Rev. (0) -2009 03502511

Specifications are subject to change without notice according to Carrier Policy of continuous development.

TABLE OF CONTENTS

PAGE NO. 1. GENERAL NOTES TO INSTALLER 1

2. MODELS 2

3. OPERATING LIMITS 2

4. DIMENSIONS, WEIGHTS AND MINIMUM CLEARANCECS 3

5. BRECAUTIONS BEFORE INSTALLATION 7

6. SPLIT SYSTEM DESCRIPTION 8

7. INSTALLATION ACCESSORIES 9

8. INSTALLATION CHART 10

9. SELECTING INSTALLATION LOCATION FOR INDOOR UNIT 11

10. SELECTING INSTALLATION LOCATION FOR OUTDOOR UNIT 12

11. INSTALLATION LOCATION-CHECK LIST 14

12. INDOOR UNIT INSTALLATION 12-1 POSSIBLE OUTLET LOCATIONS OF REFRIGERANT PIPING LINES 15 12-2 PREPARATION STEPS BEFORE INSTALLATION 15 12-3 INSTALLATION STEPS 16

13. OUTDOOR UNIT INSTALLATION 13-1 PREPARATION STEPS BEFORE INSTALLATION 17 13-2 INSTALLATION STEPS 17

14. CONNECTING REFRIGERANT PIPING LINES 18

15. CONNECTING CONDENSATE DRAIN LINE 29

16. CONNECTING ELECTRICAL WIRING 30

17. AIR MANAGEMENT SYSTEM ACCESSORY KIT 35

18. FINISHING INSTALLATION 37

19. TEST RUNNING 38

20. AFTER INSTALLATION CHECK LIST 40

21. SELF DIAGNOSTIC FUNCTION FOR MALFUNCTIONS DETECTION 42

1

1. GENERAL NOTES TO INSTALLER CARRIER split room air conditioner has been carefully designed and manufactured under strict Quality Control conditions. Therefore you are completely responsible for proper installation completion and operation of the air conditioner. Carefully read the manual carefully before proceeding with the installation to ensure correct installation. This manual describes installation instructions to help ensure trouble free operation and extended life of the air conditioner. Make sure all accessory parts are with the system before beginning installation.

You will need the following tools during installation: 1. Standard screw driver 11. Tube bender 2. Phillips head screw driver 12. Hexagonal wrench 3. Cutter drill 13. Torque wrench 4. Metal saw 14. Vacuum pump 5. Water level 15. Gas leak detector 6. Meter 16. Manometer for pressure measuring 7. Tube cutter 17. Thermometer 8. Cutter 18. Volts – ohm - millimeter 9. Reamer 19. Electro circuit tester

10. Flare tool

After completion of installation, perform a run test and give the customer full instructions on the correct operation of the air conditioner including:

• Turning the unit on and off. • Removal and cleaning of the air filters. • Functions of the remote control. • Re-installation of air filters after cleaning

Leave the owner manual with the customer so that it can to be used during operation of the air conditioner. Leave the installation manual with the customer so that it can be used for any service and maintenance operations. Advise the customer to the tips of energy saving while operating the air conditioner for cooling. These tips are:

1. KEEP DOORS, WINDOWS AND ANY OTHER OPENINGS CLOSED to prevent conditioned air from escaping and to prevent warm air from entering the space to be air-conditioned.

2. CLEAN PERIODICALLY AIR FILTERS to assure maximum efficiency and adequate air

circulation of the air conditioner.

3. KEEP DRAPES, FURNITURE OR OTHER OBSTRUCTIONS AWAY FROM BLOCKING RETURN AIR AND/OR SUPPLY AIR OF THE AIR CONDITIONER to assure maximum efficiency and adequate air circulation of the air conditioner.

2

2. MODELS 2-1 HEAT PUMP 2-2 COOL ONLY

System Model

Indoor Unit Model

Outdoor Unit Model

System Model

Indoor Unit Model

Outdoor Unit Model

53CCD20-H 42CCD20-H 38CCD20-H 53CCD20-C 42CCD20-C 38CCD20-C 53CCD28-H 42CCD28-H 38CCD28-H 53CCD28-C 42CCD28-C 38CCD28-C 53CCD32-H 42CCD32-H 38CCD32-H 53CCD32-C 42CCD32-C 38CCD32-C 53CCD39-H 42CCD39-H 38CCD39-H 53CCD39-C 42CCD39-C 38CCD39-C 53CCD48-H 42CCD48-H 38CCD48-H 53CCD48-C 42CCD48-C 38CCD48-C 53CCD60-H 42CCD60-H 38CCD60-H 53CCD60-C 42CCD60-C 38CCD60-C

3. OPERATING LIMITS **

COOLING HEATING Difference Dry Bulb

Temp. C° Wet Bulb Temp. C° Difference Dry Bulb

Temp. C° Wet Bulb Temp. C°

Indoor temperature Maximum Minimum

32 21

23 15

Indoor temperature Maximum

27

-

Outdoor temperature Maximum Minimum

*

20

- -

Outdoor temperature Maximum Minimum

24 2

18 1

MAIN POWER SUPPLY Standard Mild Ambient

Outdoor Unit

System Model

Nominal Power Supply V/1PH/50HZ

Minimum Voltage

Maximum Voltage

System Model

Nominal Power Supply V/1PH/50HZ

Minimum Voltage

Maximum Voltage

53CCD20 53CCD20 53CCD28 53CCD28 53CCD32 53CCD32 53CCD39

220/1/50 187 264

53CCD39

220-240/1/50 187 264

53CCD48 53CCD48 53CCD60

380-420/3/50 342 462 53CCD60

380-420/3/50 342 462

NOTES: * 46°C for System with Mild ambient Standard outdoor unit. 52°C for System with High ambient outdoor unit.

** When the unit is operated above or below these limits for a long time, system diagnostics may detect a malfunction and the unit will not operate properly.

*** During heat pump operation, the system will undergo several defrost cycles to eliminate ice that might possibly collect on the outdoor unit in very low ambient temperatures.

After completions of defrost cycle, the system will normally operate

NOTES: H = Heat Pump C = Cool Only

3

4. DIMENSIONS, WEIGHTS AND MINIMUM CLEARANCES 4-1 OUTDOOR UNIT WEIGHTS DIMENSIONS (MM)

Model A B C D E F 38CCD20 38CCD28 38CCD32

575

38CCD39 720 38CCD48 38CCD60

860

1150

371 665 97.5 350

MINIMUM CLEARANCES FOR FREE AIR CIRCULATION, SERVICE AND MAINTENANCE Notes: - The front of the condensing unit (Propeller discharge airside) should be free from obstructions.

Any obstruction should be away from front of the condensing unit with distance specified in the following drawings.

- The back of the condensing unit (coil intake airside) should be at least 160 mm away from any

obstruction. This distance 160 mm A is built-in design of wall support. - A free space should be left on the right side of the outdoor unit. - A free space should be left on the side of the refrigerant connections of condensing unit to ensure

easy access to the terminal block. - A free space should be left from the top cover of condensing unit to ensure easy access to electrical

components, motor and propeller. - The refrigerant line connections must be conveniently located for service and maintenance.

A

A

B

E D

C F

38CCD20 – 38CCD28 – 38CCD232

F

A

D E

C

A

B

Model Kg 38CCD20 52.8 38CCD28 58.4 38CCD32 62.4 38CCD39 79.5 38CCD48 90 38CCD60 92

38CCD48 –60

4

DIMENSIONS, WEIGHTS AND MINIMUM CLEARANCES (Cont.) MINIMUM CLERANCES OF OUTDOOR UNIT FOR FREE AIR CIRCULATION, SERVICE AND MAINTENANCE (Cont.)

Obstacle at air inlet to outdoor unit ( unit back ) No obstacle at unit top

No obstacles at unit and left sides Single unit installation Serial installation of two or more units

Obstacle at air inlet to outdoor unit ( unit back )

No obstacle at unit top obstacles at unit right and left sides

Single unit installation Serial installation of two or more units

The hieght of the obstacle should be lower than the height of the outdoor unit.

Obstacle at air inlet to outdoor unit ( unit back ) obstacle also at unit top

No obstacles at unit right and left sides

DIMENSIONS (mm)

160 mm or more

400 mm or more

400 mm or more

160 mm or more

400 mm or more

400 mm or more

400 mm or more

250 mm or more

400mm or more

160 mmor more

160 mm or more

400 mm or more

250 mm or more

160 mm or more

5

DIMENSIONS, WEIGHTS AND MINIMUM CLEARANCES (Cont.)

MINIMUM CLERANCES OF OUTDOOR UNIT FOR FREE AIR CIRCULATION, SERVICE AND MAINTENANCE (Cont.)

Obstacle at air outlet from outdoor unit ( unit front ) No obstacle also at unit top

No obstacles at unit right and left sides Single unit installation Serial installation of two or more units

Obstacle at air outlet from outdoor unit ( unit front ) Obstacle also at unit top

No obstacles at unit right and left sides

Obstacles at both air inlet and air outlet of outdoor unit ( both unit front & back ) No obstacle also at unit top

No obstacle at unit right and left sides Single unit installation Serial installation of two or more units

The height of obstacle at both front and back side, should be lower than the height of outdoor unit.

Serial installation at front and rear sides Standard installation

Open the upper side and both right and left sides.

The height of obstacle at both front and back, should be lower than the height of the outdoor unit.

or more

160 mm or more

1000 mm or more

160 mm or more

1000 mm or more

400 mm or more

400 mm or more

1000 mm or more

500 mm or more

1000 mm1000 mm or more

160 mm or more

1000 mm or more

1500 mm or more

1000 mm or more

160 mm or more

6

DIMENSIONS, WEIGHTS AND MINIMUM CLEARANCES (Cont.) 4-2 INDOOR UNIT Weight Dimensions mm

Model Kg Model H D W A B C 42CCD20 26 42CCD20 270 590 1005 857 205 895 42CCD28 28 42CCD28 270 590 1005 857 205 895 42CCD32 30 42CCD32 270 590 1215 1067 205 1105 42CCD39 35 42CCD39 270 590 1425 1277 205 1315 42CCD48 49 42CCD48 370 590 1425 1277 305 1315 42CCD60 56 42CCD60 370 590 1635 1487 305 1525

MINIMUM CLEARANCES FOR FREE AIR CIRCULATION, SERVICE AND MANTENANCE

- The installation location should permit free access space around unit right and left and ahead of return airside to ensure easy access to the unit, which in turn facilitate service and maintenance.

- Allow 200 mm or more minimum distance around unit right and left sides. - Allow 400 mm or more minimum distance ahead of unit return airside. - The refrigerant line connections must be conveniently located for servicing and maintenance.

D

H

200

200

400

A

B

WA

C

232

160

203

7

5. PRECAUTIONS BEFORE INSTALLATION

SAFETY CONSIDERATIONS

• Installation of air conditioning equipment can be hazardous due to system pressures and

electrical components. • The installation of the air conditioner must be done by Carrier or one of Carrier authorized

dealers.

WARNING • This installation manual describes the installation procedures of Carrier split room air

conditioner consisting of an outdoor unit and an indoor unit manufactured by Carrier.

What is not covered in Carrier warranty?

1- Failure due to wrong electrical connections between the electrical power supply and circuit breaker of air conditioner leading to fire due to short-circuiting. As these electrical connections are owner’s responsibility.

2- Failure due to Misuse, Abusing, overloading, negligence of air filters cleaning and negligence of instructions included in the owner’s manual.

3- Failure due to Accident / Weather Natural catastrophe, accident due to bad weather (Hail Storm, Sand Storm, lightning, Flooding, Acid Rain and Air Borne fallout, etc).

4- Failure due to damages during transport done through the owner.

5- Failure due to any modifications in the product done through the owner and not done by

Carrier or one of Carrier authorized dealers.

6- Failure due to Installation done through the owner and not done by Carrier or one of Carrier authorized dealers.

7- Failure due to Service and Maintenance done through the owner and not done by Carrier or one of Carrier authorized dealers.

8- Failure due to repair by using non-genuine Carrier Parts, or substituting other than Carrier parts done through the owner and not done by Carrier or one of Carrier authorized dealers.

9- Product normal sound ( refrigerant – moving parts )

10- Inconvenience or commercial loss is not covered.

The decision of Carrier in ascertaining the same will be final. Any such repairs will be carried - out at the expense of the owner ( purchaser ).

!

8

6. SPLIT SYSTEM DESCRIPTION

9

7. INSTALLATION ACCESSORIES 7.1 STANDARD INSTALLATION ACCESSORES: Supplied from the factory with the indoor unit

DESCRIPTION CONFIGURATION QTY USAGE

Thermostat 1 To operate the air conditioner

Operation Manual 1 To illustrate control functions of operation

Installation Manual 1 To illustrate installation

instructions. Carton Base of indoor Unit is used as Drilling Template

1 To determine the 4 (Four) locations for fixing the indoor unit by use of threaded rods

Drain Elbow

1 Outdoor unit Condensate drain

7.2 Optional Accessories supplied from the factory. as per the requirement:

DESCRIPTION CONFIGURATION QTY USAGE

Wall support for outdoor unit (only for sizes 20-28-32-39)

1 To mount outdoor unit on the wall

Floor support for outdoor unit

1 To mount outdoor unit on the

ground or floor

Insulated refrigerant piping lines with flare couplings of lengths 4-6-8-10-12 Meter

1 To connect Freon between outdoor and indoor units

PTC starting device (only for sizes 20-28)

1

To start the compressor in outdoor unit at low voltage down 180V

7.3 OTHER INSTALLATION ACCESSORIES: Not supplied from the factory but must be used at the

installation field t complete installation. DESCRIPTION USE

- Electrical connection cords See Page (33) and (34)

To electrically the main power supply, the outdoor unit, the indoor unit, the thermostat and the circuit breaker.

- Wall Sleeve - Cover Cap - Sealer putty

To fill the gap between the wall hole and the lump of refrigerant piping lines, electrical connection cables and condensate drain line.

- Finishing tape PVC film To tie together the refrigerants piping lines, electrical connection cables and condensate drain line.

- Vinyl tape To stick pipe insulation. - Drain hose ID 16-17mm To remove condensate water from the indoor unit to the outside. - Refrigerant piping lines * (See page 20) To connect Freon R22 between outdoor and indoor unit.

- Piping Insulation * To insulate suction and liquid lines. - Refrigerant R22 Adjust total system refrigerant charge (more than 4 meter). - Refrigerant Oil Added for long refrigerant lines - Saddles or Clamps To fix lump of refrigerant piping lines, electrical cables and condensate drain line.

* These items are needed if refrigerant piping lines are not supplied from the factory.

10

8. INSTALLATION CHART

1) Installing outdoor unit 5) Connecting refrigerant piping lines

9) Air purging with a vacuum pump

2) Drilling hole thru the wall

6) Connecting condensate drain line

10) Refrigerant leak test

3) Installing indoor unit 7) Connecting electrical wiring

11) Opening service valves

4) Processing pipes 8) Finishing outer pipe covering

12) Finishing installation

13) Test Running

14) Description of operation

Outdoorunit

11

9- SELECTING INSTALLATION LOCATION FOR INDOOR UNIT CONSIDERATION FOR SELECTING INSTALLATION LOCATION

a. Location of Electrical Power Supply The electrical power supply should be near to the indoor unit to facilitate electrical wiring connections and reduce length of

electrical cables. Supply must be away from curtains and any flammable materials b. Location of Indoor Unit Relative to Outdoor Unit The installation location of indoor unit should be as close as possible to the outdoor unit to reduce length of refrigerant

piping, electrical connection cords and drain line to facilitate the installation work. c. Location of Indoor Unit Relative to Space to be Air-Conditioned. The installation location should permit the unit to deliver air to all of the space to be uniformly air-conditioned. d. Effect of Direct Sunlight The installation location should be far away from the Direct sunlight. e. Effect of Heat Sources The installation location should be far away from any heat sources such as steam or flame that may affect performance of

the unit. f. Space for Free Air Circulation The installation location should allow sufficient space for free air circulation around the unit. The installation location should avoid obstructions such as Curtains, Furniture, Cloths…etc. These obstructions can affect

motion of supply air and/or return air, which in turn affects unit efficiency and airflow. ( g ) Minimum clearances for free air circulation, service and maintenance

See page (5)

12

10. SELECTING INSTALLATION LOCATION FOR OUTDOOR UNIT 10.1 INSTALLATION LOCATIONS

The condensing unit can be installed in any outside location, on a wall, roof or on a ground level. 10.2 CONSIDERATIONS FOR SELECTING INSTALLATION LOCATIONS

Avoid excessive distance between outdoor and indoor units

Avoid excessive height between outdoor and indoor units

Avoid any obstruction of the unit air outlet and intake or any obstacle that is too close (see minimum clearances required) when unit is installed on balcony or terrace, make sure that free space are respected for good air circulation. Never leave excess length of refrigerant piping lines between the wall and the unit. This will lead to reduced air flow and capacity.

Avoid multiple unit installation with units facing each other.

Avoid un necessary turns and bends in the refrigerant piping lines.

13

SELECTING INSTALLATION LOCATION FOR OUTDOOR UNIT (Cont.)

CONSIDERATIONS FOR SELECTING INSTALLATION LOCATION (Cont.)

Avoid dripping into passageways.

Avoid soiling of pipe ends

Avoid allowing piping to get wet before connection

Avoid disconnecting the refrigerant connections after installation, this will cause refrigerant leaks

Avoid connecting the condensate drain line to the outdoor unit.

a. Weight of Outdoor Unit The installation location of outdoor unit should be able to support operating weight of outdoor

unit, and not cause vibration. b. Effect of Direct Sunlight The installation location of outdoor unit is preferable to be far away from the direct sunlight. c. Effect of heat sources, steam or flammable gas The installation location of outdoor unit should be far away from heat sources, steam or

flammable gas. d. Cleanness of location The installation location of outdoor unit should be free of dust or any material, which can

cause clogging of condenser coil. When installing unit on the ground, select a location not subjected to flooding.

When the installation is made on the rooftop or other places subject to strong wind :

When the outdoor unit is to be installed on the rooftop or at the places where there are no other buildings around. it is required to avoid the strong wind from blowing directly into the air outlet of the outdoor unit so as to prevent the negative impacts on cooling or heating performances due to insufficient airflow of the outdoor unit heat exchanger and to prevent from faulty performances.

When there are walls in the vicinity, the air outlet should face the wall and keep a space of 500mm from the wall.

When the air outlet is affected by the strong wind, the installation position should be changed so as to make the air outlet at a straight angle from the wind direction.

14

11. INSTALLATION LOCATION CHECK LIST

(A) OUTDOOR UNIT - The installation location is close to the indoor unit - The installation location is able to support operating weight of outdoor unit - The installation location is far away from any sunlight - The installation location free of dust or any material, which can cause clogging of outdoor coil - The installation location allow sufficient space for air circulation around the unit - The installation location allow sufficient space for service and maintenance around

the unit

(B) INDOOR UNIT - The electrical power supply is close to the indoor unit

- The installation location is close to the outdoor unit - The hole is not chosen on a concrete wall The hole is not chosen on a wall to cut electrical wiring or conduits - The installation location permits the unit to deliver air to all of the space to be air-

conditioned - The installation location is far away from direct sunlight - The installation location is far away from any heat sources - The installation location avoid obstructions, which affect motion of supply and/or return air to the unit - The installation location permit free service space around the unit right, left and

top

(C) REFRIGERANT PIPING LINES BETWEEN INDOOR AND OUTDOOR UNITS - The excessive length of piping lines is avoided - The excessive height between indoor and outdoor units is avoided

(especially if outdoor unit is installed above indoor unit).

15

12. INDOOR UNIT INSTALLATION 12.1 POSSILE OUTLET LOCATIONS OF REFRIGERANT PIPING LINES

- The indoor unit is standard with right hand refrigerant and electrical connections. - The indoor unit can be field converted from right hand to left hand refrigerant and electrical connections by

turning coil 180º and also change fixation of electrical connections from right to left connections.

12.2 PREPARATION STEPS

STEP (1): MAKING WALL HOLE

PRECAUTIONS: Before making a hole, check carefully that - No studs or pipes are directly run behind the spot to be cut. - No electrical wiring or conduits are located. - Drill a hole of 80 mm to pass the refrigerant lines, drain hose and

electrical cables.

Decide the piping hole position according to the location of piping direction. Mark the desired drilling point.

When making wall hole, make sure to drill outwards at a downward angle, so that the height difference between the entrance and exit of the hole is at least 5-10 mm.

b. Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a slight angle 6 mm shorter than the thickness of the wall

c. After making hole, a sleeve must be mounted into wall hole and its width to be equal to wall thickness to pass refrigerant lines, drain hose and electrical cables through it.

STEP (2): - After leaving the spaces around the unit for servicing, removing

filter and good air flow, use the carton base of indoor unit to determine the 4 (Four) locations for fixing the indoor unit by use of threaded rods.

- Mount the indoor unit on the wall by inserting unit into the two

mounting bolts. Note:

a. Bolts should be at equal height. The unit back has 5mm difference in heights to provide easy drainage.

b. Make sure that unit is properly mounted on the two fixing bolts. Make sure that unit is sloped 5mmto insure water drain from

unit.

MODEL A B 42CCD20 42CCD28 1005 895

42CCD32 1215 1105 42CCD39 1425 1315 42CCD48 1480 1315 42CCD60 1690 1525

Outdoor side

Indoor side

Cut at slight angle

Outdoor side

Indoor side

Wall

Wall

5-10 mm

Dimensions ( mm)

Carton Base of Indoor Unit

16

INDOOR UNIT INSTALLATION (CONT.) 12-3 INSTALLATION STEPS

Step (1): Insert threaded rods into the ceiling

• Introduce the other ends of the rods into the drill house in the back of the unit.

Step (2): Unit Mounting. • Introduce the other ends of the rods into the drill house in

the back of the unit. • Position the shock absorbers, add washers and screw the

nuts down until the unit is correctly supported. If there is sufficient space, a rubber or neoprene sheet can

be placed between the ceiling and the unit. • Connect complementary drain hose (item 1) to the unit

drain tube and use one fixing clip (item2). • Connect complementary drain tube (item3) both

complementary drains hose and main drain hose. Use two fixing clips (item2). • Lead the draining tube out through the hole at unit bottom.

NOTES • Make sure the unit is tilted slightly towards the drainage

outlet on its right side. Test the drainage using water. • Route the main drain line so that the drain hose must be

gradually inclined downwards to the outside to ensure flow of condensate water to outside.

Step (3): Mounting of control box (Containing Receiver and leds) on the wall Mount the support (item1) on the wall by use of

the two mounting screws (item2). Mount the end of electrical cable (item2) to the

receiver/leds printed circuit board (item3). Fix the receiver/leds printed circuit board

(item3) with the support (item1). Mount the other end of electrical cable (item2)

to the main printed circuit board of indoor unit.

End of electrical cable to main PCB of indoor unit

End of electrical cable to receiver and leds PCB

MODEL A B 42CCD20 42CCD28 895 160

42CCD32 1105 160 42CCD39 1315 160 42CCD48 1315 160 42CCD60 1525 160

Dimensions (mm)

B A

A

17

13. OUTDOOR UNIT INSTALLATION

13.1 PREPARATION STEPS BEFORE INSTALLATION a. Put packed unit as shown.

b. Lift unit from cardboard.

c. Remove service door (item 2) by removing one screw (item 1).

Detach the cable clamp by removing one screw.

13.2 INSTALLATION STEPS

WALL INSTALLATION FLOOR INSTALLATION a. Wall Support Dimensions (mm) A = 414 mm for sizes 20-28-32 A = 558 for size 39

b. Floor Support Dimensions. (mm)

c. fix wall support into the wall Put unit on the wall support.

d. Put outdoor unit on the floor support

e. If the outdoor unit installed other than on the ground, connect it to a 15-16 mm inside diameter hose. This is needed because drain water flows out of the outdoor unit during heating operation. (Only for heat pump unit)

2

1

888

397564

162

A

443

888

Floor Support

18

14 - CONNECTING REFRIGERANT PIPING LINES

14-1 INSTRUCTIONS FOR CONNECTIING REFRIGERANT PIPING LINES

Avoid excessive height difference between indoor and outdoor units.

Avoid excessive length of refrigerant piping lines between indoor and outdoor units

- All bends must be considered when connecting indoor unit with outdoor unit by required length

of refrigerant piping lines. - Do not remove the protective caps from the

couplings until the refrigerant piping lines are ready for connection with both indoor and outdoor units.

This is to keep piping clean. - The installer must carefully unroll the tubing and run

it between the indoor and outdoor units. ● Do not bend the pipe more than three times at one

place. ● When extending the rolled pipe, straighten the pipe

by unwinding it. When forming the pipe. Be careful not to crush it.

Avoid flattening or kinking of refrigerant piping

When making a bend, the installer cuts insulation and slides it away from the bend area. Using a tube bender makes the bend and then the insulation is replaced gluing it together.

Not RecommendedRecommended

Insulation

Copper

19

CONNECTING REFRIGERANT PIPING LINES (Cont.) INSTRUCTIONS FOR CONNECTIING REFRIGERANT PIPING LINES (Cont.) The minimum radius of bending must not be less than 100

mm to avoid damage of tubing. Once the tubing is bent, the installer must not unbend at the same point as this causes work hardening of copper tubing and makes it more difficult to reshape

When there is excessive tubing, it must be coiled horizontally so that the flow of refrigerant is from the top to bottom of the coil and towards the outdoor unit. The excessive tubing must not be coiled vertically since the vertical coil affects the oil return to the compressor.

For bends having a radius smaller than 300 mm, the use of a tuber bender with a minimum wheel diameter of 120 mm is a must. The tube bender wheel grooves should have the same diameters as the refrigerant pipes.

Avoid excessive number of bends in refrigerant piping lines during connections with both the indoor and outdoor units. This is to avoid reduction of cooling efficiency.

Bends with tube diameter bigger than ½” or a bending radius than 300 mm should be made with a dime. Having this radius.

Avoid disconnecting refrigerant connections after they have been tightened to avoid refrigerant leaks.

Radius of Bending

Excessive tubing must be coiled

horizontally

20

L

CONNECTING REFRIGERANT PIPING LINES (Cont.)

15.2 USE OF REFRIGERANT PIPING LINES The following data refers to the use of refrigerant piping lines of diameters equivalent to that use in units where : L = Maximum length of refrigerant piping lines between outdoor and indoor unit.

M = Maximum vertical distance between outdoor and indoor units. (A) OUTDOOR UNIT BELOW INDOOR UNIT :

a. Suction line should rise above height of Indoor unit to shape a liquid trap in an inverted loop before descending to outdoor unit to prevent liquid refrigerant from draining into compressor during shutdown.

b. Slop tubing towards the outdoor unit with a fall of at least (6mm) to (305mm).

(B) OUTDOOR UNIT ABOVE INDOOR UNIT : • If height is less than or equal 4 meters, one oil trap must be at the suction line at the base of

suction riser near the Indoor unit to facilitate oil return to the compressor to ensure efficiency of compressor mechanical parts.

• If height is more than 4 meters, more than one oil trap must exist at the suction line, the first one will be at the suction line near to the indoor unit and the following one will be 4 meters from the first one and so on.

(C) OUTDOOR UNIT ON THE SAME LEVEL AS INDOOR UNIT: An oil trap shall be at the suction line at the base of suction riser near the Indoor unit to

facilitate oil return to the compressor to ensure efficiency of compressor mechanical parts.

Liquid Trap

Suction LineOutdoor

Unit

Meters System Model L H

53CCD20-28 20 10 53CCD32-39-48-60 25 15

Outdoor Unit

Indoor Unit

Slop

Oil trap

Liquid

Suction

Indoor Unit

H Max. 4m

Liquid Line

Slop

H

Outdoor Unit

Indoor Unit

Oil trap

Liquid

Suction

Meters System Model L H

53CCD20-28 20 10 53CCD32-39-48-60 25 15

Meters System Model L

53CCD20-28 20 53CCD32-39-48-60 25

21

CONNECTING REFRIGERANT PIPING LINES (Cont.) 14.3 LENGTHS AND DIAMETERS OF REFRIGERANT PIPING LINES.

UP TO 20 METER UNIT MODEL S L 53CCD-20 5/8” 3/8” 53CCD-28 5/8” 3/8” 53CCD-32 5/8” 3/8” 53CCD-39 4/3” 3/8” 53CCD-48 3/4" 1/2" 53CCD-60 7/8" 1/2"

S = Suction line diameter. L = Liquid line diameter.

14.4 REFRIGERANT CHARGE.

• For refrigerant piping lines of length more than 3 meters, add 25 grams of refrigerant per extra meter from 3 meters refrigerant piping lines: Example 1 = For 8 meter lines, refrigerant added = (8-3) x 25 = 125 grams. Example 2 = For 12 meter lines, refrigerant added = (12-3) x 25 = 225 grams.

Note: (1) The outdoor unit is factory supplied with refrigerant charge for use with refrigerant piping lines

of length 3 meters and with added 100 grams for air and moisture purge from the system. (2) Charge the refrigerant accurately. (3) Refrigerant overcharge may cause a serious trouble of compressor.

22

CONNECTING REFRIGERANT PIPING (Cont.)

14.5 DESCRIPTION OF INTERCONNECTING REFRIGERANT PIPING LINES. 14.6 CUTTING AND FLARING TOOLS

Make sure that have the required tools available before preparing refrigerant piping lines

(1) Suction flare valves three ways. (2) Needle valve. (3) Valve cap. (4) Valve needle. (5) Liquid flare valves three ways. (6) Allen (hex. Head) wrench. (7) Suction piping line. (8) Liquid piping line. (9) Flare nut service port

(1) Suction half union. (2) Suction flare nut. (3) Suction piping. (4) Liquid half union. (5) Liquid flare nut. (6) Liquid piping.

1 2 3 5

1

9 3

3 46

8

7

2

45 6

Indoor Unit Refrigerant Piping Outdoor Unit

Pipe Cutter Flare Tool

23

Corrugated Cutting

Wrap Cutting

CONNECTING REFRIGERANT PIPING LINES (Cont.) 14-6 STEPS FOR PREPARING REFRIGERANT PIPING LINES BEFORE CONNECTIONS

(IN CASE OF NOT USING THE OPTIONAL FACTORY REFRIGERANT PIPING LINES WITH THE FLARE NUTS) STEP (1): Cutting refrigerant piping lines

• Remove protective caps from copper pipe ends. • Position tube end downwards, cut the pipe to the

required length with a pipe cutter.

NOTE: • It is recommended to cut approx. 30→ 50 cm longer

than the estimated pipe length. • Take care to ensure that the cut edge remains at a

90° angle with the side of pipe, and refer to the illustrations for examples of edges cut correctly and incorrectly.

STEP (2): Removing the burrs • Remove burrs at the end of the connection pipe with

a pipe reamer or a file. This process is important and should be done carefully to make a good flare and to prevent any gas leaking out.

NOTE:

When reaming, hold the pipe end downward and be sure that no copper scraps fall into the pipe.

STEP (3): Removing the flare nuts from the indoor unit.

Remove the suction and liquid flare nuts from the indoor unit connections.

NOTES: • Do not remove the flare nuts from the indoor unit

until refrigerant piping lines are ready for connections.

• It is that easier to remove flare nuts from the indoor unit before being installed on the wall hang bracket.

STEP (4): Removing the flare nuts from the outdoor unit

Remove the suction and liquid flare nuts from the outdoor unit connections.

NOTES: • Do not remove the flare nuts from the outdoor unit

until refrigerant piping lines are ready for connection. • It is easier to remove flare nuts from the outdoor unit

before being installed on the wall support.

STEP (5): Mounting flare nuts on the refrigerant piping lines

• Mount the suction flare nut on the other side of suction piping line.

• Mount the liquid flare nut on the other side of liquid piping line.

Debarring

AfterBefore

1: Connection pipes 2: Reamer

1

2

Liquid Piping Line

Suction Piping Line

Pipe Cutter

Correct Cutting

Inclined Cutting

24

CONNECTING REFRIGERANT PIPING LINES (Cont.) STEPS FOR PREPARING REFRIGERANT PIPING LINES BEFORE CONNECTIONS (Cont.)

STEP (6): Flaring the Piping • Use flare tool to flare ends of both suction and liquid piping

lines slide a flare nut on to the tube and modify the flare. NOTES:

1) Good flare should have the following characteristics: • Inside surface is glossy and smooth. • Edge is smooth and must not have any burrs or

imperfections. • Tapered sides are of uniform length.

2) Be sure to apply a sealing cap or waterproof tape to

prevent dust or water from getting into the refrigeration piping lines before they are used.

Avoid incorrect flaring, which results in damaged or cracked or inclined with uneven thickness surface.

STEP (7): Mounting flare nuts on the other side of refrigerant piping lines

• Mount the suction flare nut (Large nut) on the other side of

suction refrigerant piping line. • Mount the liquid flare nut (Small nut) on the other side of

liquid refrigerant piping line.

Recommended

Flare tool

Refrigerant Piping

Flare Nut

Flare Tool

Liquid Line

Suction Line

Refrigerant Piping Lines After Connecting Flare Nuts From Both Sides

25

CONNECTING REFRIGERANT PIPING (Cont.) 14-7 STEPS FOR CONNECTING REFRIGERANT PIPING LINES TO INDOOR UNIT

Connecting suction and liquid piping lines respectively with suction and liquid half unions of indoor unit.

A. Lubricate suction and liquid piping line end and the threads of the suction and liquid half unions of indoor unit with anti – freeze oil. This is effective for reducing gas leaks.

B. For proper connection, align the centers of suction union pipe and flare pipe straight with each other, then finger tighten several turns the flare nut tightly at first to obtain a smooth match.

C. Then hold the union side with a double-ended wrench and tighten the flare nut by applying the tightening torque indicated in the following table (1). Be careful not to damage the flare nut threads.

NOTE:

a. Insufficient tightening torque will cause Freon leaks.

b. Over tightening the fitting will damage the tube flaring and cause Freon leaks.

14-8 STEPS FOR CONNECTING REFRIGERANT PIPING LINES TO OUTDOOR UNIT

• Connecting the other ends of suction and liquid piping lines respectively with suction and liquid flare couplings of the outdoor unit.

• Repeat steps (A), (B), (C) when connecting refrigerant piping lines to the couplings of the outdoor unit.

Flare Spanner or Torque Wrench

Indoor Side

Tightening Torque Kg - Cm Flare Nut

N.M Kgxcm 3/8” 31-35 310-350 5/8” 50-55 500-550 3/4” 50-55 500-550 7/8” 50-55 500-550

Piping Lines Table (1)

Liquid Line

Suction Line

(1) Fingers tighten several turns the flare nuts of piping at the outdoor unit valves.

Half Union

(2) Tighten the flare nuts with adjustable wrench or torque wrench.

26

CONNECTING REFRIGERANT PIPING LINES (Cont.) 14-9 AIR PURGE

In some countries the law does not permit purging by blowing refrigerant through the lines. If this is the case, please refer to B using the vacuum pump.

(A) AIR PURGE USING THE REFRIGERANT IN THE UNIT

Air and moisture in the refrigerant system have undesirable effects. They must be purged completely. The outdoor unit includes an extra 50 grams of refrigerant for air purge (only item 6.1). When the connection refrigerant piping lines are over 4 mt, add extra 20 grams of refrigerant per extra meter.

• Air purging procedure

.

(1) (2)

(1) Remove the valve caps of the liquid and suction valve and the service port nut.

(2) Loosen the valve stem of liquid valve by 90 degrees (1/4 turn) for 5 seconds with a hex key wrench (size M4)

(3) Push the valve core of the suction valve. Stop pushing the valve core as soon as the refrigerant hissing stops.

(4) Open the liquid valve for about 3 seconds, then close quickly to check for gas leaks. After checking for gas leaks, open the liquid and suction valve all the way.

(5) Reinstall the caps and of the liquid valve, suction valve and service port nut.

(5) (4) (3) COMPLETE

(1)

5

1

93

3 4 6

8

7

2

(1) Suction flare valves three ways.

(2) Needle valve. (3) Valve cap. (4) Valve needle. (5) Liquid flare valves three ways(6) Allen (hex. Head) wrench. (7) Suction piping line. (8) Liquid piping line. (9) Flare nut service port

27

CONNECTING REFRIGERANT PIPING LINES (Cont.) AIR PURGE (Cont.)

(B) AIR PURGE USING THE VACUUM PUMP

a. Connect the gauge manifold and the vacuum pump.

b. Open the low-pressure valve and close the high-pressure valve of gauge manifold completely.

c. Operate the vacuum pump during at least 20 minutes until the pressure reaches – 101Kpa (-760mm Hg).

d. Close the low-pressure valve of the gauge manifold and stop the vacuum pump operation.

(If the indicator of gauge manifold is returned within 1-2 minute after stopping the vacuum pump, check the piping connection leakage).

e. Close both the liquid and suction valve caps completely.

f. Remove the gauge manifold and the vacuum pump.

(During the disconnection, please be cautious not to loose any refrigerant and oil).

g. Reinstall the valve caps and service port nuts.

(C) NOTES: Tighten the valve caps and the service port nut to

the specified torque as shown in the table:

PART TIGHTENING TORQUE (Kgf – Cm)

SERVICE PORT NUT 150 200

VALVE CAP 170 220

Valve Needle

Valve Cap

Valve Cap

Hex key wrench

Low – pressure valve

High – pressure valve

Gauge manifold

Vacuum Pump

1

2

4

5 3

1: Indoor Unit 2: Outdoor Unit 3: Suction Line 4: Liquid Line 5: Vacuum Pump

28

CONNECTING REFRIGERANT PIPING LINES (Cont.) 14-10 REFRIGERANT LEAK CHECK

After connecting refrigerant piping with both indoor and outdoor units, leak testing must be achieved using a leak detector or soapy water.

14-11 INSULATING REFRIGERANT PIPING LINES

To conserve energy and prevent wet floors due to condensation, the

suction and liquid piping lines must be well insulated with a proper insulation material.

The thickness of the insulation should be a minimum of 9 mm. The insulation you select must have good insulation characterics, be

easy to use, resist age and not easily absorb moisture. Finally wrap the flare couplings and pipes with insulation and tighten

this with tape without exerting too much pressure on the insulation CAUTION:

• After a pipe has been insulated, never try to bend it into a narrow curve, as this way will cause the pipe to break or crack.

• Repair and cover any possible cracks in the insulation • Avoid dripping due to insufficient insulation of piping.

14-12 PUMP DOWN

Pump down means collecting all the refrigerant in the system back into the outdoor unit. Pump down must be actuated before disconnection of pipes, to avoid loss of refrigerant gas. Pump down is used when the unit is moved to another installation location or when the system is repaired.

PUMP DOWN PROCEDURE:

a. Close the liquid valve with the Allen wrench. b. Turn the system ON in cooling mode with fan operating at high speed. Then the refrigerant will be collected into the outdoor unit.

(Compressor will immediately start, provided 3 minutes have elapsed since the last stop). c. After 2 minutes of operation, close the suction valve with the Allen wrench. d. Turn the system off and switch mains supply OFF. e. Disconnect refrigerant piping lines. After disconnection, protect valves and piping ends from dust.

1

2

3

ℵ Pipe ℑ Pipe insulation ℜ Fastening tape

29

15. CONNECTING CONDENSATE DRAIN LINE INSTRUCTIONS FOR CONNECTING CONDENSATE DRAIN LINE

The condensate drain hose (not supplied) for the indoor unit must be made of PVC piping with an inside diameter of 5/8” (16mm) and have suitable length for the chosen installation site.

Connection Instructions

a. The drain hose must be gradually inclined downwards to the outside to ensure flow of Condensate water to outside.

b. The condensate water must be continuously removed to avoid water dripping from the unit. Avoid the end of drain hose to be sunk in water.

c. The drain hose must not be looped upwards to avoid over-flowing and water dripping from indoor unit.

d. The drain hose must have no kinks or bends hampering smooth drainage of water due to air stagnation and leading to water dripping from indoor unit.

e. Drainage Test Check the drainage of the unit by pouring some water into the unit drain pan and ensure it drains out through the drain hose and there is no leakage from other parts.

30

16. CONNECTING ELECTRICAL WIRING 16-1 ELECTRICAL WIRING BETWEEN ELECTRICAL POWER SUPPLY AND CIRCUIT BREAKER

OF AIR CONDITIONER

All electrical connections between electrical power supply and circuit breaker of air conditioner are the responsibility of the customer and must be done by a qualified electrical technician according to national electrical wiring regulations to avoid fire due to short-circuiting.

(A) Operating Voltage The operating voltage of electrical power supply should be within the limits of voltage mentioned

on unit nameplate data. (B) Electrical kWh Counter KWH The capacity of electrical kWh counter should be lager than the operating currents required for air

conditioner(s) and any other electrical domestic appliances in use simultaneously from the same supply.

(C) Electrical Distribution Box The installation of electrical distribution box after the electrical KWH counter is necessary

to properly distribute the electrical loads. The electrical distribution box should be equipped with circuit breakers according to the electrical

loads. For each installed air conditioner, a separate circuit breaker with its own overload should be

installed on the electrical distribution box. (D) Operation On / Off Circuit Breaker The installation of two pole automatic circuit breaker is necessary to operate the air conditioner. The circuit breaker must be installed to be far away from any flammable materials (curtains…etc.). The circuit breaker must be suitable for air conditioner as the table “ELECTRICAL DATA“ page (31). Do not use operation ON / OFF circuit breakers except the approved models for use with air

conditioners. (E) Electrical Cable Do not use electrical connection cables except the approved for use with air conditioners. The power cable should be a complete unit, without extensions. The power cable size must be suitable for the air conditioner with length up to 15 meter.

See table “ ELECTRICAL DATA “ page (31).

Note : For cable lengths more than 15 meter, use cable of larger cross section.

(F) Electrical Wiring a. Make ground connection prior to any other electrical connections in accordance with the

electrical codes.

b. Ensure that mains supply connection is made through a switch that disconnects all poles, with contact gap of at least 3 mm.

c. Avoid slack connections of the electrical cords when connected to the terminal blocks of

indoor and outdoor units. These slack connections lead to voltage drop and unit malfunctions.

WARNING !

31

CONNECTING ELECTRICAL WIRING (Cont.) 16-2 ELECTRICAL WIRING BETWEEN INDOOR UNIT, OUTDOOR UNIT AND CIRCUIT BREAKER

OF AIR CONDITIONER

All electrical connections between the outdoor unit, indoor unit and circuit breaker are the responsibility of the qualified installer and must be done according to national electrical wiring regulations to avoid fire due to short circuiting.

- Both of the outdoor and indoor units leave the factory with complete internal electrical wiring. Do not change any internal electrical wiring of both units. - A qualified electrical technician should carry out the electrical connections. - It is very important before making the electrical connections between the indoor, outdoor units,

and the power supply, to pay attention to the following safety instructions:

(A) Operating Voltage The operating voltage of electrical power supply should be within the limits of voltage mentioned on unit

nameplate data.

Shown on the indoor and outdoor units of the air conditioner.

(B) Field Electrical Connection Cables * Do not use electrical connection cords except the approved one for use with air conditioners. * Each cable should be a complete unit, without extensions.

(C) Electrical Connections a. Check that the electrical connections between the terminal blocks of indoor and outdoor units are in

accordance with the wiring diagrams and caution field electrical wiring contained in the manual.

Miswiring may cause malfunction of the system and an electric shock. b. Do not connect wires when power is ON. c. Make ground connection prior to any other electrical connections in accordance with the electrical

local codes. d. Make electrical connections between outdoor and indoor units prior to proceeding to mains supply

connection. e. Before proceeding with the unit connection to the mains supply locates live L and neutral N, then

make connections as shown in the wiring diagram.

Be sure that the live and neutral wire connected respectively to the Live (L) and the Neutral (N) terminals of terminal block of outdoor units.

f. Ensure that mains supply connection is made through a switch that disconnects all poles, with

contact gap of at least 3 mm. g. Avoid slack connections of the electrical cords when connected to the terminal blocks of indoor

and outdoor units. and also to circuit breaker These slack connections lead to voltage drop and unit malfunctions. Every wire must be connected firmly.

WARNING !

32

CONNECTING ELECTRICAL WIRING (Cont.)

16-3 ELECTRICAL DATA

Input Power Main Power Connections

Cooling Split

System Model

Starting Current (Note 1)

System Power Supply 35 °C

* 46 °C

** 52 °C

***

Heating ****

Circuit Breaker

Wire Size

(Note 2) Standard mild ambient outdoor unit with rotary compressor

Heat Pump Amp V/Ph/Hz Amp Watt Amp Watt Amp Watt Amp Watt Amp mm² 53CCD20-H 45 9.2 1915 10.9 2275 11.9 2505 7.5 1575 20 4mm² 53CCD28-H 67 12.3 2540 14.0 2920 15.7 3275 10.9 2265 25 4mm² 53CCD32-H 91

220/1/50 15.7 3080 16.5 3290 17.5 3520 14.2 2825 32 6mm²

High ambient outdoor unit with reciprocating compressor 53CCD20-H 45 53CCD28-H 67 53CCD32-H 91 53CCD32-H 91 15.7 3080 16.5 3290 17.5 3520 14.2 2825 32 6mm² 53CCD39-H 110

220/1/50

19.5 4020 20.5 4295 23.2 4595 15.8 3260 40 6mm² High ambient outdoor unit with scroll compressor

Cool Only Amp V/Ph/Hz Amp Watt Amp Watt Amp Watt Amp Watt Amp mm² 53CCD32-C 91 15.7 3080 16.5 3290 17.5 3520 - - 32 6mm² 53CCD39-C 110 220/1/50 19.5 4020 20.5 4295 23.2 4595 - - 40 6mm²

High ambient outdoor unit with reciprocating compressor Heat Pump Amp V/Ph/Hz Amp Watt Amp Watt Amp Watt Amp Watt Amp mm² 53CCD48-H 67 9.5 3955 10.5 4190 11.5 4480 7.4 3815 20 4mm² 53CCD60-H 81 400/3/50 11.2 5100 12.1 5395 13.2 5765 10.7 4910 20 4mm² Cool Only Amp V/Ph/Hz Amp Watt Amp Watt Amp Watt Amp Watt Amp mm²

53CCD48-C 67 9.2 3970 10.3 4205 11.2 4490 - - 20 4mm² 53CCD60-C 81 400/3/50 10.9 5045 11.8 5345 12.9 5710 - - 20 4mm²

Notes: 1. Starting Current duration is usually less than 1 Second. 2. Wire size shown applies to standard applications with line length up to 15 meter and a subsequent voltage drop not to

exceed 3%. For specific conditions and long lines, the resulting voltage drop must be checked and it may be necessary to use the

next larger size. When sizing wires consider the amperage at peak conditions with the highest possible ambient temperature expected

for the installation area and lowest probable line voltage.

3. Operating Conditions. * Conditions for Temperate Climate. Indoor 27/19 °C DBT/WBT Outdoor 35 °C DBT

High speed of indoor unit motor

** Conditions for Tropical Climate. Indoor 29/19 °C DBT/WBT Outdoor 46 °C DBT High speed of indoor unit motor

*** Max Conditions for Tropical Climate. Indoor 29/19 °C DBT/WBT Outdoor 52 °C DBT High speed of indoor unit motor

**** Conditions for Heat Pump Indoor 20 °C DBT Outdoor 7/6 °C DBT/WBT High speed of indoor unit motor

33

LEGEND Earth L Live power supply. N Neutral power supply. R Live connection indoor/outdoor unit. C Neutral connection indoor/outdoor unit. Y Compressor control. O Reversing valve control. W2 Outdoor fan motor control. S1 Outdoor coil sensor. S2 Outdoor coil sensor.

LEGEND Earth L Live power supply. N Neutral power supply. R Live connection indoor/outdoor unit. C Neutral connection indoor/outdoor unit. Y Compressor control.

CONNECTING ELECTRICAL WIRING (Cont.)

16-6 CONNECTING ELECTRICAL WIRING FOR HEAT PUMP SYSTEM 53CCD20-28-32-39

Sizes of electrical wires connecting outdoor and indoor units R C Y O W2 S1 S2

1 mm2 1 mm2 1 mm2 1 mm2 1 mm2 1 mm2 1 mm2

16-7 CONNECTING ELECTRICAL WIRING FOR COOL ONLY SYSTEM 53CCD20-28-32-39

Sizes of electrical wires connecting outdoor and indoor units

R C Y 1 mm2 1 mm2 1 mm2

Note: (1) Connect the power supply to the outdoor unit and then get the power required for the indoor unit from the outdoor unit.

(2) All dotted lines to be fitted by installer. (3) Refer to wiring diagrams and stickers-caution sticked inside the outdoor & indoor units.

200 - 240V ~ 50Hz

Circuit Breaker

Main Switch

Indoor Unit

Outdoor Unit

200 - 240V ~ 50Hz

Circuit Breaker

Main Switch

Indoor Unit

Outdoor Unit

R C Y

R C Y

34

CONNECTING ELECTRICAL WIRING (Cont.) 16-8 FIELD ELECTRICAL CONNECTIONS MATCHING SIZES 48-60 (HEAT PUMP SYSTEM) 16-9 FIELD ELECTRICAL CONNECTIONS MATCHING SIZES 48-60 (COOL ONLY SYSTEM)

Earth L Live power supply. N Neutral power supply. R Live connection indoor/outdoor unit. C Neutral connection indoor/outdoor unit Y Compressor control. O Reversing Valve Control (Only for heat pump system). W2 Outdoor Unit Motor Control (Only for heat pump system). S1 Outdoor Coil Sensor (Only for heat pump system). S2 Outdoor Coil Sensor (Only for heat pump system).

Note: The mains supply must be connected to the outdoor unit.

Circuit Breaker

Main Switch Power Supply380 - 420V ~ 50Hz

Indoor Unit

Outdoor Unit

Indoor Unit

Outdoor Unit

Circuit Breaker

Main SwitchPower Supply380 - 420V ~ 50Hz

35

17. DUCT WORK 17-1 The ductwork dimensions should be determined in accordance wit the available with the air circulating

through it and with the available static pressure of the unit.

Various suggestions are made here below, regarding the layout and design of the said ductwork: a) Whatever type of duct is used, it should not be made of materials which are flammable, or which

give off toxic gases in the event of a fire. The internal surfaces should be smooth, and not contaminate the air, which passes through.

b) At the points where the duct joins with the unit, it is advisable to use a flexible connection, which

absorbs vibration and prevents the transmission of noise inside the ductwork.

c) Bends should be avoidable, they should be as slight as possible, and internal deflectors should be used when the duct is of large dimensions.

Supply Grille

Indoor Unit

Plenum

Flexible Connection

36

DUCT WORK (Cont.) 17.3 DUCT WORK APPLICATION EXAMPLES FOR 42CCD28: 17.4 DUCT WORK APPLICATION EXAMPLES FOR 42CCD32 & 42CCD39: 17.5 DUCT WORK APPLICATION EXAMPLES FOR 42CCD48 & 42CCD60:

1 - Indoor Unit 2 - Supply Plenum 3 - Flexible Duct 4 - Grille Plenum

1. - Indoor Unit 2. - Supply Plenum 3. - Flexible Duct 4. - Grille Plenum

1

2

3

4

1

2

3

4

1

2

3

4

1. Indoor Unit 2. Supply Plenum 3. Flexible Duct 4. Grille Plenum

37

18. FINISHING INSTALLATION FINISHING STEPS FOR INSTALLATION A. Tie together refrigerant piping, lines, electrical connection cords and drain line. Form the refrigerant piping in the required direction and bind the drain hose and electrical

connection cords together with vinyl tape. • The drain hose should be always at the bottom of lump to assure smooth drainage. • The lump must be of circular shape.

B. Fill the gap between the outside wall hole and the piping with sealing wall sleeve, wall cap and

sealer putty so that rain and wind cannot enter.

C. After completion of electrical wiring to the outdoor unit:

• Fasten the electrical cords with the cable clamp. • Install again the service door.

Wall CapWall Sleeve

Sealer Putty

Outdoor sideWallIndoor Side

Electric Cables & Defrost sensor cable

Liquid Line

Drain Hose

Suction Line Piping

Decorative Tape

Saddles

38

19. TEST RUNNING 19.1 STEP FOR COOLING TEST RUNNING

a - Move circuit breaker to ON position. b - Operate system for cooling by room controller

or by wireless remote control. c - After system operation becomes stabilized, Measure high and low pressures to check correct

refrigerant charge. Also measure total amps consumed by the system.

Note: Operate running test after mounting air filters.

A. COOLING RUNNING TEST (OUTDOOR UNIT WITH ROTARY COMPRESSOR)

SYSTEM MODEL 53CCD20 53CCD28 53CCD32 AMBIENT TEMP ºC 35 40 46 52 35 40 46 52 35 40 46 52 HIGH PRESSURE PSI 283 306 332 382 269 303 337 390 302 336 372 406 LOW PRESSURE PSI 74 75.5 77 79 66 67 68 71 69 71 72 74 TOTAL AMPS 9 9.7 10.4 11.1 13 13.9 14.9 16.5 15.7 16.1 16.5 17.5

B. COOLING RUNNING TEST (OUTDOOR UNIT WITH RECIPROCATING COMPRESSOR)

SYSTEM MODEL 53CCD20 53CCD28 AMBIENT TEMP ºC 35 40 46 52 35 40 46 52 HIGH PRESSURE PSI 295 327 359 385 275 307 340 370 LOW PRESSURE PSI 77 79 81 84 75 77 79 82 TOTAL AMPS 12.5 13.1 13.7 14.6 15.4 15.9 16.4 17.2

SYSTEM MODEL 53CCD32 53CCD39 AMBIENT TEMP ºC 35 40 46 52 35 40 46 52 HIGH PRESSURE PSI 294 326 359 403 287 323 360 410 LOW PRESSURE PSI 68 71 75 78 65 68 71 74 TOTAL AMPS 16.5 17 17.5 18.3 18.7 19.6 20.5 21.8

C. COOLING RUNNING TEST (OUTDOOR UNIT WITH SCROLL COMPRESSOR)

SYSTEM MODEL 53CCD48 53CCD60 AMBIENT TEMP ºC 35 40 46 52 35 40 46 52 HIGH PRESSURE PSI 261 298 339 385 269 307 348 393 LOW PRESSURE PSI 69 70 72 75 71 73 76 79 TOTAL AMPS 9.5 9.9 10.5 11.5 11.2 11.7 12.1 13.2

Readings at 220 volt and 27 ºc return air to indoor unit (for systems 53ccd 20-28-32-39). Readings at high speed of indoor motor. Readings at 380 volt and 27 ºc return air to indoor unit (for systems 53ccd 48-60). Readings at high speed of indoor motor

(1)

(2)

Outdoor Unit

39

TEST RUNNING (Cont.) 19.2 STEP FOR HEATING TEST RUNNING

a- Move circuit breaker to ON position. b- Operate system for heating by wireless remote

control. c- After system operation becomes stabilized, Measure high and low pressures to check correct

refrigerant charge. Also measure total amps consumed by the system.

Note: Operate running test after mounting air filters.

19.2.1 HEATING TEST RUNNING (SYSTEM WITH ROTARY COMPRESSOR) SYSTEM MODEL 53CCD20-H 53CCD28-H 53CCD32-H

AMBIENT TEMP ºC 2 7 2 7 2 7 HIGH PRESSURE PSI 230 250 235 270 210 230 LOW PRESSURE PSI 46 56 46 58 57 67 TOTAL AMPS 7.6 8.1 10.5 11.7 13.5 14.2

19.2.2 HEATING TEST RUNNING (SYSTEM WITH RECIPROCATING COMPRESSOR)

SYSTEM MODEL 53CCD32-H 53CCD29-H AMBIENT TEMP ºC 2 7 2 7

HIGH PRESSURE PSI 225 260 235 263 LOW PRESSURE PSI 42 52 40 50 TOTAL AMPS 13.5 14.2 15.8 16.4

19.2.3 HEATING TEST RUNNING (SYSTEM WITH SCROLL COMPRESSOR)

SYSTEM MODEL 53CCD48-H 53CCD60-H AMBIENT TEMP ºC 2 7 2 7

HIGH PRESSURE PSI 210 240236 205 245 LOW PRESSURE PSI 42 51 44 56 TOTAL AMPS 6.7 7.4 9.8 10.7

Readings at 220 volt and 20 ºc return air to indoor unit (for systems 53ccd 20-28-32-39). Readings at high speed of indoor motor. Readings at 380 volt and 20 ºc return air to indoor unit (for systems 53ccd 48-60). Readings at high speed of indoor motor.

(1)

(2)

Outdoor Unit

40

20. AFTER INSTALLATION CHECK LIST 20.1 INDOOR UNIT

a. The installation location is adequate

b. The air filters are installed correctly

c. The duct is installed securely 20.2 OUTDOOR UNIT

a. The installation location is adequate

b. The unit is solidly mounted and levelled

c. The unit is fixed with wall support

d. The service door and attachment are replaced 20.3 REFRIGERANT PIPING LINES CONNECTIONS

a. The refrigerant piping lines are adequate with system model b. The insulation is wrapped on the coupling connections

c. The air purge is properly done

d. The refrigerant piping lines are tested for refrigerant leakage

e. The service valves for suction and liquid in outdoor unit are open.

f. The cap nuts for flare valves are properly tightened

20.4 CONDENSATE DRAIN LINE CONNECTIONS

a. The Condensate drain line from indoor unit is gradually inclined downwards to the outside

b. The Condensate water flow smoothly

20.5 ELECTRICAL CONNECTIONS

a. The operating voltage electrical power supply is in the voltage range shown on the unit’s nameplates

b. The sizes of electrical connection cords are adequate according to

system model c. The size and type of unit circuit breaker are adequate according to

system model

d. The electrical wiring connections between power supply, circuit breaker, outdoor unit, indoor unit are adequate

e. All fields electrical wiring connections are tightened and secured

f. The ground wire is connected to the ground

41

AFTER INSTALLATION CHECK LIST (Cont.) 20.6 FINISHING INSTALLATION

a. The refrigerant piping lines, electrical cables and drain hose are lumped together

The drain hose is at the bottom of lump. b. The wall passage hole is properly sealed

20.7 TESTING RUNNING

a. The cooling and heating cycles are tested At least one complete cooling cycle of system operation is observed. At least one complete heating cycle of system operation is observed.

b. There is no any abnormal noise or vibration from the outdoor unit

during operation g. There is no any abnormal noise or vibration from the indoor unit during

operation h. The thermostat operate Correctly

20.8 CUSTOMER GUIDANCE

a. The correct operation of the air conditioner has been explained to the customer including the following points:

Starting and stopping method

Operation switching

Temperature adjustment

Fan speed adjustment

Filter removal and cleaning

b. The operation and installation manuals are given to the customer

42

21- SELF DIAGNOSTIC FUNCTION FOR MALFUNCTIONS DETECTION

EXPLAINATION OF SELF-DIAGNOSTIC FUNCTION

- When the system is on and in a malfunction, the fault code will be flashed out on the unit display located on the indoor unit according to the following table :

- Self-diagnostic function is the key for success of the operation of air conditioner.

- The printed circuit boards existing inside the indoor unit are equipped with self-diagnostic

function to detect malfunction stops the operation at the air conditioner.

- Once a malfunction is detected, the diagnostic control section will show the malfunction code on the display of indoor unit according to the following table :

Malfunction Reason code

Allowed Mode

Return Air Sensor E1 Fan Only Indoor Coil Sensor E2 Fan Only Outdoor Coil Sensor* E3 Fan Only Compressor Drive

Reversing Valve * E4 Fan Only

Notes : 1- Prior to the malfunction repair, disconnect the electrical mains supply by moving the circuit

breaker to OFF position.

2- After repairing the malfunction, connect the electrical main supply by moving the circuit breaker to ON position and operate the air conditioner by using the wireless remote control or using wired room controller.

Malfunction Code appears On the display

* Only for Heat Pump