HITACHI RAK-DJ25PCAT Indoor Unit Instruction Manual

HITACHI RAK-DJ25PCAT Indoor Unit

FOR SERVICE PERSONNEL ONLY

• Carefully read through the procedures of proper installation before starting installation work.
• The sales agent should inform customers regarding the correct operation of installation.

Tools Needed For Installation Work
(Mark©is exclusive use tool for R410A.R32)

• Screwdriver
• Measuring Tape Knife Saw 65mm PowerDrill
• Hexagonal Wrench Key (4mm)
• Wrench(14,17,19,22mm)
• Gas leakage
• Detector Pipe
• Cutter Putty Vinyl Tape Pliers
• Flare Tool Vacuum Pump Adapter
• Manifold Valve
• Charge Hose
• Vacuum Pump

SAFETY PRECAUTION

Read the safety precautions carefully before operating the unit.
The contents of this section are vital to ensure safety. Please pay special attention to the following sign.
WARNING ………. Incorrect methods of installation may cause death or serious injury.
CAUTION ………. Improper installation may result in serious consequence.

• Make sure to connect earth line.
• This sign in the figures indicates prohibition.
• Be sure that the unit operates in proper condition after installation. Explain to customer the proper operation and maintenance of the unit as described in the user’ s guide.
• Ask a customer to keep this installation manual together with the instruction manual.

WARNING

• Please request your sales agent or qualified technician to install your unit. Water leakage, short circuit or fire may occur if you do the installation work yourself.
• Please observe the installation stated in the installation manual during the process of installation. Improper installation may cause water leakage, electric shock and fire.
• Make sure that the units are mounted at locations which are able to provide full support to the weight of the units. If not, the units may collapse and impose danger.
• Observe the rules and regulations of the electrical installation and the methods described in the installation manual when dealing with the electrical work. Use cables which are approved official in your country. Be sure to use the specified circuit. A short circuit and fire may occur due to the use of low quality wire or improper work.
• Be sure to use the specified cables for connecting the indoor and outdoor units. Please ensure that the connections are tight after the conductors of the wire are inserted into the terminals to prevent the external force is being applied to the connection section of the terminal base. Improper insertion and loose contact may cause over-heating and fire.
• Please use the specified components for installation work. Otherwise, the unit may collapse or water leakage, electric shock, fire or stronger vibration may occur.
• Be sure to use the specified piping set for R32. Otherwise, this may result in broken copper pipes or faults.
• When installing or transferring an air conditioner to another location, make sure that air other than the specified refrigerant( R32) does not enter the refrigeration cycle. If other air should enter, the pressure level of the refrigeration cycle may increase abnormally which could result in a rupture and injury.
• Be sure to ventilate fully if a refrigerant gas leak while at work. If the refrigerant gas comes into contact with fire, a poisonous gas may occur.
• After completion of installation work, check to make sure that there is no refrigeration gas leakage. If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.
• Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician. Improper repairs may result in water leakage, electric shock and fire, etc.
• Be sure to connect the earth line from the power supply wire to the outdoor unit and between the outdoor and indoor unit. Do not connect the earth line to the gas tube, water pipe, lighting rod or the earth line of the telephone unit. Improper earthing may cause electric shocks.
• When finishing the refrigerant collection (pumping down), stop the compressor and then remove the coolant pipe.
• If you remove the refrigerant pipe while the compressor is operating and the service valve is released, air is sucked and a pressure in the freezing cycle system will build up steeply, causing an explosion or injury.
• When installing the unit, be sure to install the refrigerant pipe before starting the compressor.
• If the refrigerant pipe is not installed and the compressor is operated with the service valve released, air is sucked and the pressure level of the refrigeration cycle may increase abnormally which could result in a rupture and injury.
• The electric cables should neither be reworked nor added.
• Make sure to use an exclusive circuit breaker.
• Otherwise fire or electric shock might occur by connection failure, isolation failure or over current.
• Make sure to connect cables to terminal properly and terminal cover should close firmly.
• Otherwise, over heating at terminal contact, fire or electric shock might occur.
• Make sure that there is no dust on any connected points of electric cables and fix firmly.
• Otherwise, fire or electric shock might occur.

CAUTION

• A circuit breaker must be installed in the house distribution box for the direct connected power supply cables to the outdoor unit. In case of other installations a main switch with a contact gap or more than 3mm has to be installed.
• Without a circuit breaker, the danger of electric shock exists.
• Do not install the unit near a location where there is flammable gas.
• The outdoor unit may catch fire if flammable gas leaks around it.
• Please ensure smooth flow of water when installing the drain hose. Improperv installing may wet your fu niture.
• An IEC approved power cord should be used. Power cord type: NYM.

THE CHOICE OF MOUNTING SITE

(Please note the following matters and obtain permission from customer before installation.)

WARNING
The unit should be mounted at stable, non-vibratory location which can provide full support to the unit.

CAUTION

1. No nearby heat source and no obstruction near the air outlet is allowed.
2. The clearance distances from top, right and left are specified in figure below.
3. The location must be convenient for water drainage and pipe connection with the Outdoor unit.
4. No nearby leakage risk of flammable gas, and no nearby source of vapor or oil smoke.
5. To avoid interference from noise, please place the unit and its remote controller at least 1m from the radio and television.
6. To avoid any error in signal transmission from the remote controller, please put the controller far away from high- frequency machines and high-power wireless systems
7. The installation height should be at least 2300 mm or more from the floor.
8. The distance from the air outlet to the fire alarm must be at least 1500mm and there must be no fire alarm in the front direction of the indoor unit

Figure showing the Installation of Indoor Unit.

Direction of Piping

There are 4 directions allowed, namely, backward piping, horizontally piping from right,horizontally piping from left, vertically down from right.

Names of Indoor Components

Installation of Hanger Wall Penetration and Installation of Protection

Pipe

CAUTION

• The draining of the water container inside the Indoor unit can be done from the left.
• Therefore the hanger must be fixed horizontally or slightly tilted towards the side of drain hose. Otherwise, condensed water may overflow the water container

Direct Mounting On The Wall

• Please use hidden beams in the wall to hold the hanger.

Procedures of Installation and Precautions

1. Drill holes on wall. (As shown below)
2. .Push plug into the holes (As shown below)
3. Fix the hanger on wall with 4.1 x 32 screw. (As shown in figure below).

Procedures to fix the holder of remote control.

1. Drill holes on wall.(As shown below) 2.Push plug into the holes.(As shown below)

Installation Of Remote Controller

• The remote controller can be placed in its holder which is fixed on wall or beam.
• To operate the remote controller at its holder, please ensure that the unit can receive signal transmitted from the controller at the place where the holder is to be fixed.The unit will beep when signal is received from the remote controller. The signal transmission is weaken by the fluorescent light. Therefore, during the installation of the remote control holder, please switch on the light, even during day time, to determine the mounting location of the holder.

Wall Penetration and Installation of Protection Pipe

• Drill a ø65mm hole on wall which is slightly tilted towards the outdoor side.
• Drill the wall at a small angle.
• Cut the protection pipe according to the wall thickness.
• Empty gap in the sleeve of protection pipe should be completely sealed with putty to avoid dripping of rain water into the room.
• Please ensure smooth flow of water when installing the drain hose. Improper installing may wet your funiture.
• An IEC approved power cord should be used. Power cord type: NYM

WARNING
Be sure that the wire is not in contact with any metal in the wall. Please use the protection pipe as wire passing through the hollow part of the wall so as to prevent the possibility of damaged by mouse. Unless it seals completely,any air with highVhumidity flows from outdoor and any dew may drop

Installation Of The Indoor Unit

Cutting Low Cover bush
While installing the pipe from the right, left or bottom side, use a knife to cut openings as shown in figure. Then smoothen the edges of openings with a file

PIPING FROM THE RIGHT SIDE (BACKWARD, DOWNWARD, HORIZONTAL)

Preparation

• Connect connecting cord.
• Pull out the pipe, connecting cord and drain hose

Installation

Insert the pipe through the wall hole

1. The upper part of the Indoor unit is hanged on the hanger.
2. The projection at the lower part of the Indoor unit is hooked onto the hanger

PIPING FROM THE LEFT SIDE (BACKWARD, DOWNWARD, HORIZONTAL)

Changed of Drain Hose and Installation Procedures.
Exchange the location of drain hose and drain cap while installing the pipe from the left side as shown in below. Be sure to plug in the drain hose until the insulating material folds upon itself.
Please use pliers to pull out the drain cap. (This is an easier way to remove the drain cap).

CAUTION

• The rubber strap used for fixing the insulator should not be tied with great force. Otherwise,this will damage heat insulation and causes water condensation.
• Please pull the lower part of the Indoor unit outwards to check if the unit is hooked onto the hanger. Improper installation may cause vibration and noise.
• Transform the piping while holding down the lower portion of pipe-support by hand

INSTALLATION AFTER CONNECTION OF REFRIGERATING PIPES

• The refrigerating pipe should be adjusted to fit into the hole on the wall and then ready for further connection.
• The terminals of 2 connected pipes must be covered with insulator used for terminal connection. Then the pipes are wrapped with insulation pipe.
• Connect the connecting cord after removing low cover. (Refer to “CONNECTION OF POWER CORD”)
• After adjustment, fit the connecting cord and pipes into the space available under the unit. Use holder to hold them tight.
• Be sure to cut the extra binding band. (Otherwise, it may result in abnormal noise or dewfall

THE CONNECTION OF REFRIGERATING PIPE DURING THE INSTALLATION OF INDOOR UNIT

Preparation To Install Refrigerating Pipes

The refrigerating pipes and connecting cord transform and are attached.

Installation

• Hang the indoor unit onto the hanger. Use the temporary stand at the back of the Indoor unit to push its lower part 15cm forwards.
• Place the drain hose through the hole on the wall.
• Wrap the refrigerating pipes with insulation pipe after connecting refrigerating pipe.
• Connect the connecting cord after removing low cover (Refer to “Connection of Power Cord”)
• After adjustment, the connecting cord and refrigerating pipes are placed into the space available under the Indoor unit.
• The projection of Indoor unit must hook to the hanger

Heat Insulation and Finish of the Piping

• The connected terminals should be completed sealed with heat insulator and then tied up with rubber strap.
• Do not tie the terminals with the tape too tight.
• If any clearance or over-tightening may cause condensation.
• Please tie the pipe and power line together with vinyl tape as shown in the figure showing the installation of Indoor and Outdoor units.
• To enhance the heat insulation and to prevent water condensation, please cover the outdoor part of the drain hose and pipe with insulation pipe.
• Completely seal any gap with putty.

Installation of Drain Hose

CAUTION
Be sure that the drain hose is not loosely connected bend or proper condition like left figure

CAUTION

You are free to choose the side (left or right) for the installation of drain hose. Please ensure the smooth flow of condensed water of the Indoor unit during installation. (Careless may result in water leakage.)

HOW TO REMOVE INDOOR UNIT

Push up the [PUSH] sections at the bottom of the indoor unit and pull the bottom plate towards you. Then the claws are released from the stationary plate. (The [PUSH] sections are indicated by 2 arrows in the right figure )

INSTALLATION OF REFRIGERATING PIPES AND AIR RE

Preparation of Pipe

• Use a pipe cutter to cut the copper pipe and remove burr.
  CAUTION
  

  • Remove burr and jagged edge will cause leakage.
  • Point the side to be trimmed downwards during trimming to prevent copper chips from entering the pipe

• Before flaring, please put on the flare nut.

• Please use exclusive tool for refrigerant R410A, R32.

• Please be careful when bending the copper pipe.

• Screw in manually while adjusting the center.

• After that, use a torque wrench to tighten the connection.

Small diameter side Large diameter side

| Outer diameter of pipe (ø)

6.35 (1/4″)

9.52 (3/8″)

| Torque N·m (kgf·cm)

13.7-18.6 (140 – 190)

34.3-44.1 (350 – 450)

|
---|---|---|---
Valve| Small diameter side| 6.35 (1/4″)| 19.6-24.5 (200 – 250)|
head cap| Large diameter side| 9.52 (3/8″)| 19.6-24.5 (200 – 250)|
 | Valve core cap|  | 12.3-15.7 (125 – 160)|

Pipe Connection

• In case of removing flare nut of a indoor unit, first remove a nut of small diameter side, or a seal cap of big diameter side will fly out. Free from water into the piping when working.
• Be sure to tighten the flare nut to the specified torque with a torque wrench.
• If the flare nut is overtightened, the nut may be split after a long period has passed, and may cause a refrigerant leak

Gas leakage inspection

Please use gas leakage detector to check if leakage occurs at connection of Flare nut as shown in below. If gas leakage occurs, further tighten the connection to stop leakage

CONNECTION OF POWER CORD

WARNING THIS APPLIANCE MUST BE EARTHED.

Detail of Cutting the Connecting Cord

WARNING

• Leave some space in the connecting cord for maintenance purpose and be sure to secure it with the cord band.
• Secure the connecting cord along the coated part of the wire using the cord band. Do not exert pressure on the wire as this may cause overheating or fire

Wiring of The Indoor Unit

• For wire connection of the Indoor unit, you need to remove the front cover, the low cover under the body of the unit and terminal cover.
• Remove the cover from the terminal base and screw the cable

Method to remove the low cover

Pull at the 1 and 2 in the directions as shown by arrows to remove the cover.

How to connect the optional parts (H-LINK RAC Adapter, Dry contact, Wired Remote Controller, Run status and alarm output)

• For cable connection to control P.W.B., you need to remove front cover and electrical box cover.
  Each connecting location is as below.

  • Dry contact: CN6
  • H-LINK RAC Adapter: CN7B
  • Wired Remote Control : CN20
  • Relay kit for run status and alarm output: CN25

• Please check and confirm manuals attached to each optional parts for more connection details.

• Please check service manual about how to set from remote controller.

• You can refer to this installation manual how to remove and re-attach the front cover.

• Please be careful not to damage lead wires by edge of plate when connecting the optional parts

• Please do the operation test after the connection.

HOW TO REMOVE OR ATTACH THE FRONT COVER

How to remove the front cover

1. Remove the front panel
2. Push the end of the right-side arm outward to release the tab.
3. Move the left-side arm outward to release the left tab, and then pull the panel towards you.
4. Remove the filters.
5. After removing 1 screw, remove the cover of electric box, then remove the 2 screws, pull the center of the front cover towards you and release the claws.
6. Pull the side faces (lower sections) of the front cover towards you as shown in the figure and remove the cover.

How to Attach the Front Cover

1. After installing the front cover onto the unit, hook three claws at upper side of the cover securely. Then, push the center of the front cover to lock the claws.
2. Tighten the 2 screws.
3. Assemble the cover of electric box, then tighten the screw.
4. Install the filter.
5. Attaching the Front Panel
6. `Insert the shaft of the left arm along the step on the unit into the hole.
7. Securely insert the shaft of the right arm along the step on the unit into the hole.
8. Make sure that the front panel is securely attached, and then close the front panel.

CAUTION

Remove and attach the front cover to the direction as shown in the figure to ensure no damage occurs to the ECO sensor

• Please mount the Outdoor unit of stable ground to prevent vibration and increase of noise level.
• Decide the location for piping after sorting out the different types of pipe available.
• When removing side cover, please pull the handle after undoing the hook by pulling it downward. Reinstall the side cover in the reverse order of the removal.

CAUTION
Do not touch the suction port, bottom surface,or aluminum fin of the outdoor unit.Failure to do so may cause an injury

THE CHOICE OF MOUNTING SITE
(Please note the following matters and obtain permission from customer before installation.)

WARNING
The Outdoor unit must be mounted at a location which can support heavy weight. Otherwise, noise and vibration will increase

CAUTION

• Selecting the installation location: Suitable location that will reduce the impact from rain and direct sun that may affect the unit performance.
• Besides,ventilation must be good and clear of obstruction .
• The air blown out of the unit should not point directly to animals or plants. The clearances of the unit from top, left, right and front are specified in figure below . At least three of the above sides must be open air .
• Be sure that the hot air blown out of the unit and noise do not disturb the neighborhood.
• Do not install at a location where there is flammable gas,steam, oil and smoke. The location must be convenient for water drainage.
• Place the Outdoor unit and its connecting cord at least 1 m away from the antenna or signal line of television, radio or telephone. This is to avoid noise interference.

Figure showing the Installation of Outdoor Unit.

Preparation of Pipe

• Use a pipe cutter to cut the copper pipe and remove burr.
• Before flaring, please put on the flare nut
• Please use exclusive tool for refrigerant R410 R32
  Outer

Diameter (Ø)

| A (mm) Rigid Flaring Tool
---|---
For R410A,R32 tool| For R22 tool
6.35 (1/4″)| 0 – 0.5| 1.0
9.52 (3/8″)| 0 – 0.5| 1.0

CAUTION

• Remove burr and jagged edge will cause leakage.
• Point the side to be trimmed downwards during trimming to prevent copper chips from entering the pipe.

Pipe Connection

• In case of removing flare nut of a indoor unit, first remove a nut of small diameter side, or a seal cap of big diameter side will fly out. Free from water into the piping when working.
• Be sure to tighten the flare nut to the specified torque with a torque wrench.
• If the flare nut is overtightened, the nut may be split after a long period has passed, and may cause a refrigerant leak.

1. Please be careful when bending the copper pipe.
2. Screw in manually while adjusting the center. After that, use a torque wrench to tighten the connection

Remove of Air From The Pipe And Gas Leakage Inspection

Procedures of using Vacuum Pump for Air Removal

1. As shown in right figure, remove the cap of valve core. Then, connect the charge hose. Remove the cap of valve head. Connect the vacuum pump adapter to the vacuum pump and connect the charge hose to the adapter.
2. Fully tighter the “Hi” shuttle of the manifold valve and completely unscrew the “Lo” shuttle. Run the vacuum pump for about 10-15 minutes, then completely tighten the”Lo” shuttle and switch off the vacuum pump.
3. Loosen the spindle of the service valve with small diameter by 1/4 turn and tighten the spindle immediately after 5 to 6 seconds.
4. Remove the charging hose from the service valve.
5. Completely unscrew the spindle of the service valve (at 2 places) in anticlockwise direction to allow the flow of refrigerant (using Hexagonal Wrench key).
6. Tighten the cap of valve head. Check the cap’s periphery if there is any gas leakage. The task is then completed

Gas leakage inspection

Please use gas leakage detector to check if leakage occurs at connection of Flare nut as shown on the right.
If gas leakage occurs, further tighten the connection to stop leakage

Procedures of Wiring

Detail of Cutting the Connecting Cord

WARNING

• The naked part of the wire core should be 10mm fix it to the terminal tightly. Then try to pull the individual wire to check if the contact is tight. Improper insertion may burn the terminal.
• Be sure to use only wire specified for the use of air-conditioner.
• Please refer to the manual for wire connection and the wiring technique should meet the standard of the electrical installation.
• There is an AC voltage drop between the LN terminal if the power is on. Therefore, be sure to remove the plug from its socket.
• When the fuse (F5 or F6) has been blown out by the improper connection of power cable, it can be restored by exchanging the fuse (service part No.HWRAC-50NX2 A52).
• Please exchange the blown-out fuse after making sure the right connection.

WARNING

• Leave some space in the connecting cord for maintenance purpose and be sure to secure it with the cord band.
• Secure the connecting cord along the coated part of the wire using the cord band.Do not exert pressure on the wire as this may cause overheating or fire

Wiring of the Outdoor Unit

Please remove the side cover for wire connection

• If you cannot attach the side plate due to the connection cord, please press the connecting cord in the direction to the front panel to fix it.
• Be sure that the hooks of the side cover fixed in certainly. Otherwise water leakage may occur and this causes short circuit or faults

Checking for the electric source and the voltage range

Before installation, the power source must be checked and necessary wiring work must be completed. To make the wiring capacity proper, use the wire gauge list below for the wiring from house distribution fuse box to the outdoor unit in consideration of the blocked rotor current

• Investigate the power supply capacity and other electrical conditions at the installing location.
• Depending on the model of room air conditioner to be installed, request the customer to make arrangements for the necessary electrical work etc.
• The electrical work includes the wiring work up the outdoor unit. In localities where electrical conditions are poor, use of a voltage regulation is recommended.
• Install outdoor for the room air conditioner within the reaching range of the line cord.

IMPORTANT

Fuse Capacity

RAC-DJ25/35PCAT| 15A time delay fuse
Wire length| Wire cross-section
---|---
up to 6m up to 15m up to 20m| 1.5mm2 2.5mm2 4.0mm2

Power Source And Operation Test

Power Source

• Never remodel the power plug nor extend the long-distance cord.
• Keep additional length for the power cord and do not render the plug under external force as this may cause poor contact.
• Do not fix the power cord with U-shape nail.
• The power cable easily generates heat. Do not bring the cable together with a wire or vinyl tie.

Operation test

Please be sure to measure the supply voltage before operation test. Please ensure that the air conditioner is in normal operating condition during the operation test.

1. Operate with Cooling Mode(in summer).

2. Press Temperature Button on the remote controller to set the desired temperature to 16.0 for Cooling Mode.
   Set the desired fan speed to ” “(High).

3. Operate the air conditioner for 20 minutes at least and make sure that the air from the air conditioner is cool.

4. Press On/Off Button on the remote controller and make sure that the air conditioner stops the operation.

If the indication lamps of the indoor unit flash with sounding of the buzzer during the operation test, perform a check following the procedures below.

Indication lamps flashing

mode

| What to check
---|---

All indication lamps flash three times repeatedly.

| Make sure that the spindles of both service valves are open. (Outdoor fan might operate for near 15 minutes after the operation stop for remove the protection. For the reoperation at that case, do it after outdoor fan will stop.)

• Befor the check and the reoperation, reset the power supply by turning off and on the circuit breaker only after waiting for at least 5 mintes; or pressing the Temporary Switch Button only once while the power is OFF.

CAUTION

• Don’t operate for over 5 minutes with the situation that the spindle of the service valve is closed. This will cause the defect.
• Don’t operate by Cool Mode or Dry Mode with the door and windows opened, (the room humidity is always above 80%) for a long period of time. Water will condense and drip down occasionally.
• This will wet your furniture

1. Explain to your customer the proper operation procedures as described in the user’ s manual.
2. If the indoor unit won’t operate, check the cable for correct connection
3. Turn on the lamp in the room where the indoor unit is installed and check the remote controller for normal operation.

Refrigerant

Documents / Resources

| HITACHI RAK-DJ25PCAT Indoor Unit [pdf] Instruction Manual
RAK-DJ25PCAT, RAK-DJ35PCAT, RAK-DJ25PCAT Indoor Unit, Indoor Unit
---|---

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