Innovair Hyper Heat Multi System Instruction Manual

Innovair Hyper Heat Multi System Instruction Manual

Safety precautions

1. This air conditioner uses new refrigerant HFC (R410A).
2. Since the max. working pressure is 550psig (3.8MPa), some of the piping and installation  and service tools are special.
3. This air conditioner uses power supply: 208-230V ~, 60Hz

Please read these SAFETY PRECAUTIONS carefully to ensure correct installation.

• Be sure to use a dedicated power circuit, and do not put other loads on the power supply.

• Be sure to read these SAFETY PRECAUTIONS carefully before installation.

• Be sure to comply with SAFETY PRECAUTIONS of installation manual, because it contains important safety issues. Definitions for identifying hazard levels are provide below with their respective safety symbols.
  WARNING：Hazards or unsafe practices which COULD result in severe personal injury or death.
  CAUTION： Hazards or unsafe practices which COULD result in minor personal injury or product  or property damage.

• Please carefully file indoor and outdoor unit manual away for future reference.

CAUTION

• Perform grounding Does not connect the earth wire to a gas pipe, water pipe, lightning rod or telephone earth wire. Defective grounding could cause an electric shock.
• Do not install the unit in a place where an inflammable gas leaks. If gas leaks and accumulates in the area surrounding the unit, it could cause an explosion.
• Fasten a flare nut with a torque wrench as specified in this manual. When fastened too tight, a flare nut may break after a long period and cause a leakage of refrigerant.
• Install an earth leakage breaker depending on the installation place(where it is humid). If an earth leakage breaker is not installed, it could cause an electric shock.
• Perform the drainage/piping work securely according to the installation manual.
• If there is a defect in the drainage/piping work, water could drop from the unit and household goods could be wet and damaged.

Safety instructions

• Do not let air enter the refrigeration system or discharge refrigerant when moving the air conditioner.
• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety.
• Children should be supervised to ensure that they do not play with the appliance.
• If the appliance is fixed wiring, the appliance must be fitted with means for disconnection from the supply mains having a contact separation in all poles that provide full disconnection under over voltage category III conditions, and these means must be incorporated in the fixed wiring in accordance with the wiring rules.
• If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard.
• The appliance shall be installed in accordance with national wiring regulations.
• Servicing shall only be performed as recommended by the equipment manufacturer.
• The method of connection of the appliance to the electrical supply and interconnection of separate components is detailed in below part. The wiring diagram with a clear indication of the connections and wiring to external control devices and supply cord is detailed in below part.
• In order to avoid a hazard due to inadvertent resetting of the thermal cut-out, this appliance must not be supplied through an external switching device, such as a timer, or connected to a circuit that i regularly switched on and off by the utility.
• It is necessary to allow disconnection of the appliance from the supply after installation. The  disconnection may be achieved by incorporating a switch in the fixed wiring in accordance with the wiring rules. During service and when replacing parts, be sure to disconnect the appliance from its power source. If the disconnection is not foreseen, a disconnection with a locking system in the isolated position shall be provided.
• The information of dimensions of the space necessary for correct installation of the appliance including the minimum permissible distances to adjacent structures is detailed in below part.
• This appliance is intended to be used by expert or trained users in shops, in light industry and on farms, or for commercial use by lay persons.
• Instructions on addition charging of refrigerants are detailed in below part.

Refrigerant flow diagram

Installation instructions

Installation diagram

transportation and handling before installation

Transport the product as close to the installation location as practical before unpacking.

• Handling Method
  When hanging the unit, ensure a balance of the unit, check safety and lift up smoothly.

1. Do not remove any packing materials.
2. Hang the unit under packing condition with two ropes, as shown in Fig below.
   

Handling
If have no package to move, Please protect with cloth or paper.

Installation locations selection

Before choosing the installation site, obtain user approval.

• Where it is not exposed to strong wind.
• Where airflow is good and clean.
• Where it is not exposed to rain and direct sunshine.
• Where neighbors are not annoyed by operation sound or hot air.
• Where rigid wall or support is available to prevent the increase of operation sound or vibration.
• Where there is no risk of combustible gas leakage.
• Where it is at least 3m away from the antenna of TV set or radio. An amplifier may be required for the affected device.
• Install the unit horizontally.
• Please install it in an area not affected by snowfall or blowing snow. In areas with heavy snow, please install a canopy, a pedestal and/or some baffle boards.

CAUTION：

Avoid the following places for installation where air conditioner trouble is liable to occur.

• Where there is much machine oil.
• Salty places such as seaside.
• Where sulfide gas is generated such as a hot spring.
• Where there is high-frequency or wireless equipment.

Drainage elbow and drain hose installation

Install Drainage Elbow and Drain Hose

• The condensate water may drains from the outdoor unit when the unit operates in heating mode. In order to avoid disturbing neighbors also to protect the environment, it is necessary to install a drainage elbow and a drain hose to drain out the condensate water.
• Please do the drainage work before the indoor unit and outdoor unit are connected. Otherwise, it will be difficult to install drainage elbow after the machine becomes immovable.)
• Connect the drain hose (field-supplied, inside diameter: 15mm) as shown in the figure for drainage.
  

Outdoor Installation

Refrigerant piping

Piping requirement

The maximum allowable length of refrigerant piping, and the maximum allowable height difference between the outdoor and indoor units, are listed below. The shorter the refrigerant piping is, the better the performance will be. So the connecting pipe should be as short as possible.

≤65.6(20)
Total length of piping between all units| ft./m| A+B≤164(50)| A+B+C≤197(60)| A+B+C+D≤246(75)| A+B+C+D+E≤262(80)
Max height difference between indoor unit and outdoor unit (F)| ft./m| ≤49 (15)
max height difference between indoor units (G)| ft./m| ≤25 (7.5)

Additional refrigerant charge
The unit has been filled with refrigerant, but if L (total pipe length) exceeds standard length, additional efrigerant (R410A) change is required.
For 18K: Additional refrigerant charge=[L-50ft (15m)]×0.807oz/5ft (15g/m)
For 24K: Additional refrigerant charge=[L-75ft (22.5m)]×0.807oz/5ft (15g/m)
For 36K: Additional refrigerant charge=[L-98ft (30m)]×0.807oz/5ft (15g/m)
For 42K: Additional refrigerant charge=[L-125ft (37.5m)]×0.807oz/5ft (15g/m)

Piping material

1. Prepare the copper pipe on the spot.
2. Choose dustless, non-humid, clean copper pipe. Before installing the pipe, use nitrogen or dry air to blow away the dust and impurity on the tube.
3. Piping thickness and material use the pipe as below.

CAUTION

Processing of Refrigerant Piping

1. Pipe cutting
   • Cut the cooper pipe correctly with pipe cutter.
2. Burrs removal
   • Completely remove all burrs from the cut cross section of the pipe.
   • Put the end of the copper pipe downward to prevent burrs from dropping in the pipe.
3. Putting nut on
   • Remove flare nuts attached to indoor and outdoor units, then put them on pipe having completed burr removal. (Not possible to put them on after flaring work).
   • Flare nut for pipe depending on the diameter of pipe.
4. Flaring work
   • Perform flaring work using flaring tool as shown below.
5. Check
   • Compare the flared work with the figure below.
   • If flare is noted to be defective, cut off the flared section and perform flaring work again.

14.75ft-lb (20N·m)29.5ft-lb (40N·m)44.25ft-lb (60N·m)59ft-lb (80N·m)

After finishing connecting the refrigerant pipes, keep it warm with the insulation material like figure right.

• For outdoor unit side, surely insulate every piping including valves.
• Cover piping joints with pipe cover.
• Using piping tape, apply taping starting from the entry of outdoor unit. Fix the end of piping tape with adhesive tape.
• Fix the end of piping tape with adhesive tape.
• When piping has to be arranged through above ceiling, closet or area where temperature and humidity are high, wind additional commercially sold insulation for prevention of condensation.

If the diameter of connection pipe does not match the port size of outdoor unit, select proper differentdiameter joints in the accessory according to the following table.

Connect pipes using different-diameter joint

Air tight test

Connect the gauge manifold using charging hoses with a nitrogen cylinder to the check joints of the liquid line and the gas line stop valves. Perform the air-tight test. Don’t open the gas line stop valves. Apply nitrogen gas pressure of psi ( MPa 550 3.8 ). Check for any gas leakage at the flare nut connections, or brazed parts by gas leak detector or foaming agent. Gas pressure doesn’t decrease is OK. After the air tight test, release nitrogen gas

Vacuum pumping and charge refrigerant

1. Remove the service port cap of the stop valve on the gas pipe side of the outdoor unit.
2. Connect the manifold gauge and vacuum pump to the service port of the stop valve on the gas pipe side of the outdoor unit.
3. Run the vacuum pump. (Work for more than 15 minutes.)
4. Check the vacuum with the gauge manifold valve, then close the gauge manifold valve and stop the vacuum pump.
5. Leave it as is for one or two minutes. Make sure the pointer of the manifold gauge remains in the same position. Confirm that the pressure gauge shows -14.7 psi(-0.101MPa or -760mHg).
6. Remove the manifold gauge quickly from the service port of the stop valve.
7. After refrigerant pipes are connected and evacuated, fully open all stop valves on both sides of gas pipe and liquid pipe.
8. Open adjusted valve to add refrigerant (must be refrigerant is liquid).
9. Tighten the cap to the service port .
10. Retighten the cap.
11. Leak test foam with halogen leak detector to check the flare nut and brazing Carolina Department leaks. Use foam that not generate ammonia (NH3) in the reaction.

CAUTION

1. For 18K~36K models, each pipelines needs to be evacuated individually. For 42K, only need to vacuum at the main stop valve.
2. An excess or a shortage of refrigerant is the main cause of trouble to the unit. Charge the correct refrigerant quantity according to the description of label at the inside of the manual.
3. Check refrigerant leakage in detail. If a large refrigerant leakage occurs, it will cause difficulty with breathing or harmful gases will occur if a fire is being used in the room.

Additional refrigerant charge

Filling a cylinder with an attached siphon

Stand the cylinder upright when filling. There is a siphon pipe inside,so the cyliner need not to be upside-down to fill with liquid.

Filling other cylinders

Turn the cylinder upside -down when filling.

Wiring

• With tape material along the wire wrapped, sealed wiring holes, prevent the condensed water and insects.
• Tightly secure the power source wiring using the cord clamp inside the unit.
  NOTE: Fix the rubber bushes with adhesive when conduit tubes to the outdoor unit are not used

General Check

1. Make sure that the field-selected electrical components (main power switches, circuit breakers, wires, conduit connectors and wire terminals) have been properly selected according to the electrical data. Make sure that the components comply with National Electrical Code (NEC).
2. Check to ensure that the voltage of power supply is within +10% of nominal voltage and earth phase is contained in the power supply wires. If not, electrical parts will be damaged.
3. Check to ensure that the capacity of power supply is enough. If not, the compressor will be not able to operate cause of voltage drop abnormally at starting.
4. Check to ensure that the earth wire is connected.
5. Install a main switch ,multi-pole main switch with a space of 1/8 in (3.5mm) or more, single phase main switch with a space o 1/8 in. (3.0mm) or more between each phase. Please use the special three phase power switch for 3-Phase product.
6. Check to ensure that the electrical resistance is more than 2 MΩ, by measuring the resistance between ground and the terminal of the electrical parts. If not, do not operate the system until the electrical leakage is found and repaired.

Electrical wiring diagram

NOTES:

1. For 18K model, there is no INDOOR UNIT C, D and E.
2. For 24K model, there is no INDOOR UNIT D and E.
3. For 36K model, there is no INDOOR UNIT E.
4. Since there may be differences in some models’ terminal blocks, wiring connection should be done according to letters on the terminal block. Please disregard numbers in this case.

Note: For some indoor units

Wires connect steps:

1. Valve cover removal Remove the two mounting screws. Remove the valve cover as shown by the arrow mark.
2. Fasten the power supply cable and the connection cable to the conduit holder using the lock nut.
3. Connect the power supply cable and the connection cable to terminal.
4. Fasten the power supply cable and the connection cable with the cable clamp.
5. Be sure to seal the holes when applying the putty. Place the cables side to side.(Do not overlap the cables.)
6. Put the service cover and valve cover back after completion of the work

36K/42K

1. Knock off 5 conductor holes (36K)/ 6 conductor holes (42K) on right side plate gentally using hammer etc..
2. Unscrew the screws on maintenance plate, and remove it as shown by the arrow mark.
3. Fasten the power supply cable and the connection cable through conductor hole using the lock nut.
4. Connect the power supply cable and the connection cable to terminal.
5. Fasten the power supply cable and the connection cable with the cable clamp.
6. Be sure to seal the holes when applying the putty. Place the cables side to side. (Do not overlap the cables.)
7. Put the maintenance plate back after completion of the work.

Electrical Data

Model (Capacity: Btu/h)| **Power Supply| ELB| ****Power Source Cable Size| ****Transmitting Cable Size| ****Circuit Breaker (A)
---|---|---|---|---|---
Rated Current (A)| Nominal Sensitive Current (mA)**
18K| 208/230V ~/60Hz| 30| 30| 14AWG2cable+Ground| 16AWG3cable+Ground| 30
24K| 208/230V ~/60Hz| 30| 30| 12AWG2cable+Ground| 16AWG3cable+Ground| 30
36K| 208/230V ~/60Hz| 50| 30| 10AWG2cable+Ground| 16AWG3cable+Ground| 50
42K| 208/230V ~/60Hz| 50| 30| 10AWG2cable+Ground| 16AWG3cable+Ground| 50

Note：

1. Follow local codes and regulations when select field wires, and all the above are the minimum wire size.
2. When transmitting cable length is more than 49ft. (15 m), a larger wire size should be selected.
3. Install main switch and ELB for each system separately. Select the high response type ELB that is acted within 0.1second.

1. When connecting the terminal block using stranded wire, make sure to use the round crimp-style terminal for connection to the power supply terminal block. Place the round crimp-style terminals on the wires up to the covered part and secure in place.
2. When connecting the terminal block using a single core wire, be sure to perform curing.

CAUTION

The air-conditioner is provided with a crankcase heater, check to ensure that the switch on the main power source has been ON for more than 6 hours ahead of power on preheating, otherwise it might damage the compressor!

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