** 613 mm 131 mm 24 mm 360.5 mm
Evacuation
(Step 3-4)
Tightness Test
with Inert Gas
(Step 5-7)
For connection joint location at inside building
• Refer to indoor installation instruction.
YES
Pressure drop?
(Step 8)
NO
Torque
wrench
Recovery
of Test Gas
Do not overtighten, overtightening may cause gas leakage. (Step 13)
Piping size Torque
6.35 mm (1/4") [18 N•m (1.8 kgf•m)]
9.52 mm (3/8") [42 N•m (4.3 kgf•m)]
Evacuation
12.7 mm (1/2") [55 N•m (5.6 kgf•m)]
(Step 3-4)
15.88 mm (5/8") [65 N•m (6.6 kgf•m)]
19.05 mm (3/4") [100 N•m (10.2 kgf•m)]
Open 2 and 3
valves
(Step 14-18)
Complete
2 (3/4 ~ 1.75HP) or 4 x 2.5 mm 2 (2.0 ~ 2.5HP) fl exible cord, type designation
Notes:
Recommended use of any of the following leak detector,
I) Universal Sniffer leak detector
S1 2 3
II) Electronic halogen leak detector
III) Ultrasonic Leak Detector
L 1 N S1 2 3
6
PIPING INSULATION
•
WARNING Earth wire shall be Yellow/Green (Y/G) in 1. Please carry out insulation at pipe connection portion as mentioned in Indoor/Outdoor Unit Installation
colour and longer than other AC wires for Diagram. Please wrap the insulated piping end to prevent water from going inside the piping.
safety reason.
2. If drain hose or connecting piping is in the room (where dew may form), please increase the insulation by using
POLY-E FOAM with thickness 6 mm or above.
Proper Pump Down Method
1
Operate air conditioner
at cooling mode for
10 ~ 15 minutes.
Drain elbow 1 Hose
Most Important Process
Install the hose at an angle so that the water
Purpose: To make the oil
smoothly fl ows out.
& refrigerant mix together.
They are in separated
condition when
air conditioner
is stopped.
CHECK ITEMS
Is there any gas leakage at fl are nut connections?
Has the heat insulation been carried out at fl are
nut connection?
Is the connection cable being fi xed to terminal
board fi rmly?
Is the connection cable being clamped fi rmly?
/ (2.5 x (LFL) (5/4) x h )) ²
c ** not less than safety factor margin
0
A , shall also be governed by the safety factor margin formula below :
min
= m / (SF x LFL x h )
c 0
Connection cable ()
1/4" Liquid side piping ()
Gas side piping ()
Additional drain
hose ()
Installation parts you
should purchase ()
AIR PURGING METHOD IS PROHIBITED FOR R32 SYSTEM
1) Connect a charging hose with a push pin to the Low side of a charging set and the
service port of the 3-way valve.
2) Attach the gauge manifold set correctly and tightly. Make sure that both valves of the
manifold gauge (low pressure and high pressure) is in close position.
3) Connect the center hose of the manifold gauge to a vacuum pump.
4) Turn on the power switch of the vacuum pump, then turn open the low side manifold
gauge valve and make sure that the needle in the gauge moves from 0 cmHg (0 MPa)
to –76 cmHg (–0.1 MPa) or vacuum until 500 microns is achieved. This process
continues for approximately ten minutes.
Then close the low side manifold gauge valve.
5) Remove the vacuum pump from the centre hose and connect the center hose to
cylinder of any applicable inert gas as test gas.
6) Charge test gas into the system and wait until the pressure within the
system to reach min. 1.04 MPa (10.4 barg).
7) Wait and monitor the pressure reading on the gauges. Check if there
is any pressure drop. Waiting time depends on the size of the system.
8) If there is any pressure drop, perform step 9-12. If there is no pressure drop, perform
step 13.
9) Use Gas Leak Detector to check for leaks. Must use the detection
equipment with a sensitivity of 5 grams per year of test gas or better.
Leak detection
10) Move the probe along the air conditioning system to check for leaks, and
and repair
mark for repair.
(Step 9-12) 11) Any leak detected and marked shall be repaired.
12) After repair, repeat evacuation steps 3-4 and tightness test steps 5-7.
Check the pressure drop as in step 8.
13) If no leak,
Recover the test gas.
Liquid side
Perform evacuation of Indoor unit
Two-way valve
Outdoor unit
steps 3-4.
Then proceed to
Close
step 14.
Gas side
Three-way valve
OPEN
Tank
Cylinder Close
Vacuum
CLOSE
Inert
pump
gas
14) Disconnect the charging hose from the service port of the 3-way valve.
15) Tighten the service port caps of the 3-way valve at a torque of 18 N•m with a torque
wrench.
16) Remove the valve caps of both of the 2-way valve and 3-way valve.
17) Open both of the valves, using a hexagonal wrench (4 mm).
It is recommended to allow refrigerant slowly fl ow into the refrigerant system to prevent
refrigerant freezing. Slightly open 2-way valve for 5 seconds then close the valve.
Repeat this action for 3 cycles then fully open the valve.
18) Mount back the valve caps onto the 2-way valve and the 3-way valve to complete this
process.
2 3 4
After 10 ~ 15 minutes of pre Take out air Install New
operation, close 2 way valve. conditioner Refrigerant air
After 3 minutes, close 3 way unit. conditioner.
valve.
Mixed refrigerant
Only very small
& oil will be
amount of oil remain
collected into
inside piping, which
outdoor unit.
is acceptable.
Is the earth wire connection properly done?
Is the power supply voltage complied
with rated value?
Is there any abnormal sound?
Is the cooling/heating operation normal?
Is the thermostat operation normal?
ENGLISH
ACXF60-47850
PRINTED IN MALAYSIA