HITACHI RPS-90AN Split Type Air Conditioners Instruction Manual

HITACHI RPS-90AN Split Type Air Conditioners

Installation, Operation and Maintenance
INSTRUCTIONS MANUAL

HITACHI SPLIT-TYPE AIR CONDITIONERS
INVERTER DRIVEN AIR-COOLED TYPE

IMPORTANT:
READ AND UNDERSTAND THIS INSTRUCTION MANUAL BEFORE USING THIS AIR CONDITIONER. KEEP THIS MANUAL FOR FUTURE REFERENCE.

IMPORTANT NOTICE

• HITACHI pursues a policy of continuing improvement in design and performance of its products. Specification/Design are subject to change without prior notice.

• HITACHI cannot anticipate every possible circumstance that might involve a potential hazard.

• This air conditioner is designed for standard air conditioning only. Do not use for other purposes such as drying clothes, refrigerating foods or for any other cooling process.

• The installer and system specialist shall secure safety against leakage according to local Regulations or standards.

• No part of this manual may be reproduced without written permission.

• Signal words (DANGER, WARNING and CAUTION) are used to identify levels of hazard seriousness. Definitions for identifying hazard levels are provided below with their respective signal words.
  : Immediate hazards which WILL result in severe personal injury or death.
  : Hazards or unsafe practices which COULD result in severe personal injury or death.
  : Hazards or unsafe practices which COULD result in minor personal injury or product or property damage.
  NOTE : Useful information for this operation and/or maintenance.

• If you have any questions, contact your installer, dealer of HITACHI or our customer care.

• This manual gives you description and information on how to operate this air conditioning unit.

• This air conditioner has been designed from the following temperatures.

This manual should be considered as a permanent part of the air conditioning equipment and should remain with the air conditioning equipment.

Operation Instructions

Precautions on Usage

1. Please use fuse/circuit breaker with proper amperage.
   • Never use metal or copper wire as a fuse to avoid fault or occurrence of fire hazard.
2. Don’t insert any material into the air inlet and air outlet.
   • It may cause accidents and may injure and damage the units.
3. Don’t spray flammable gas toward the air conditioner.
   • It may cause fire.
4. Overloaded heat source should be reduced.
   • If there are heat sources which exceeds the air conditioning capacity in the room (room with many people entering or when using heat producing appliances), set room temperature cannot be reached.
5. Set up window curtains or window blinds.
   • It can insulate the heat source coming through the windows.
6. Doors or windows should be closed properly to prevent the cooled air to leak outside the room.
   • During cooling operation, please don’t open windows, entrances, and exits unless necessary and minimize as possible the number of persons entering or leaving the room.
7. The setting of room temperature should be suitable.
   • Adjust the temperature setting button to a suitable index to maintain the most comfortable temperature. Too high or too low temperature will cause discomfort. (A temperature difference of 5°C to 7°C between the indoor and the outdoor is appropriate)
8. When there is possibility of lightning strike.
   • When there is a possibility of lightning strike, turn the unit off to protect the air conditioner, and switch off the power switch. Make sure that the unit is provided with ground.

Wired remote controller (RC-A01ET1)

Parts inside the box (Please check)

1. Wired remote controller x1 (communication wire x1, length = 9m)
2. Accessory assembly (plug x2, screw x2, cable tie x2)

CAUTION (For safety, please obey the following items)

1. Please read the user’s manual carefully before installation, keep this manual for future reference.
2. This wired remote controller is used for room air-conditioner only and not for any other extended use.
3. Do not install at places as below:
4. the place with oil spray of sulfur gas (fire, deformation, corruption, damage will result)
5. the place near coast and the salty environment will cause corrosion.
6. the place that children can easily touch.
7. the place near heat (fire).
8. the place of high humidity.
9. Use for the place where install medical instruments with electromagnetic wave, please watch out the mal-operation of this device.
10. when installation, do not let the launching side of electromagnetic wave forward this device directly. 4.2 keep away from the source with electromagnetic wave at least 3m above. For example: radio
11. If noise signals generated by the unit, please add noise filter to countermeasure.
12. Because heat element designed inside, the surface is warm when we touch, this is a normal phenomenon.
13. Do not pull out the communication wire to avoid the poor signal transmission.

Installation and Wiring

1. Do not install at places where flammable objects and flammable gases exist, otherwise it may occur fire.
2. Never install the remote controller on an unstable base or fixed incompletely. It can fall easily and cause fire, electric shock, even injury of a person.
3. Please follow the rules by the corresponding country’s national legislation to begin the wiring process. Be sure to use the specific electric shock loop to avoid the insufficient of power volume and any fire or electric shock caused by poor or wrong installation.
4. Please contact your agent for installation, improper self-installation may cause electric shock and fire.
5. Please choose the specified wire for the connection between indoor unit and outdoor unit. If wrong specification of wire is used, it will cause electric shock.
6. Please turn off the power source before open the service cover for wiring to avoid the electric shock.

Installation of Remote Controller

1. Separate the base of the wired remote controller. Please follow the procedure:
   Use flat screwdriver to insert the groove and rotate lightly.
   Be careful, do not break the claws near the groove, if the claws are broken then wired remote controller will not easily fix on the base.

2. Installation for screws.
   Please use the screws attached in the accessory assembly, fixed by opposite angle position.

Name of each part

Main Function Introduction
NOTE ! Always press once to turn the Remote-Control LCD light ON.

SCAN ME
Scan this QR code with your mobile device to see further instructions on how to maximize the functions of your air conditioner and for other related information.

Wiring

1. Method of connecting to air-conditioner:
2. Remove the front cover and electric box cover of the Indoor unit.
3. Connect the communication wire to the PCB of the Indoor unit (connector no: CN22)
4. Re-install the electric box cover and front cover, be careful don’t clip the wire.

Abnormality

1. When abnormality occurs, there will be a display on the control panel indicating “PRESS [ON/OFF] SWITCH TO RESTART”
2. Reset Button – when errors happen (the display is interfered by noise signal and system can’t operate). Please use a small pin to insert in the hole and press 3 seconds above, under power ON status. Then it will return to its initial factory setting.

Power Failure

1. All the indications are OFF.
2. Once the unit is stop by power failure, the unit will not be started again although the power recovers. Perform the starting procedures again.
3. In case of instantaneous power failure within 2 seconds the unit will be started again automatically.

Troubleshooting

Unit does not start:

1. Is the main power source switch to the unit ON?
2. Is the main fuse normal?

Warning
Please contact your service center if the problem is still not solved. Do not try to repair the unit by yourself.

Poor cooling operation:

1. Are there any obstacles which hamper sufficient air to the indoor unit and outdoor unit coil?
2. Check the temperature setting to make sure that it is set at the desired temperature.
3. Check the air filter if it is dirty or clogged.

Maintenance

1. Clean or replace the air filter.
2. Clean the cabinet with clean dry cloth.
3. Clean the condensate drain pan and the drain piping.
4. Clean the condenser and evaporator coil. Call your serviceman to do this type of work.
5. Check for abnormal sound and vibration. If you find abnormal sound and vibration, stop the unit, and contact your service center for proper maintenance.

Warning
Switch the unit OFF before cleaning the air filter.

Preparation

Installation Location

1. Required Material – Measure, Architectural Information Regarding Installation Location.
2. Confirm that the final installation location is provided with convenient piping and wiring work.
3. Check the total piping length and difference in height between indoor and outdoor unit, it should not exceed the following:
   Maximum Piping Length| Difference in Height| Bending Quantity
   ---|---|---
   under 30m| under 20m| under 12
4. Do not install the air conditioner in place where there are flammable gases and acid solvents.
5. Do not install the air conditioner near high-frequency machines.
6. No radiation sources shall be allowed near the installation site.
7. The installation shall be duly secured for vibration and noise. Hot air released from the outdoor unit shall be led off the neighboring windows. Water drops, drainage, vibration and noise shall be kept off the neighborhood.

Installation Space

1. Check for obstacles that restricts unit air flow or hamper maintenance and service work, keep a proper space for operation.
   Operation Space for Indoor Unit

Operation Space for Outdoor Unit Individual Outdoor Unit

1. In case of existence of obstruction on top and in the back (open space at front and by the side).
2. In case of existence of obstruction in the back and by the side (open space at front and on top).
3. In case of existence of obstruction on the front (open space in the back, by the sides and on the top)
4. In case of existence of obstruction in the back and on the front (open space by the sides and on the top)
5. In case of existence of obstruction in the surrounding (open space on top)

Combined Installation

1. Horizontal
2. 2-Unit Leveled Installation
3. Sequential Installation

Foundation

1. Check to ensure that the foundation is flat leveled and sufficiently strong.
2. Confirm elevation provision for the outdoor unit on a solid base with an iron frame or concrete curbs.
3. To obtain proper clearance beneath the either rooftop or on-the-ground installation, provide a gravel or concrete space around the outdoor unit air intake. To avoid air flow obstruction due to grass or other vegetation.

Unit Check
Check to ensure that the unit has been transported without damage. File a damage claim with the transportation companies if mishandling due to transportation company negligence is suspected.

Installation

Anti-tumbler for Indoor Unit

1. Be sure to secure the air conditioner with the anti-tumbler angle iron.
2. To keep the air conditioner from tumbling, fix it on the floor and the wall.

Securing of the wall fixation angle iron

• Refer to the table below for measurement of distance between air conditioner and wall.
• For vertical measurement to the floor refer to the angle iron installation site.

Anti-tumbler for Outdoor Unit

1. Use fix bolts as shown in the figure right to secure the unit on the base.
2. Apply enhanced installation to keep off seismic movements and typhoons.
3. Use cement base. Refer to figure below.
   Remark: The securing bolts are measured from 15mm in the base.

Watch for strong wind

• In case of installation in an open space, such as on top of a tall building where the outdoor unit outlet opposes strong winds, with impacts on its rotation and cooling capacity as well, the following are suggestions for improvement.
• Keep outdoor unit face (as shown) the wall and the inlet toward outside with a gap of 60cm between the wall and the front of the outdoor unit.
• Keep outdoor unit outlet and the wind direction of the installation site in a perpendicular position.

Refrigerant and Drainage Piping

Tools and Instruments
One set of piping tools ((+) (-) screw drivers, Tape measure, Knife, Hacksaw, Hexagon spanner, Spanner (14,17,19,22,24 & 30mm opening), Hose cutter, Flared tube expander), Gas Leak Detector, R32 Refrigerant.

Piping Material

1. The used copper tubes of refrigerant (R32) unit must be updated, washing, and using repeatedly is extremely prohibited.

2. The pipe end flare mouth of flare nut connection, please refer to refrigerant (R32) piping require size to process as below.
   Piping Diameter (ØD)| Size of (ØA)| Thickness (t)
   ---|---|---
   Ø6.35 (1/4”)| Ø10.0| 0.8
   Ø9.53 (3/8”)| Ø13.2| 0.8
   Ø12.7 (1/2”)| Ø16.6| 0.8
   Ø15.88 (5/8”)| Ø19.7| 1.0

3. The unit uses environmentally refrigerant (R32), when it is in the construction, please make sure the cycle system to keep dry, clean, and airtight. Before piping connections, please use nitrogen or dry air clear the dust or impurities within the pipe.

Preparations

1. Confirm that the piping are de-oxidized seamless copper tubes, and that they are free from dirt and moisture.
2. Piping connections to the outdoor unit can be performed at the stop valves for liquid outlet and gas inlet in the machine compartment. Flare nuts are attached at liquid and gas connections of the indoor and the outdoor unit.
3. All refrigerant and drainage piping shall be duly insulated to keep off frost.

Specification of refrigerant and drainage piping

Model| Refrigerant Piping Length (1-30m)| Drainage Piping| Additional Refrigerant (30g) of each increasing 1m
---|---|---|---
Indoor Unit| Outdoor Unit| Liquid Line| Gas Line| Outer Diameter
RPS-90AN| RAC-90JP| Size : Ø 6.35mm| Size :      Ø 15.88mm| Ø 20mm| From (11~30m)
Type :  1/4 Flare Nut| Type : 5/8 Flare Nut
Quantity :     1| Quantity :         1

Confirm that the indoor unit piping direction and accessories is suitable.

Indoor unit piping direction

NOTE:
For unit operational durability, it is recommended to use a field-supplied filter dryer in the refrigeration cycle.

Refrigerant Piping

1. Check to ensure that the stop valves of outdoor unit have been closed.
2. Attach the connection pipes to the stop valves.
3. Remove the air inlet grill, filter, filter guide and lower front cover.
4. Connect the indoor and the outdoor unit with the specified refrigerant pipes.
5. Charge nitrogen or refrigerant from the check joint of the liquid stop valve, using a Gas Leak Detector perform leakage test
6. After completing the piping, the entire exposed tube adapter shall be duly covered with insulator and tightened with a band.

Tightening Flare Nut – When tightening the flare nut, utilize two spanners as shown below. The required tightening torque is as follows:

Danger
Do not charge OXYGEN, ACETYLENE or other flammable and poisonous gases into the refrigeration cycle when performing a leakage test or an airtight test. These types of gases are extremely dangerous because explosion can occur. It is recommended that compressed air, nitrogen, or refrigerant be charged for these types of tests.

Refrigerant and Drainage Piping

• A. Outdoor Unit Below
• B. Outdoor Unit Above

Field Piping Arrangement (Maximum piping length = 30m)

Drainage piping

1. The indoor drainage and the outdoor drainage shall be joined with adherent agents.
2. For assurance of normal drainage tubing operation, a water filler shall be given for a gradual adding of 1000cc of water from the right side of the air outlet to the evaporator while checking for leakage in the drainage.

Evacuation and Refrigerant Charge

Tools and Instruments
Vacuum Pump, High Pressure Compound Gauge, Low Pressure Compound Gauge, Refrigerant Cylinder with Sufficient R32A Refrigerant, Weighing Scale, Charging Hoses (Lead Pipes), Other General Piping Tools and Ratchet Wrenches.

Preparation
Confirm the required amount of refrigerant, referring to the piping instruction label. Arrange piping connection work for evacuation and refrigerant charging as shown in Figure below.

Evacuation Procedures
Fully close the stop valves of the indoor unit and release the backseat position of the liquid inlet valve.

1. Operate the vacuum pump and ensure that the refrigeration cycle is being evacuated (V1: open, V2: closed).
2. Continue the vacuum pump operation until the pressure indication of the gauge shows approximately-756mmHg.
3. Stop the vacuum pump, wait for approximately 5 minutes, and confirm the vacuum pressure has not increased.
4. Close the vacuum pump connection line (V1, V2: closed).

Refrigerant Charge

1. Purge air from the refrigerant cylinder connection line (V1, V2: closed).
2. Charge liquid refrigerant gas as required into the refrigeration cycle by weighing the refrigerant cylinder (V1: closed, V2: open).
3. Close the charging line (V1, V2: closed).
4. After all evacuation and charging work, backseat the stop valves of the indoor unit and tighten the packing glands and the cap nuts.

Notes ：

1. A gauge manifold or equivalent piping connected with a vacuum pump and a refrigerant cylinder is recommended for rapid evacuation and charging work.
2. When charging by weight is stopped due to high ambient temperature or piping arrangements, charge the gas refrigerant from the low pressure check joint while operation the entire system at the stage of initial start-up.

Electrical Wiring

Tools and Instruments
One Set of Wiring Tools, Electrical Testers (Clamp Meter)

Schedule Check
Confirm that the field-selected electrical components (main power switch, fuses, wires, conduit connections, wire terminals) are properly selected according to the table and to ensure that they comply with national and local codes. It is recommended that the main power switch be locked at the OFF position to prevent against accidental supply of the power during unit servicing.

11.9A

| ****

15A

Outdoor Unit| RAC-90JP| 1 PHASE, 230V/60Hz

Main Power Wiring Procedures

1. If the phase is wrong, exchange two of the three wires connected from the main power source to the main terminals of the unit as indicated with the dotted lines, and then check the rotation direction of the phase sequence indicator once again. Do not exchange the wires in the unit side in order to protect the compressor against the reversal rotation.
2. The power cord (LN terminal block) end of handle and docking description:
3. When use single-core wire, no need to use a round terminal.

Main Power Wiring Specification

Control Wiring
Connect the control wires between the indoor unit terminals and the outdoor unit terminals according to the following to the wiring label.

Grounding Specification

1. Grounding impedance shall be below 100.
2. Grounding wire of over Ø 2.0mm and up in diameter.

Test Running

Final Installation Check
Inspect the installation work according to all documents and drawings. Installation Work Check List shows the minimum check points.

Installation Work Check List

Preparation
Tools and Instruments – High- and Low-Pressure Compound Gauge(s), Electrical Tester, General Tools Confirm the system switch is at the OFF position.

Test Running
When the unit is wired according to the standard label, test running should be performed as follows.

1. Confirm the system switch is at OFF position.
2. Check to ensure that the electrical resistance is more than 1 mega ohm by measuring the resistance between earth and the terminal of the electric parts. If not, do not try to operate the unit until the electrical leakage is found and repaired.
3. Ensure that the stop valves of the outdoor unit are fully open, and then start the unit.
4. Check the room temperature if it is higher than 21°C DB and 15°C WB while on cooling operation.
5. Switch ON the main power source.
6. Check the operating voltage, phase balance and operating current.
7. Check to ensure that the operate panel functions properly.
8. Check to ensure that the control and protective devices functions properly (refer to Test Running and Maintenance Record).

Safety and Control Device Setting

Maintenance

The unit should be periodically inspected according to the same items as those described in the paragraph entitled “Test Running”. To ensure dependable operation and long life, the following additional items should be given particular attention.

Components (Outdoor Unit)

1. Compressor – No maintenance work is required for hermetic compressor if the refrigeration cycle remains sealed.
2. Air-Cooled Condenser – Inspect the condenser and remove any accumulated dirt from the coil at regular intervals. Other obstacles such as growing grass and pieces of paper, which might restrict air flow, should also be removed.
3. Electrical Equipment – Always pay careful attention to working voltage, amperage and phase balance. Check for faulty contact caused by loosened terminal connections, oxidized contacts, foreign matters and others.
4. Safety and Control Devices – Do not readjust the setting in the field unless the setting is maintained at a point other than the point listed in Table . (Indoor Unit)
5. Air Filter – Inspect for accumulated dirt on the filter. Change or clean the filter if required. The inspection interval may be determined by the operating conditions for each installation site.
6. Condensate Drain pan and Drain Line – Inspect and clean the condensate drain line at least twice a year.
7. Evaporator Fan – Check for loosened fixed screw and abnormal sounds.
8. Operate Panel – Check for abnormal function.

Lubrication

• Compressor – The compressors are charged at the factory with the correct quantity of oil listed on the compressor nameplates. It is unnecessary to add oil if the refrigeration cycle remains sealed.
• Fan Motor – Bearings of fan motor are pre-lubricated. Lubrication is not required.

Refrigerant Charge
When the refrigeration cycle requires recharging due to leakage or part replacement, follow the procedures given below for two cases:

1. When the refrigeration cycle completely leaked, evacuate, and recharge the cycle according to the procedures given in “Evacuation and Refrigerant Charge”.
2. When the refrigeration cycle slightly leaked, evacuation may not be required. Refrigerant addition can
   be performed by liquid charging the service joint of the unit while operating the entire system. Slowly charge refrigerant into the refrigeration cycle, checking the discharge and suction pressure.

NOTE :
Do not purge the refrigerant gas from the service joint of the liquid line stop valve to prevent the oil from draining from the refrigeration cycle.

Compressor Removal

When removing the compressor:

1. Shut off the power supply of the unit.
2. Close all the unit stop valves, gas inlet and liquid outlet valves.
3. Remove all wiring connections and piping connections to the compressor.
4. Remove refrigerant.
5. Remove the bolts fastened on the compressor base.
6. Pull out the compressor base.
7. Slightly lift the compressor and pull the compressor from the unit.

Start-Up After Extended Shutdown
After any extended period of shutdown, prepare the unit for operation as follows:

1. Thoroughly inspect and clean the unit.
2. Clean or replace the air filter.
3. Clean the condensate drain lines.
4. Remove any accumulated dirt from the condenser and evaporator coils.
5. Check the fan screw tightness.
6. Check the fan balance and try to operate the fan.
7. Inspect the refrigerant piping for leakage.
8. Tighten all wiring connections and access panels.

Replacement of Parts
Replacement of parts should be performed by ordering from the HITACHI Parts List. The Form A HITACHI Recommended Spare Parts List is advisable. When replacement of parts becomes necessary, prepare the parts shown in the Form A Parts List.

Test Running and Maintenance Record

*See the applicable range in “Working Range”.

Johnson Controls-Hitachi Air Conditioning Philippines, Inc.

• No. 1A Binictican Drive
• Subic Bay Industrial Park Phase ll
• Subic Bay Freeport Zone
• Philippines
• TEL: (02

Specifications in this manual are subject to change without prior notice, in order that HITACHI may bring the latest innovations to our customers.

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