HITACHI RAC-DJ60PHAT Split Unit Air Conditioner Outdoor Unit Instruction Manual

HITACHI RAC-DJ60PHAT Split Unit Air Conditioner Outdoor Unit

Product Information

Specifications :

• Product: Split Unit Air Conditioner Outdoor Unit
  RAC-DJ60PHAT

• Refrigerant: R32

• Tools Required for Installation:

  • Knife
  • Saw
  • Pipe Cutter
  • Hexagonal Wrench Key (4mm)
  • Vacuum Pump
  • Pliers or Wrench
  • Torque Wrench
  • Vacuum Pump Adaptor
  • Flare Tool
  • Gas Leakage Detector
  • Manifold Valve
  • Charge Hose
  • Reamer
  • File

Product Usage Instructions

• Installation Precautions:
  Before starting the installation work, carefully read through the procedures outlined in the installation manual. It is recommended that a qualified technician or sales agent performs the installation to avoid potential hazards.

• Proper Installation Guidelines:
  Ensure that a proper mechanical connection is made before opening the valves to allow refrigerant flow. Use the specified tools and components for installation to prevent issues like gas leakage, electric shock, or fire.

• Electrical Installation:
  Observe electrical installation rules and regulations, using approved power cables. Tighten connections properly to avoid overheating and fire hazards.

• Refrigerant Handling:
  Only use specified refrigerant (R32) during installation or removal of the air conditioner. Prevent air or moisture from entering the refrigeration cycle to avoid abnormal pressure levels.

• Ventilation and Safety:
  In case of refrigerant gas leaks, ensure proper ventilation. Be cautious as refrigerants may produce poisonous gases when in contact with fire.

Frequently Asked Questions (FAQ)

• Q: Can I install the unit myself?
  A: It is recommended to have a qualified technician or sales agent install the unit to prevent potential hazards like water leakage, short circuits, or fire.

• Q: What refrigerant should be used during installation?
  A: Only specified refrigerant (R32) should be used. Avoid allowing air or moisture to remain in the refrigeration cycle to prevent pressure abnormalities.

• Q: What precautions should be taken during electrical installation?
  A: Follow the rules and regulations of electrical installation, using approved power cables. Ensure tight connections to prevent overheating and fire risks.

INSTALLATION MANUAL

SPLIT UNIT AIR CONDITIONER
OUTDOOR UNIT
RAC-DJ60PHAT
EN INSTRUCTION MANUAL
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.

WARNING

• Flare nut must use a torque wrench without fail. Tighten with the specified tightening torque. If the fl are nut is tightened too much, after a long period of time, the fl are nut breaks, Gas leakage, stagnation, touching fi re, rarely cause ignition.
• Sharp bending of the pipe use the polyethylene rod, bend not crushed the pipe. Gas leakage from the crushed part, stagnation, touching fi re, rarely cause ignition.
• Please request your sales agent or qualified technician to install your unit. Water leakage, short circuit or fi re may occur if you do the installation work yourself.
• Please observe the instructions stated in the installation manual during the process of installation. Improper installation may cause water leakage, electric shock and fi re.
• A brazed, welded, or mechanical connection shall be made before opening the valves to permit refrigerant to fl ow between the refrigerating system parts. A vacuum valve shall be provided to evacuate the interconnecting pipe and/or any uncharged refrigerating system part.
• Mechanical connectors used indoors shall comply with ISO 14903. When mechanical connectors are reused indoors, sealing parts shall be renewed. When flared joints are reused indoors, the fl are part shall be re-fabricated.
• Refrigerant tubing shall be protected or enclosed to avoid damage.
• 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 power cables approved by the authorities of your country.
• Be sure to use the specified wire 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. Improper insertion and loose contact may cause over-heating and fi re.
• Please use the specified components for installation work. Otherwise, the units may collapse or water leakage, electric shock and fi re 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 removing an air conditioner, only specified refrigerant (R32) shall be allowed, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture may be caused.
• Be sure to ventilate fully if a refrigerant gas leak while at work. If the refrigerant gas comes into contact with fi re, a poisonous gas may occur. Be aware that refrigerants may not contain an odour.
• 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 fi re 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 fi re, etc.

Refrigerant pipe size (outer diameter): Narrow pipe, Liquid (ø6.35mm); Wide pipe, Gas (ø12.70mm/ø15.88mm)

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.
• Be sure that the unit operates in proper condition after installation. Explain to customer the proper way of operating the unit as described in the user’s guide.
• Access the full version of the User Installation Manual by scanning the code.

CAUTION

• A circuit breaker or fuse must be installed. Without a circuit breaker or fuse the danger of electric shock exists. The external switch shall be incorporated to completely disconnect from power supply. It should disconnect all poles, and a contact separation of at least 3mm must be present.
• Do not install the unit near a location where there is fl ammable gas. The outdoor unit may catch fi re if fl ammable gas leaks around it.
• Do not install the indoor unit in a machine shop or kitchen where vapor from oil or its mist flows to the indoor unit. The oil will deposit on the heat exchanger, thereby reducing the indoor unit performance and may deform and in the worst case, break the plastic parts of the indoor unit.
• Please ensure smooth fl ow of water when installing the drain hose.
• Piping shall be suitable supported with a maximum spacing of 1m between the supports.

WARNING

• Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. Any unfit method or using incompatible material may cause product damage, burst and serious injury.
• The appliance/pipe-work shall be stored in a well ventilated room with indoor floor area larger than Amin [refer to Table 1] and without any continuously operating ignition source. Keep away from open flames, any operating gas appliances or any operating electric heater. Else, it may explode and cause injury or death.
• The appliance/pipe-work shall be installed, and/or operated in a room with floor area larger than Amin [refer to Table 1] and keep away from ignition sources, such as heat/spark/open flame or hazardous areas such as gas appliances, gas cooking, reticulated gas supply systems or electric cooking appliances, etc.
• Do not pierce or burn as the appliance/pipe-work is pressurized. Do not expose the appliance/pipe-work to heat, flame, sparks, or other sources of ignition. Else, it may explode and cause injury or death.

The Choice of Mounting Site (Please note the following matters and obtain permission from customer before installation).

OUTDOOR UNIT

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

CAUTION

• Do not expose the unit under direct sunshine or rain. 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 1. At least 3 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 neighbourhood.
• Do not install at a location where there is fl ammable gas, steam, oil and smoke.
• The location must be convenient for water drainage.
• Place the Outdoor unit and its connecting cord at least 1m away from the antenna or signal line of television, radio or telephone. This is to avoid noise interference.
• Do not install outdoor unit facing strong wind direction. It may damage the fan motor.
• Do not install the outdoor unit in a place where small animals may build their nests. If small animal goes inside the unit and touches the electrical parts, failure of the unit, smoke or fi re may be caused. Request your customer to keep the surrounding of the unit is clean.

Names of Outdoor Components

Figure showing the Installation of Outdoor Unit.

CAUTION

• This unit is chargeless up 30m pipe length.
• Installation of pipe length less than minimum pipe length requirement (3 meters) may generate an abnormal sound.

WARNING
This symbol shows that this equipment uses a fl ammable refrigerant.
If the refrigerant is leaked, together with an external ignition source, there is a possibility of ignition.

CAUTION
This symbol shows that the Operation Instructions should be read carefully.

CAUTION
This symbol shows that a service personnel should be handling this equipment with reference to the Installation Manual.

CAUTION
This symbol shows that there is information included in the Operation Manual and/or Installation Manual

WARNING

• BURST HAZARD
• Do not allow air, etc. to get into refrigerant cycle (piping)
• RISK OF EXPLOSION Compressor must be stopped before removing refrigerant pipes.
• All service valve must be fully closed after pumping down operation.

Table 1: Minimum Floor area of the room Amin (m2)

Outdoor Model| Max Piping Length

(m)

| Max refrigerant charge amount (g)| Minimum Floor area of the room Amin (m2)
---|---|---|---
RAK-DJ**PHAT
RAC-DJ60PHAT| 30| 1500| 2.13

Figure 1

• Please mount the Outdoor unit on 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.

CONDENSED WATER DISPOSAL OF OUTDOOR UNIT

• There are holes on the base of Outdoor unit for condensed water to exhaust.
• In order to flow condensed water to the drain, the unit is installed on a stand or a block so that the unit is 100mm above the ground as shown figure. Join the drain pipe to one hole.
• At first insert one portion of the hook to the base (Portion A), then pull the drain pipe in the direction shown by the arrow while inserting the hook into the base. After installation, check whether the drain pipe cling to the base firmly.

When Using and Installing In Cold Areas

• When the air conditioner is used in low temperature and in snowy conditions, water from the heat exchanger may freeze on the base surface to cause poor drainage. When using the air conditioner in such areas, do not install the bushings. Keep a minimum of 250mm between the drain hole and the ground. When using the drain pipe, consult your sales agent.
• For more details, refer to the installation Manual for Cold Areas.

INSTALLATION OF REFRIGERATING PIPES AND AIR REMOVAL

Preparation of Pipe

Use a pipe cutter to cut the copper pipe.

CAUTION

• 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 fl are nut.

Pipe Connection

CAUTION
In case of removing flare nut of an Indoor unit, first remove a nut of small diameter side, or a seal cap of big diameter side will fly out. Prevent water from entering into the piping when working.

| Outer dia. of pipe| Torque N·m (kgf · cm)
---|---|---
Small dia. side| 6.35 (1/4″)| 14.0| –| 18.0| (140| ~| 180)
Large dia. side| 9.52 (3/8″)| 33.0| –| 42.0| (330| ~| 420)
| 12.70 (1/2″)| 50.0| –| 62.0| (500| ~| 620)
| 15.88 (5/8″)| 63.0| –| 77.0| (630| ~| 770)
| Small dia. side| 6.35 (1/4″)| 19.6| –| 24.5| (200| ~| 250)
Valve head cap| Large dia. side| 9.52 (3/8″)
12.7 (1/2″)| 19.6

29.4

| –

–

| 24.5

34.3

| (200

(300

| ~

~

| 250)

| | 15.88 (5/8″)| 29.0| –| 31.0| (296| ~| 316)
Valve core cap| | | 12.3| –| 15.7| (125| ~| 160)

AIR REMOVAL

Removal 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 tighten the “Hi” knob of the manifold valve and completely unscrew the “Lo” knob. Run the vacuum pump for about 10~15 minutes, then completely tighten the “Lo” knob and switch off the vacuum pump.
3. Remove the charge hose and tighten the cap of valve core. Check the cap’s periphery if there is any gas leakage.
4. Completely unscrew the spindle of the service valve (at 2 places) in anti-clockwise direction to allow the fl ow of refrigerant (using Hexagonal Wrench key).
5. Re-cap the service valve and tighten using wrench. Check the cap’s periphery if there is any gas leakage. The task is then completed.

CAUTION

• Prevent moisture from entering pipe connection. Refrigerating machine oil not be applied to the outside of the flare.
• When refrigerating machine oil is applied to the outside of the fl are, excessive tightening of the fl are nut, cracking of the fl are nut, destruction of the fl are and gas leakage may occur. When using the control valve, do not use deteriorated packing. And, do not overtighten the steering wheel.
• Gas leakage from the service valve part, stagnation, touching fire, rarely cause ignition.

Gas Leakage Inspection

• Please use gas leakage detector to check if leakage occurs at the connection of Flare nut as shown on the right.
• If gas leakage occurs, further tighten the connection to stop leakage. (Be sure to use R32 detector)

CONNECTION OF POWER CORD

WARNING THIS APPLIANCE MUST BE EARTHED.

• Procedures of Wiring
• Detail of Cutting the Connecting Cord

WARNING

• The naked part of the wire core should be 10 mm and fi x 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.

Wiring of The Outdoor Unit
Please remove the side plate for wire connection.

WARNING

• 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 fi x it.
• Be sure that the hooks of the side plate is fixed in certainly. Otherwise water leakage may occur and this causes short circuit or faults.
• The connecting cord should not touch to service valve and pipes. (It becomes high temperature in heating operation.)

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 locked 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.

CAUTION
Outdoor supply cords shall not be lighter than polychloroprene sheathed flexible cord with code designation 60245 IEC 57.

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 fi re.

FINAL STAGE OF INSTALLATION

Insulation And Maintenance Of Pipe Connection

• The connected terminals should be completely sealed with heat insulator and then tied up with rubber strap.
• Please tie the pipe and power line together with vinyl tape as shown in the figure showing the installation of Indoor and Outdoor units. Then fix their position with holders.
• 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.

Power Source And Operation Test

Power Source

WARNING

• 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 fi x 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 Cool Mode(in summer) or Heat Mode(in winter).

  2. Press Temperature Button on the remote controller to set the desired temperature to 16.0°C for Cool Mode or 32.0°C for Heating 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 or warm.

  4. Press the ON/Off button on the remote controller to make sure that the air conditioner stops running.

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

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

Before the check and the reoperation, reset the power supply by turning off and on the circuit breaker only after:-

1. waiting for at least 5 minutes; or
2. 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.
• Explain to your customer the proper operation procedures as described in the user’ s manual.
• If the indoor unit won’t operate, check the cable for correct connection.
• Turn on the lamp in the room where the indoor unit is installed and check the remote controller for normal operation.

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