Panasonic ACXF60-03890 Air Conditioner Instruction Manual

Panasonic ACXF60-03890 Air Conditioner

Product Information

The ACXF60-03890 is an air conditioner that operates with refrigerant R32, which is flammable. The product must only be installed or serviced by qualified personnel who are familiar with national, state, territory, and local legislation, regulations, codes, installation, and operation manuals. The required tools for installation include a 12 Megameter, 13 Multimeter, and 14 Torque wrench. The indoor and outdoor units display symbols to indicate warnings and cautions, which should be followed to avoid harm or damage.

Product Usage Instructions

• Do not tie up the power supply cord into a bundle by band to avoid abnormal temperature rise on the cord.
• Do not insert fingers or other objects into the unit to avoid injury from the high-speed rotating fan.
• Do not sit or step on the unit to avoid accidental falls.
• Keep plastic bags and packaging materials away from small children to prevent them from clinging to their nose and mouth andcausing breathing difficulties.
• When installing or relocating the air conditioner, do not let any substance other than the specified refrigerant mix into the refrigeration cycle (piping) to avoid abnormal high pressure in the refrigeration cycle, which can result in explosion or injury.
• Do not pierce or burn the appliance as it is pressurized. Do not expose the appliance to heat, flame, sparks, or other sources of ignition to avoid explosion or injury.
• Do not add or replace refrigerant other than the specified type to avoid product damage, burst, and injury.
• Do not perform flare connection inside a building or dwelling or room when joining the heat exchanger of the indoor unit with interconnecting piping. Refrigerant connection inside a building or dwelling or room must be made by brazing or welding. Joint connection of indoor unit by flaring method can only be made at outdoor or at outside of a building or dwelling or room to avoid gas leak and flammable atmosphere.
• Engage authorized dealer or specialist for installation to avoid water leakage, electrical shock, or fire.

Customers should keep the operating instructions for future reference.

CAUTION
R32 REFRIGERANT
This Air Conditioner contains and operates with refrigerant R32.
THIS PRODUCT MUST ONLY BE INSTALLED OR SERVICED BY QUALIFIED PERSONNEL.
Refer to National, State, Territory and local legislation, regulations, codes, installation & operation manuals, before the installation, maintenance and/or service of this product.

Required tools for Installation Works

1. Phillips screw driver

2. Level gauge

3. Electric drill, hole core drill (ø70 mm)

4. Hexagonal wrench (4 mm)

5. Spanner

6. Pipe cutter

7. Reamer

8. Knife

9. Gas leak detector

10. Measuring tape

11. Thermometer

12. Megameter

13. Multimeter

14. Torque wrench
    18 N•m (1.8 kgf•m)
    42 N•m (4.3 kgf•m)
    55 N•m (5.6 kgf•m)
    65 N•m (6.6 kgf•m)
    100 N•m (10.2 kgf•m)

15. Vacuum pump

16. Gauge manifold

Explanation of symbols displayed on the indoor unit or outdoor unit

SAFETY PRECAUTIONS

• Read the following “SAFETY PRECAUTIONS” carefully before installation.
• Electrical work must be installed by a licensed electrician. Be sure to use the correct rating of the power plug and main circuit for the model to be installed.
• The caution items stated here must be followed because these important contents are related to safety. The meaning of each indication used is as below. Incorrect installation due to ignoring of the instruction will cause harm or damage, and the seriousness is classifi ed by the following indications.

WARNING This indication shows the possibility of causing death or serious injury.
CAUTION This indication shows the possibility of causing injury or damage to properties only.

The items to be followed are classifi ed by the symbols:

• Carry out test running to confi rm that no abnormality occurs after the installation. Then, explain to user the operation, care and maintenance as stated in instructions. Please remind the customer to keep the operating instructions for future reference.
• This appliance is not intended for accessibility by the general public.

WARNING

CAUTION

PRECAUTION FOR USING R32 REFRIGERANT

• The basic installation work procedures are the same as conventional refrigerant (R410A, R22) models.

However, pay careful attention to the following points:
WARNING

• Since the working pressure is higher than that of refrigerant R22 models, some of the piping and installation and service tools are special.
  Especially, when replacing a refrigerant R22 model with a new refrigerant R32 model, always replace the conventional piping and fl are nuts with the R32 and R410A piping and fl are nuts on the outdoor unit side.
  For R32 and R410A, the same fl are nut on the outdoor unit side and pipe can be used.

• Models that use refrigerant R32 and R410A have a different charging port thread diameter to prevent erroneous charging with refrigerant R22 and for safety.
  Therefore, check beforehand. [The charging port thread diameter for R32 and R410A is 12.7 mm (1/2 inch).]

• Be more careful than R22 so that foreign matter (oil, water, etc.) does not enter the piping.
  Also, when storing the piping, securely seal the opening by pinching, taping, etc. (Handling of R32 is similar to R410A.

CAUTION

Installation (Space)

• Must ensure the installation of pipe-work shall be kept to a minimum. Avoid use dented pipe and do not allow acute bending.
• Must ensure that pipe-work shall be protected from physical damage.
• Must comply with national gas regulations, state municipal rules and legislation. Notify relevant authorities in accordance with all applicable regulations.
• Must ensure mechanical connections be accessible for maintenance purposes.
• In cases that require mechanical ventilation, ventilation openings shall be kept clear of obstruction.
• When disposal of the product, do follow to the precautions in #12 and comply with national regulations.
  Always contact to local municipal offi ces for proper handling.

Servicing
Service personnel

• Any qualifi ed person who is involved with working on or breaking into a refrigerant circuit should hold a current valid certifi cate from an industry-accredited assessment authority, which authorizes their competence to handle refrigerants safely in accordance with an industry recognized assessment specifi cation.
• Servicing shall only be performed as recommended by the equipment manufacturer. Maintenance and repair requiring the assistance of other skilled personnel shall be carried out under the supervision of the person competent in the use of fl ammable refrigerants.
• Servicing shall be performed only as recommended by the manufacturer.

Work

• Prior to beginning work on systems containing fl ammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised.
  For repair to the refrigerating system, the precautions in #2-2 to #2-8 must be followed before conducting work on the system.

• Work shall be undertaken under a controlled procedure so as to minimize the risk of a fl ammable gas or vapour being present while the work is being performed.

• All maintenance staff and others working in the local area shall be instructed and supervised on the nature of work being carried out.

• Avoid working in confi ned spaces.

• Wear appropriate protective equipment, including respiratory protection, as conditions warrant.

• Ensure that the conditions within the area have been made safe by limit of use of any fl ammable material. Keep all sources of ignition and hot metal surfaces away.

Checking for presence of refrigerant

• The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially fl ammable atmospheres.
• Ensure that the leak detection equipment being used is suitable for use with fl ammable refrigerants, i.e. non sparking, adequately sealed or intrinsically safe.
• In case of leakage/spillage happened, immediately ventilate area and stay upwind and away from spill/release.
• In case of leakage/spillage happened, do notify persons down wind of the leaking/spill, isolate immediate hazard area and keep unauthorized personnel out.

Presence of fi re extinguisher

• If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fi re extinguishing equipment shall be available at hand.
• Have a dry powder or CO2 fi re extinguisher adjacent to the charging area.

No ignition sources

• No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that contains or has contained fl ammable refrigerant shall use any sources of ignition in such a manner that it may lead to the risk of fi re or explosion. He/She must not be smoking when carrying out such work.
• All possible ignition sources, including cigarette smoking, should be kept suffi ciently far away from the site of installation, repairing, removing and disposal, during which fl ammable refrigerant can possibly be released to the surrounding space.
• Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no fl ammable hazards or ignition risks.
• “No Smoking” signs shall be displayed.

Ventilated area

• Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work.
• A degree of ventilation shall continue during the period that the work is carried out.
• The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.

Checks to the refrigeration equipment

• Where electrical components are being changed, they shall be fi t for the purpose and to the correct specifi cation.
• At all times the manufacturer’s maintenance and service guidelines shall be followed.
• If in doubt consult the manufacturer’s technical department for assistance.
• The following checks shall be applied to installations using fl ammable refrigerants.
  • The charge size is in accordance with the room size within which the refrigerant containing parts are installed.
  • The ventilation machinery and outlets are operating adequately and are not obstructed.
  • If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant.
  • Marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected.
  • Refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing components, unless the components are constructed of materials which are inherently resistant to being corroded or are properly protected against being so corroded.

Checks to electrical devices

• Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures.
• Initial safety checks shall include but not limit to:-
  • That capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking.
  • That there is no live electrical components and wiring are exposed while charging, recovering or purging the system.
  • That there is continuity of earth bonding.
• At all times the manufacturer’s maintenance and service guidelines shall be followed.
• If in doubt consult the manufacturer’s technical department for assistance.
• If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with.
• If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used.
• The owner of the equipment must be informed or reported so all parties are advised thereinafter.

Repairs to sealed components

• During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers, etc.
• If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the most critical point to warn of a potentially hazardous situation.
• Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specifi cation, damage to seals, incorrect fi tting of glands, etc.
• Ensure that apparatus is mounted securely.
• Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the ingress of fl ammable atmospheres.
• Replacement parts shall be in accordance with the manufacturer’s specifi cations.
  NOTE : The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment. Intrinsically safe components do not have to be isolated prior to working on them.

Repair to intrinsically safe components

• Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for the equipment in use.
• Intrinsically safe components are the only types that can be worked on while live in the presence of a fl ammable atmosphere.
• The test apparatus shall be at the correct rating.
• Replace components only with parts specifi ed by the manufacturer. Unspecifi ed parts by manufacturer may result ignition of refrigerant in the atmosphere from a leak.

Cabling

• Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects.
• The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.

Detection of fl ammable refrigerants

• Under no circumstances shall potential sources of ignition be used in the searching or detection of refrigerant leaks.
• A halide torch (or any other detector using a naked fl ame) shall not be used.

Leak detection methods

• Electronic leak detectors shall be used to detect fl ammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration. (Detection equipment shall be calibrated in a refrigerant-free area.)
• Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used.
• Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate percentage of gas (25 % maximum) is confi rmed.
• Leak detection fl uids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work.
• If a leak is suspected, all naked fl ames shall be removed/extinguished.
• If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a part of the system remote from the leak. Oxygen free nitrogen (OFN) shall then be purged through the system both before and during the brazing process.

Removal and evacuation

• When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures shall be used.
  However, it is important that best practice is followed since fl ammability is a consideration.
  The following procedure shall be adhered to:

  • remove refrigerant -> • purge the circuit with inert gas -> • evacuate -> • purge again with inert gas -> • open the circuit by cutting or brazing

• The refrigerant charge shall be recovered into the correct recovery cylinders.

• The system shall be “fl ushed” with OFN to render the unit safe.

• This process may need to be repeated several times.

• Compressed air or oxygen shall not be used for this task.

• Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fi ll until the working pressure is achieved, then venting to atmosphere, and fi nally pulling down to a vacuum.

• This process shall be repeated until no refrigerant is within the system.

• When the fi nal OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place.

• This operation is absolutely vital if brazing operations on the pipe work are to take place.

• Ensure that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation available.

Charging procedures

• In addition to conventional charging procedures, the following requirements shall be followed.
  • Ensure that contamination of different refrigerants does not occur when using charging equipment.
  • Hoses or lines shall be as short as possible to minimize the amount of refrigerant contained in them.
  • Cylinders shall be kept upright.
  • Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
  • Label the system when charging is complete (if not already).
  • Extreme care shall be taken not to over fi ll the refrigeration system.
• Prior to recharging the system it shall be pressure tested with OFN (refer to #7).
• The system shall be leak tested on completion of charging but prior to commissioning.
• A follow up leak test shall be carried out prior to leaving the site.
• Electrostatic charge may accumulate and create a hazardous condition when charging and discharging the refrigerant.
  To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging.

Decommissioning

• Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its details.
• It is recommended good practice that all refrigerants are recovered safely.
• Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of reclaimed refrigerant.
• It is essential that electrical power is available before the task is commenced.
  • a) Become familiar with the equipment and its operation.
  • b) Isolate system electrically.
  • c) Before attempting the procedure ensure that:
  • mechanical handling equipment is available, if required, for handling refrigerant cylinders;
  • all personal protective equipment is available and being used correctly;
  • the recovery process is supervised at all times by a competent person;
  • recovery equipment and cylinders conform to the appropriate standards.
  • d) Pump down refrigerant system, if possible.
  • e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
  • f) Make sure that cylinder is situated on the scales before recovery takes place.
  • g) Start the recovery machine and operate in accordance with manufacturer’s instructions.
  • h) Do not over fi ll cylinders. (No more than 80 % volume liquid charge).
  • i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
  • j) When the cylinders have been fi lled correctly and the process completed, make sure that the cylinders and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
  • k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.
• An electrostatic charge may accumulate and create a hazardous condition when charging or discharging the refrigerant.
  To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging

Labeling

• Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant.
• The label shall be dated and signed.
• Ensure that there are labels on the equipment stating the equipment contains fl ammable refrigerant.

Recovery

• When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
• When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed.
• Ensure that the correct number of cylinders for holding the total system charge are available.
• All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i.e. special cylinders for the recovery of refrigerant).
• Cylinders shall be complete with pressure relief valve and associated shut-off valves in good working order.
• Recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
• The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of fl ammable refrigerants
• In addition, a set of calibrated weighing scales shall be available and in good working order.
• Hoses shall be complete with leak-free disconnect couplings and in good condition.
• Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a refrigerant release. Consult manufacturer if in doubt.
• The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged.
• Do not mix refrigerants in recovery units and especially not in cylinders.
• If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that fl ammable refrigerant does not remain within the lubricant.
• The evacuation process shall be carried out prior to returning the compressor to the suppliers.
• Only electric heating to the compressor body shall be employed to accelerate this process.
• When oil is drained from a system, it shall be carried out safely

Attached accessories

SELECT THE BEST LOCATION
OUTDOOR UNIT

• If an awning is built over the unit to prevent direct sunlight or rain, be careful that heat radiation from the condenser is not obstructed.
• There should not be any animal or plant which could be affected by hot air discharged.
• Keep the spaces indicated by arrows from wall, ceiling, fence or other obstacles.
• Do not place any obstacles which may cause a short circuit of the discharged air.
• If piping length is over the [piping length for additional gas], additional refrigerant should be added as shown in the table

Table A

Amin = ( M / (2.5 x (LFL)(5/4) x h0)) ²

• Amin = Required minimum room area, in m²
• M = Refrigerant charge amount in appliance, in kg
• LFL = Lower fl ammable limit (0.306 kg/m³)
• h0 = Installation height of the appliance (1.8 m for wall mounted)

OUTDOOR UNIT

1. SELECT THE BEST LOCATION
   (Refer to “Select the best location” section)

2. INSTALL THE OUTDOOR UNIT
   After selecting the best location, start installation to Indoor/Outdoor Unit Installation Diagram.

3. Fix the unit on concrete or rigid frame fi rmly and horizontally by bolt nut (ø10 mm).

4. When installing at roof, please consider strong wind and earthquake. Please fasten the installation stand fi rmly with bolt, screws or nails.

5. CONNECT THE PIPING
   Connecting The Piping to Indoor Connecting The Piping to Outdoor
   Decide piping length and then cut by using pipe cutter.
   Remove burrs from cut edge.
   Make fl are after inserting the fl are nut (locate at valve) onto the copper pipe. Align center of piping to valve and then tighten with torque wrench to the specifi ed torque as stated in the table. AIR PURGING METHOD IS PROHIBITED FOR R32 SYSTEM

6. EVACUATION OF THE EQUIPMENT
   WHEN INSTALLING AN AIR CONDITIONER, BE SURE TO EVACUATE THE AIR INSIDE THE INDOOR UNIT AND PIPES in the following procedure.
   Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.
   There is no extra refrigerant in the outdoor unit for air purging.

7. Connect a charging hose with a push pin to the Low side of a charging set and the service port of the 3-way valve.
   Be sure to connect the end of the charging hose with the push pin to the service port.

8. Connect the center hose of the charging set to a vacuum pump.

9. Turn on the power switch of the vacuum pump and make sure that the needle in the gauge moves from 0 cmHg (0 MPa) to –76 cmHg (–0.1 MPa). Then evacuate the air approximately ten minutes.

10. Close the Low side valve of the charging set and turn off the vacuum pump. Make sure that the needle in the gauge does not move after approximately fi ve minutes.
    Note: BE SURE TO TAKE THIS
    PROCEDURE IN ORDER TO AVOID REFRIGERANT GAS LEAKAGE.

11. Disconnect the charging hose from the vacuum pump and from the service port of the 3-way valve.

12. Tighten the service port caps of the 3-way valve at a torque of 18 N•m with a torque wrench.

13. Remove the valve caps of both of the 2-way valve and 3-way valve. Position both of the valves to “OPEN” using a hexagonal wrench (4 mm).

14. Mount valve caps onto the 2-way valve and the 3-way valve.

  * Be sure to check whole system for gas leakage.
  * If gauge needle does not move from 0 cmHg (0 MPa) to –76 cmHg (–0.1 MPa), in step 3 above take the following measure:
  * If the leak stops when the piping connections are tightened further, continue working from step 3.
  * If the leak does not stop when the connections are retightened, repair location of leak.
  * Do not release refrigerant during piping work for installation and reinstallation.
  * Take care of the liquid refrigerant, it may cause frostbite.

5. CONNECT THE CABLE TO THE OUTDOOR UNIT
6. . Remove the control board cover from the unit by loosening the screw.
7. Connection cable between indoor unit and outdoor unit shall be approved polychloroprene sheathed 4 x 1.5 mm2 (3/4 ~ 1.75HP) or 4 x 2.5 mm2 (2.0 ~ 2.5HP) fl exible cord, type designation 60245 IEC 57 or heavier cord. Do not use joint connection cable. Replace the wire if the existing wire (from concealed wiring, or otherwise) is too short.
8. Secure the cable onto the control board with the holder (clamper).
9. Attach the control board cover back to the original position with screw.
10. For wire stripping and connection requirement, refer to instruction 5 of indoor unit. Earth wire shall be Yellow/Green (Y/G) in colour and longer than other AC wires for safety reason.
11. PIPING INSULATION
12. Please carry out insulation at pipe connection portion as mentioned in Indoor/Outdoor Unit Installation Diagram. Please wrap the insulated piping end to prevent water from going inside the piping.
13. If drain hose or connecting piping is in the room (where dew may form), please increase the insulation by using POLY-E FOAM with thickness 6 mm or above

DISPOSAL OF OUTDOOR UNIT DRAIN WATER

• If a drain elbow is used, the unit should be placed on a stand which is taller than 3 cm.
• If the unit is used in an area where temperature falls below 0°C for 2 or 3 days in succession, it is recommended not to use a drain elbow, for the drain water freezes and the fan will not rotate

ACXF60-03890
PRINTED IN MALAYSIA

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