2023 Breeze_ODU_IOM Heat Pump Air Conditioner Instruction Manual

2023 Breeze_ODU_IOM Heat Pump Air Conditioner

Specifications

• Model: Heat Pump Air Conditioner
• Cooling Operation Temperature Range: 5°F (-15°C) to 122°F (50°C)
• Heating Operation Temperature Range: -13°F (-25°C) to 75°F (24°C)
• Refrigerant: R410A
• Piping Requirements:
  • Gas Pipe Diameter: 5/8 in. (15.88 mm)
  • Liquid Pipe Diameter: 3/8 in. (9.52 mm)

FAQs

• Q: What should I do if I encounter freezing issues with the drainage elbow in cold climates?
  • A: In cold climate applications, avoid using the drainage elbow. If necessary, consider using field-supplied insulation to prevent freezing which may lead to fan operation stoppage.
• Q: What type of material should be used for brazing the refrigerant piping?
  • A: The refrigerant piping should be brazed with a phosphorous-copper alloy material such as Silfos-5 or an equivalent.

PRODUCT INTRODUCTION

• Thank you very much for purchasing this Heat Pump Air Conditioner Please read this use and installation instructions carefully before installing and using this appliance and keep this manual for future reference.

WARNING

• This product can expose you to chemicals that are known to the State of California to cause cancer, birth defects, or other reproductive harm.
• For more information go to www.P65Warnings.ca.gov.

NOTE:

• This air conditioner has been designed for the following temperatures. Operate the heat pump air conditioner within this range.

• Storage condition: Temperature -13~140°F (-25~60°C) Humidity 30%~80%

Safety Precautions

1. This Heat Pump Air Conditioner uses refrigerant HFC (R410A).
2. Since the max working pressure is 550 psig, some of the piping, installation, and service tools are specialized.
3. This air conditioner uses a power supply: of 208/230V ~, 60Hz.
4. The outdoor unit must be installed with an indoor coil equipped with TXV and ensure that the TXV can be opened to the maximum angle while running heating mode.
5. The outdoor unit must be matched with the indoor unit refrigerant R410A.
6. For the 2-ton outdoor unit, it must be connected to a 2-ton indoor unit.
   • For the 3-ton outdoor unit, it can be connected with a 3-ton indoor unit.
   • For the 4-ton outdoor unit, it can be connected with a 4-ton indoor unit.
   • For the 5-ton outdoor unit, it can be connected with a 5-ton indoor unit.
7. A filter drier is required on the liquid pipe when connecting the units, installation close to the indoor coil is recommended for best performance.
8. Be sure that servicing equipment and replacement components are applicable for R410A refrigerant.
9. Do not discharge R410A refrigerant into the atmosphere. When recovering, the cylinder service pressure rating must be over 550 psig. R410A refrigerant systems should be charged with liquid refrigerant and the service pressure rating of the hoses used must be over 750 psig.
10. Leak detectors should be designed to detect HFC refrigerant.
11. R410A refrigerant is only compatible with POE oils, which absorb moisture rapidly and are not exposed to the air.
12. Replace all the filter driers after maintenance to ensure the system is moisture-free
    • Please read these SAFETY PRECAUTIONS carefully to ensure the correct installation
    • Be sure to use a dedicated power circuit. Do not put other loads on the power supply.
    • Be sure to read these SAFETY PRECAUTIONS carefully before installation.
    • Be sure to comply with the SAFETY PRECAUTIONS of the installation manual.
    • Definitions for identifying hazard levels are provided below with their respective safety symbol.
    • WARNING: Hazards or unsafe practices may result in severe personal injury or death.
    • CAUTION: Hazards or unsafe practices that may result in minor personal injury, product, or property damage.
    • Please carefully file indoor and outdoor unit manuals away for future reference.

WARNING

• Installation should be performed by a qualified licensed service provider.
• Improper Installation may cause water leakage, electrical shock, or fire.
• Install the equipment on a solid base that can support the unit weight.
• An inadequate base or incomplete installation may cause injury if the unit falls off the base.
• Use the specified type of wire to safely make electrical connections between the indoor and outdoor units. Firmly clamp the interconnecting wires so their terminals receive no external stresses.
• For wiring, use a cable long enough to cover the entire distance with no splicing. Do not connect multiple devices to the same AC power supply.
• Exceeding the allowable current due to improper torque of contacts or poor insulation may cause fire or electric shock.
• After all installation steps are completed, check to make sure that there are no refrigerant leaks.
• Refrigerant gas leakage in interior spaces will create harmful substances when exposed to heat or flame.
• Perform the installation securely by referring to the installation manual.
• Incomplete installation may cause personal injury due to fire, electric shock, equipment falling, or water leakage.
• Per the installation instructions for electrical work, please be sure to use a dedicated line.
• If the power supply circuit capacity or electrical work is not in place, it may cause a fire or electric shock. Secure electrical cover to the indoor unit and service panel to the outdoor unit.
• Failing to properly secure the electrical cover or service panel may result in fire or electric shock.
• Shut off the main power supply before the installation of indoor electronic PCB or wiring.
• Not doing so may cause an electric shock.
• Installation wiring shall be by the state/municipal code requirements.
• Carefully select the outdoor unit installation location to avoid contact with people and pets with the electrical components.
• When installing or relocating equipment, make sure that no substance other than the specified refrigerant (R410A) enters the refrigerant circuit. (Install filter drier on the liquid line at AHU)
• The presence of foreign substances such as air can cause abnormal pressure rise, malfunction, or an explosion.
• Perform proper grounding to NEC requirements.
• Do not connect the earth wire to a gas pipe, water pipe, lightning rod, or telephone earth wire.
• Defective grounding may cause electric shock.
• Do not install the equipment in a location where there is potential for a flammable gas leak.
• Flammable gas leaks in the area surrounding the equipment may cause an explosion.
• Install an earth leakage breaker depending on the installation location.
• Failing to use earth leakage breakers in a humid environment may cause electric shock.
• Perform drainage/piping work securely according to the installation manual.

Safety instructions CAUTION

• Do not let air enter the refrigeration system or discharge refrigerant when moving the air conditioner.
• Children should be supervised to ensure that they do not play with the appliance.
• The appliance shall be installed per national wiring regulations.
• Service shall only be performed as recommended by the equipment manufacturer.
• The maintenance and repair must be done by qualified personnel.
• Means for disconnection, such as a circuit breaker, which can provide full disconnection in all poles, must be incorporated in the fixed wiring per the wiring rules.
• It is required to allow the disconnection of the appliance from the supply after installation.
• Ensure the disconnection means can be locked out to protect personnel servicing.
• The power supply connection to the appliance and interconnection between units/components shall be performed according to wiring diagrams and instructions in the product documentation.
• Details of the type and rating of circuit breakers / ELB are detailed in this manual.
• Dimensions and space requirements are detailed in this manual.
• Instructions on additional charging of refrigerants are detailed below.

Diagram of refrigerant cycle & Wiring

Refrigerant flow diagram

Electrical wiring diagram – Example: Matched AHU+ODU

Note: The SI (signal) wire between the indoor and outdoor units is not applicable when the outdoor unit is connected to an indoor unit of a different brand. In a matched system, SI (signal) enables more energy savings when the outdoor unit is connected to an indoor unit of the same brand. SI (signal) is not required in non-matched configurations.

Installation instructions

Transportation and handling before installation

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

Handling Method
When handling the unit, ensure the unit is balanced, check that the connection is secure, and then lift smoothly.

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

Handling

• Make sure the product is protected by package, cloth, or similar when it is being moved.

Installation locations selection

• Before choosing the installation site, obtain the user’s approval.
• Where it is not exposed to direct wind gusts.
• Where adequate airflow is possible.
• Where it is not exposed to rain and direct sunshine.
• Where neighbors are not disturbed 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 10ft (3m) away from the antenna of the TV set or radio To limit EMF exposure.
• Install the unit horizontally.
• Please install it in an area that is prone to snow above anticipated snow depth.

CAUTION

• Avoid the following places for installation as the lifecycle of the product can be deteriorated.
• Where there is machine/fryer oil.
• Salt corrosive locations- Increased maintenance must be done.
• Where corrosive gases may be present
• Where there is high-frequency or wireless equipment.

NOTE:

• When operating the air conditioner in low outside temperatures, be sure to follow the instructions described below.
• Never install the outdoor unit in a location where the air inlet/outlet side may be exposed directly to the wind.
• To prevent exposure to wind, install the outdoor unit with the air inlet side facing the wall.
• To prevent exposure to wind, it is recommended to install a (Field supplied) wind baffle on the air outlet side of the outdoor unit.

Drainage elbow and condensate drain hose installation

• Install drainage elbow and condensate drain hose
  • Condensate may drain from the outdoor unit when the unit operates in heating mode. It is recommended to install the supplied elbow to allow the installer to direct drainage away from the unit.
  • Connect the condensate drain hose [field-supplied, inside diameter: 3/5″ (15mm) ] as shown in the figure for drainage.
  • NOTE: Do not use the drainage elbow in cold climate applications. If elbow must be used, field-supplied insulation should be considered as the drain may freeze and stop the fan operation if the base pan heater cannot overcome ice build-up due to stoppage.

Outdoor unit installation

1. Use washers when mounting the unit with bolts to the foundation.
2. When fastening the outdoor unit with bolts. Reference Fig 1. for fastener hole locations.
3. Fasten the outdoor unit as shown in Fig 2.
4. Make sure to fasten the outdoor unit tight and horizontally to ensure the unit operates correctly.
5. Make sure the condensate drain is routed away to ensure safe and reliable operation.
6. Use a robust base for the equipment (made of concrete, etc.) The equipment should be installed no less than 4″ (10 cm) above grade level, to ensure proper drainage and operation. Failing to meet the installation requirements may reduce the equipment life cycle. (Fig.3)

Refrigerant piping

1. Piping requirement
   Model| Outer Diameter of Pipe [ in. (mm)]
   ---|---
   Gas| Liquid
   24k| 5/8 (15.88)| 3/8 (9.52)
   36k| 3/4 (19.05)| 3/8 (9.52)
   48k/60k| 7/8 (22.22)| 3/8 (9.52)
   • The shorter the refrigerant piping is, the better the performance will be.
   • Refrigerant additional charge
   • The outdoor unit is pre-charged with refrigerant to accommodate a total piping length of 25ft (7.6m).
   • Additional refrigerant (R410A) is required for extending the piping beyond 25ft (7.6m).
   • 24K/36K: Additional refrigerant charge= (L-25) ft ×0.38 oz/ft
   • 48K/60K: Additional refrigerant charge= (L-25) ft ×0.60 oz/ft
2. Piping material
3. Use local supplied copper piping
4. Use clean copper pipes. Make sure that there is no dust and moisture inside the pipes. Blow the inside of the pipes with nitrogen or dry air to remove any dust or foreign material before connecting pipes.
5. Piping thickness and material of the pipe are shown below.
   Diameter [in. (mm)]| Thickness [in. (mm)]
   ---|---
   Ø 1/4 (6.35)| 1/32 (0.8)
   Ø 3/8 (9.52)| 1/32 (0.8)
   Ø 1/2 (12.70)| 1/32 (0.8)
   Ø 5/8 (15.88)| 1/32 (1.0)
   Ø 3/4 (19.05)| 1/32 (1.0)
   Ø 7/8 (22.22)| 1/32 (1.0)

  *         *  **CAUTION**

3. Refrigerant piping work
4. Pipe cutting-

  * Cut the copper pipe correctly with a pipe cutter.
2. Burrs removal-
  * Completely remove all burrs from the cut cross-section of the pipe.
  * Position the end of the copper pipe downward to prevent burrs from dropping into the pipe.

4. Piping connection
5. 1. Confirm that the valves are closed.
6. Connect the indoor unit and the outdoor unit with field-supplied refrigerant pipes. The refrigerant piping should be brazed with a phosphorous-copper alloy material such as Silfos-5 or equivalent.

    *  **Precautions and steps during brazing service valve:**
      *  **a.** Remove the caps from both the liquid and gas service valve service ports at the outdoor unit.
      *  **b.** Braze the liquid piping and gas piping to the respective valve at the outdoor unit. Before brazing, wrap a wet cloth around each service valve to prevent heat damage while brazing. A fire plate or divider can be used to protect painted surfaces and insulation while brazing.
      *  **c.** Cool joints and other heat-sensitive components with a wet rag during brazing.
  3. After connecting the refrigerant pipes, insulate the pipes according to local codes and temperature/humidity conditions. See also detailed figure.
    * For the outdoor unit side, insulate all piping including valves.
    * Cover piping joints with pipe cover.
    * Using piping tape, apply taping starting from the entry of the outdoor unit.
      * Secure the end of the piping tape with adhesive tape.
      * When piping has to be routed above the ceiling, closet, or area where temperature and humidity are high, apply additional insulation for prevention of condensation.

5. Airtight test
   • Use Nitrogen only.
   • Using a charging hose, connect the gauge manifold at the 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 550 psig (3.8 MPa).
   • Check for any gas leaks at the flare nut connections, or brazed parts utilizing a gas leak detector or foaming agent.
   • In addition, observe the gas pressure during the leak test to make sure that it does not decrease.
   • After the air tight test, release nitrogen gas.
6. Vacuum evacuation and charging
   • Remove the service cap from the stop valve on the gas pipe side of the outdoor unit.
   • Connect the manifold gauge vacuum pump and micron gauge to the service port of the stop valve on the gas pipe side of the outdoor unit.
   • Run the vacuum at a minimum of 15-30 minutes with a Micron of lower than 500.
   • Check the vacuum with a micron gauge. To ensure a tight/dry system.
   • Isolate the vacuum and perform a rise test, to verify that microns do not rise to unsafe levels.
   • After successfully performing evacuation procedures, fully open all stop valves on both sides of the gas pipe and liquid pipe.
   • If necessary: Adjust the charge in the liquid state based on calculation.
   • Secure the cap to the service port.
   • Perform a bubble leak test or utilize a digital leak detector.

CAUTION

• Incorrect refrigerant charge (over or under-charging) is the main cause of service issues. Charge with the correct quantity according to the installation manual.
• Thoroughly check for refrigerant leaks. If a large leak is found, follow procedures to fix and recharge the system.
• The unit is pre-charged with refrigerant at the factory.
• See “Piping Requirement” to calculate the additional charge.
• After the vacuum pump procedure has been finished, first exhaust air from the charge hose, then open valves, and charge refrigerant as “liquid” through the Liquid stop valve.
• When finished, it is recommended to document the charge amount on the manual, as well as on the unit.

Wiring

WARNING

• Follow safe procedures to shut off the breaker of the outdoor/indoor unit before performing any electrical work. For the outdoor unit please allow 3 minutes before working on the electrical, as the inverter board capacitor must discharge. (Risk of personal injury can occur if not followed)
• Make sure that the indoor and outdoor fans have stopped completely before performing electrical work or reaching into the equipment.
• Protect the wires, electrical parts, etc. from small animals as well as lizards and ants. If not protected, damage to the electrical system or fire could occur.
• Prevent the wiring from touching refrigerant pipes, plate edges, and electrical parts inside the unit.
• Install an ELB (Electric Leakage Breaker) at the power source. If ELB is not used, it can cause electric shock or fire.
• This unit utilizes an inverter, which means that protections must be made to ensure harmonics in the electrical system are maintained, as well it is recommended that a surge protector be installed inline to protect the electrical components.
• The use of temporary connection wires, stranded wires, extension cables, or control line connections, is prohibited. The use of such connections may cause electric shock or fire.
• The tightening torque of each screw shall be as followed.
  • M4: 0.7 to 1.0 ft. lb (1.0 to 1.3 N·m)
  • M5: 1.5 to 1.8 ft. lb (2.0 to 2.5 N·m)
  • M6: 3.0 to 3.7 ft. lb (4.0 to 5.0 N·m)
  • M8: 6.6 to 8.1 ft. lb (9.0 to 11.0 N·m)
  • M10: 13.3 to 217 ft. lb (18.0 to 23.0 N·m)
• Proper torquing of fasteners ensures not only safe and reliable operation but also lower risk of ARC or fire.

CAUTION General check

• 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 and that they all comply with the National Electrical Code (NEC).
• Ensure that the voltage of the power supply is within +10% of the nominal voltage and earth/ground wire is connected to to that power supply. Failing to do so will damage electrical components.
• Ensure that the power supply is adequately sized. Failure to properly size the power supply may cause compressor malfunction or failure.
• Ensure that the earth/ground wire is connected.
• Install a mains switch. Multi-pole mains switch with a space of 0.14 in. (3.5mm) or more, single phase main switch with a space of 0.12 in. (3.0mm) or more between each phase.
• Ensure that the electrical resistance is more than 2 MΩ, by measuring the resistance between the ground and the terminal of the electrical parts. If not, do not operate the system until the electrical leakage is found and repaired.

Wire connection steps: 24K/36K

• Electric box cover removal- Unscrew the mounting screws to remove the electric box cover.

• Fasten the power supply cable and the transmission cable to the conduit holder using a lock nut.

• Connect the power supply cable and the transmission cable to the terminal.

• Fasten the power supply cable and the transmission cable with the cable clamp.

• Seal holes and gaps using putty.

• Place cables side by side. (Do not overlap the cables.)

• Re-install the electric box cover back after completion of the work. 48K/60K

• Electric box cover removal- Unscrew the mounting screws, valve box, and maintenance panel to remove the electric box cover.

• Fasten the power supply cable and the transmission cable to the conduit holder using a lock nut.

• Connect the power supply cable and the transmission cable to the terminal.

• Fasten the power supply cable and the transmission cable with the cable clamp.

• Seal holes and gaps using putty.

• Place cables side by side. (Do not overlap the cables.)

• Re-install the electric box cover back after completion of the work.

Electrical Data

Model (Capacity)| Power Supply| ELB (Electrical Leakage Breaker)| Power Source Cable Size| Transmitting Cable Size
---|---|---|---|---
Rated Current (A)| Nominal Sensitive Current (mA)
24k| 208/230V-/60Hz| 25| 30| See NEC| 5x18AWG
36k| 208/230V-/60Hz| 35| 30| See NEC| 5x18AWG
48k/60k| 208/230V-/60Hz| 50| 30| See NEC| 5x18AWG

Max. Running Current (A): REFER TO NAMEPLATE

Note：

• Follow local codes/regulations when selecting wire. All of the above are minimum wire sizes.
• Transmission (SI) cable length is longer than 262ft. (80m), a larger wire size should be selected.
• Install the main switch and ELB for each system separately. Select the high response type ELB that is activated within 0.1 seconds. Recommended capacity to see outdoor equipment switch capacity.

Test run

The test run should be performed after refrigerant piping, drain, wiring, etc. have been finished.

CAUTION

• This heat pump air conditioner comes equipped with a crankcase heater. Ensure that the main power supply has been turned ON for more than 6 hours ahead of power on, doing so will ensure compressor oil is fluid.
• Failure to do so may cause damage to the compressor.
• Do not operate the system until all the checkpoints have been cleared.
• Ensure that the stop valves of the outdoor unit are fully opened.
• Ensure that all wires have been fully connected and torqued.
• Ensure that the electrical resistance is more than 2MΩ by measuring the resistance between the ground and the terminal of the electrical parts. If not, do not operate the system until the electrical leakage is found and repaired.

Test run function identification

• Operate the thermostat to turn ON the equipment, then proceed test run.
• Pay attention to the following items while the system is running.
• Do not touch any of the parts by hand at the discharge gas side. The compressor body and pipes at the discharge side will reach temperatures over 194°F (90°C).
• Turn off the power after the test run is finished. Installation of the equipment is complete after concluding the test run. For additional information, contact the
• local technical service center for further information.

References

• P65Warnings.ca.gov

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