HEAT CONTROLLER, INC.
Wall Mounted Multi-Zone Split System Air Conditioner Installation Manual TABLE OF CONTENTS Installation Requirements Required Tools Installation Parts Provided .........................................3 ❏ Level gauge Safety Precautions ......................................................4 ❏ Screw driver ❏ Electric drill Installation of Indoor, Outdoor Unit...........................7 Select the best location ...........................................7 Seaside Applications and Installation.........
Installation Parts Provided Installation Parts Provided Standard Type Installation plate Type "A" screws and plastic anchors Remote Control Holder Type "B" screws 18/24K BTU/h Air Intake (side, rear) more than 30 cm (11.8 inch) more than 30 cm (11.8 inch) Control cover Connecting wire Connection pipe Drain hose more than 70 cm (27.6 inch) more than 60 cm (23.6 inch) Air Outlet 36K BTU/h Air Intake (side, rear) more than 30 cm (11.8 inch) more than 30 cm (11.
Safety Precautions Safety Precautions To prevent injury to the user or other people and property damage, the following instructions must be followed. ■ Incorrect operation due to ignoring instructions will cause harm or damage. The seriousness is classified by the following indications. WARNING This symbol indicates the possibility of death or serious injury. CAUTION This symbol indicates the possibility of injury or damage. ■ Meanings of symbols used in this manual are as shown below.
Safety Precautions Do not modify or extend the power cable. • There is risk of fire or electric shock. Do not install the product on a defective installation stand. • It may cause injury, accident, or damage to the product. Be cautious when unpacking and installing the product. For installation, always contact the dealer or an Authorized Service Center. • Sharp edges could cause • There is risk of fire, electric injury. Be especially careful of shock, explosion, or injury.
Safety Precautions ■ Operation Do not store or use flammable gas or combustibles near the product. • There is risk of fire or failure of product. Gasolin CAUTION ■ Installation Always check for gas (refrigerant) leakage after installation or repair of product. • Low refrigerant levels may cause failure of product. Install the drain hose to ensure that water is drained away properly. • A bad connection may cause water leakage. Keep level even when installing the product.
Installation of Indoor, Outdoor Unit Installation of Indoor, Outdoor Unit Read completely, then follow step by step. Select the best location Indoor unit 1. Does not have any heat or steam near the unit. 2. Select a place where there are no obstacles in front of the unit. 3. Make sure that condensation drainage can be conveniently routed away. 4. Do not install near a doorway. 5.
Installation of Indoor, Outdoor Unit Seaside Applications and Installation 1. Air conditioners should not be installed in areas where corrosive gases, such as acid or alkaline gas, are produced. 2. Do not install the product where it could be exposed to sea wind (salty wind) directly. It can result in corrosion to the product. Particularly on the condenser and evaporator fins, could cause product malfunction or inefficient performance. 3.
Installation of Indoor, Outdoor Unit Piping length and elevation Multi-Zone Piping Recommendations: Max Elevation Max elevation between each between indoor indoor unit and units (h2) outdoor unit (h1) 7.5 m (25 ft) 7.5 m (25 ft) Capacity Max total length of all pipes (A+B/A+B+C) Max length of each pipe (A/B/C) Min length of each pipe (A/B/C) 18K BTU/h 30 m (100 ft) 15 m (50 ft) 3 m (10 ft) 24K BTU/h 30 m (100 ft) 15 m (50 ft) 3 m (10 ft) 7.5 m (25 ft) 7.
Installation of Indoor, Outdoor Unit Mounting Installation Plate The wall you select should be strong and solid enough to prevent vibration 1. Mount the installation plate on the wall with type "A" screws. If mounting the unit on a concrete wall, use anchor bolts. • Mount the installation plate horizontally by aligning the centerline using a level. Installation Plate Chassis Hook Type "A" screw 2. Measure the wall and mark the centerline.
Flaring Work and Connection of Piping Flaring Work and Connection of Piping Flaring work Main cause for gas leakage is due to defect in flaring work. Carry out the correct flaring work by using the following procedures. Cut the pipes 1. Use the piping kit accessory or the pipes purchased locally. 2. Measure the distance between the indoor and the outdoor unit. Copper pipe Slanted Uneven Rough 90° 3. Cut the pipes a little longer than measured distance. 4. Cut the cable 1.5 m (5.
Flaring Work and Connection of Piping Check 1. Compare the flared work with the figure on the right. Smooth all round Inside is shiny without scratches 2. If a flared section is defective, cut it off and repeat the flaring process again. = Improper flaring = Even length all round Inclined Surface Cracked Uneven damaged thickness Connecting the Piping Indoor 1. Prepare the indoor unit's piping and drain hose for installation through the wall. 2.
Flaring Work and Connection of Piping 4. Indoor unit installation Hook the indoor unit onto the upper portion of the installation plate.(Engage the two hooks of the rear top of the indoor unit with the upper edge of the installation plate.) Ensure that the hooks are properly seated on the installation plate by moving it left and right. Connecting cable Drain hose Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots(clicking sound).
Flaring Work and Connection of Piping For left rear piping 1. Route the indoor tubing and the drain hose to the required piping hole position. Connecting cable 2. Insert the piping, drain hose, and the connecting cable into the piping hole. 3. Insert the connecting cable into the indoor unit. • Don't connect the cable to the indoor unit. • Make a small loop with the cable for easy connection later. Drain pipe 4. Tape the drain hose and the connecting cables. 5.
Flaring Work and Connection of Piping Wrap the insulation material around the connecting portion. 1. Overlap the connection pipe insulation and the indoor unit pipe heat insulation material. Bind them together with vinyl tape so that there is no gap. 2. Wrap the area which accommodates the rear piping housing section with vinyl tape. Plastic bands Insulation material Indoor unit piping Connection pipe Vinyl tape (wide) Wrap with vinyl tape Pipe Vinyl tape(narrow) Connecting cable 3.
Flaring Work and Connection of Piping Installation Information. For left piping. Follow the instruction below. Best Practice • Press on the upper side of clamp and unfold the tubing to slowly downward. Worst Practice • Bending the pipe from right to left may cause damage to the tubing.
Flaring Work and Connection of Piping Outdoor Align the center of the piping and sufficiently tighten the flare nut by hand. Finally, tighten the flare nut with a torque wrench until the wrench clicks. Outdoor unit 18/24K BTU/h • When tightening the flare nut with the torque wrench, ensure the direction for tightening follows the arrow on the wrench. Outside diameter mm inch Ø6.35 1/4 Ø9.52 3/8 A-UNIT Gas side piping Torque kgf.m (lbf-ft) 1.8 ~ 2.5 (13) 3.4 ~ 4.
Connecting the Cable between Indoor Unit and Outdoor Unit Connecting the Cable between Indoor Unit and Outdoor Unit Connect the cable to the Indoor unit Connect the cable to the indoor unit by connecting the wires to the terminals on the control board individually according to the outdoor unit connection. (Ensure that the color of the wires of the outdoor unit and the terminal No. are the same as those of the indoor unit.) The ground wire should be longer than the common wires.
Connecting the Cable between Indoor Unit and Outdoor Unit Connect the cable to the Outdoor unit 1. Remove the control cover from the unit by loosening the screws. Connect the wires to the terminals on the control board individually per the following. Outdoor unit Terminal block Over 5 mm (0.2 inch) Holder for power supply cord 2. Secure the cable onto the control board with the holder (clamper). 3. Re-attach the control cover to the original position using the screws.
Connecting the Cable between Indoor Unit and Outdoor Unit Methods of connecting the cable (1) Remove two-caps on the conduit panel. (for low voltage line) (2) Pull the connection cable through conduit. (3) After conduit is through the panel, secure the nut on the opposite side of panel. (4) Pass the connection cable through the hole. (5) Properly connect the cable onto the terminal block.
Connecting the Cable between Indoor Unit and Outdoor Unit CAUTION: Provide a circuit breaker between power source and the unit as shown below. Main power source Model Air Conditioner Circuit Breaker Use a circuit breaker or time delay fuse. Power source Fuse or breaker Capacity 18K BTU/h 1Ø, 230 / 208V 24K BTU/h 1Ø, 230 / 208V 36K BTU/h 1Ø, 230 / 208V 20 A 25 A 40 A Connect the cable to the indoor unit 1.
Checking the Drainage, Insulating the Pipe and Special Piping Applications Checking the Drainage, Insulating the Pipe and Special Piping Applications Checking the drainage To check the drainage. 1. Pour a glass of water into the evaporator. 2. Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out through the drain exit. Drain piping 1. The drain hose should point downward for optimum drainage. Downward slope 2.
Checking the Drainage, Insulating the Pipe and Special Piping Applications Insulating the Pipe and Special Piping Applications Insulate the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tape. • If you want to connect an additional drain hose, the end of the drain outlet should be routed above the ground. Secure the drain hose appropriately. Seal a small opening around the pipings with gum type sealant.
Air Purging and Evacuation Air Purging and Evacuation Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. 1. Pressure in the system rises. 2. Operating current rises. 3. Cooling(or heating) efficiency drops. 4. Moisture in the refrigerant circuit may freeze and block capillary tubing. 5. Water may lead to corrosion of parts in the refrigeration system.
Air Purging and Evacuation Evacuation 1. Connect the charge hose end described in the preceding steps to the vacuum pump to evacuate the tubing and indoor unit. Confirm the "Lo" knob of the manifold valve is open. Then, run the vacuum pump. The operation time for evacuation varies with tubing length and capacity of the pump. Indoor unit [Each Room] The vacuum pump must be operated less than 0.8torr (0.015 psi) of the gage pressure. Outdoor unit 2.
Charging Charging ■ Each outdoor unit is factory charged (see rating plate) for the evaporator as well as a 7.5 m (25 ft) line set for each indoor line. Any time total line set is used either shorter or longer then the nominal, which is for Single Zone = 7.5m, Dual Zone = 15m, and Tri-Zone = 22.5 (Single Zone = 25ft, Dual Zone = 50ft, and Tri Zone = 75 ft), the line set length the refrigerant charge has to be adjusted.
Test Running Test Running 1. Check that all tubing and wiring have been properly connected. 2. Check that the gas and liquid side service valves are fully open. Prepare remote control Remove the battery cover by pulling it according to the arrow direction. Insert new batteries making sure that the (+) and (–) of battery are installed correctly. Reattach the cover by pushing it back into position. Bolt : • Use 2 AAA(1.5volt) batteries. Do not use rechargeable batteries.
Specifications and performance data subject to change without notice. 03-18-08 P/No.