BONAIRE B007RS User manual

Installation Manual
DUCTED REVERSE CYCLE
REFRIGERATED AIR CONDITIONING
B007RS, B009RS, B012RS, B015RS, B016RT, B019RT

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 3
Table of Contents
General ......................................................................................................................................... 4
UNIT DETAILS.................................................................................................................................5
Outdoor Unit Dimensions .............................................................................................................. 5
Outdoor Unit Access and Clearances ........................................................................................... 7
Indoor Unit Dimensions................................................................................................................. 8
Indoor Unit Clearances ................................................................................................................. 9
UNIT INSTALLATION.................................................................................................................... 10
Indoor Installation........................................................................................................................ 10
Indoor Unit Location................................................................................................................................ 11
Floor or Platform Mounting...................................................................................................................... 12
Suspension Mounting.............................................................................................................................. 12
Leveling the Unit...................................................................................................................................... 12
Outdoor Unit................................................................................................................................ 13
Condenser Installation ................................................................................................................ 14
Interconnecting Tubing................................................................................................................ 14
Installation Notes..................................................................................................................................... 15
Unit Interconnecting Tubing Table .......................................................................................................... 15
Recommendation for Interconnection Tubing Installation....................................................................... 16
Pipe Installation........................................................................................................................... 17
Flare Preparation..................................................................................................................................... 17
Pipe Welding Preparation........................................................................................................................ 17
Pipe Welding........................................................................................................................................... 18
Connecting the tubes .............................................................................................................................. 18
Evacuation and setting in operation ............................................................................................ 19
Additional Charge........................................................................................................................ 20
Drain Line Installation.................................................................................................................. 20
ELECTRICAL CONNECTIONS......................................................................................................21
Indoor Unit Connections.............................................................................................................. 21
Outdoor Unit Connections........................................................................................................... 22
Wiring Diagram - Single Phase Indoor Unit................................................................................. 22
Wiring Diagram - Single Phase Outdoor Unit.............................................................................. 23
Wiring Diagram - 3 Phase Outdoor Unit...................................................................................... 24
CONTROL INSTALLATION...........................................................................................................25
Before Starting ............................................................................................................................ 25
Installation ............................................................................................................................................... 25
Setting Up the Thermostat ...................................................................................................................... 26
Coding The Unit ...................................................................................................................................... 26
COMMISSION ................................................................................................................................27
Operating Parameters................................................................................................................. 27
Setting the Operating Parameters............................................................................................... 27
Led Operation And Interpretation................................................................................................28
Commissioning Check List.......................................................................................................... 29

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 4
General
GENERAL
Bonaire Ducted Reverse Cycle air conditioners include two separate units – Indoor and Outdoor
Unit. The two units are interconnected by two refrigerant tubes and an electric cable. Unit
functions are controlled by a Radio Frequency Remote controller or a hard wired low voltage
controller (depending on the option purchased).
WARNING
The air conditioner must be installed by authorized technicians, according to Climate Technologies
specifications and using recommended standard tubing, electric cables and proper installation
tools. Failure to comply with the above may invalidate your warranty!

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 5
Dimensions & Clearances
Unit Details
OUTDOOR UNIT DIMENSIONS
Unit Weight A B C D E
B007RS 60kg 870 860 340 Connections Inside Unit
B009RS 92kg 970 960 365 160 90
B012RS 97kg 970 960 365 160 90
B007RS
B009RS
B012RS

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
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Dimensions & Clearances
Unit Weight A B C D E
B015RS 103kg 970 1260 395 Connections Inside Unit
B016RT 108kg 970 1260 395 Connections Inside Unit
B019RT 131kg 970 1460 365 160 90
B015RS
B016RT
B019RT

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 7
Dimensions & Clearances
OUTDOOR UNIT ACCESS AND CLEARANCES
In selecting a proper location, the following criteria
must be considered:
a) The outdoor unit and the indoor unit must be
installed as close to each other as possible, within
10m. If longer tubing is required see table on
page 14 or consult your technical sales rep.
b) Outdoor unit installation should provide for:
1. Easy service access.
2. Minimum disturbance to the owner and nearby
neighbors.
3. A minimum distance of 100 mm from the wall
4. If installed in a closed place (balcony, attic, etc),
outdoor air vent must be provided to prevent
hot/cold air from recirculation through the
outdoor unit.
5. If several outdoor units are installed in the
same area, make sure that the hot air outlet
from one outdoor unit does not enter another
outdoor unit.
6. Verify that any wall on which the outdoor unit is
installed is capable of carrying the unit’s
weight. Do not install on a light unstable
structure susceptible to vibration.
7. When installing on a balcony above the first
floor, make sure that the outdoor unit location
allows easy access for removal of the top
cover and/or the entire unit, if necessary.
8. If the outdoor unit is installed in a non-
accessible location, long and flexible
refrigerant tubing and electrical cable must be
installed to allow the unit to be moved for
servicing.
9. Do not install the unit in a highly polluted area
in which the air is contaminated by oil mist, salt
or sulfuric gas.
When the top is blocked
The front and the sides must be clear for
these minimum clearances.
When the back & sides are blocked
The back and the side minimum
clearances must be achieved
When all the sides are blocked
If all sides are blocked, this will be an
unacceptable installation
Multiple Units – Lateral and Behind relationships
When the back is close to the Wall
The top and the front need to be open.
This includes protruding window sills.

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 8
Dimensions & Clearances
INDOOR UNIT DIMENSIONS
Unit Dimensions
Unit Net
Weight
A B C D E F G H I
B007HD 39Kg 946 891 246 510 716 831 381 292 251
B009HD 39Kg 946 891 246 510 716 831 381 292 251
B012HD 46Kg 1181 1126 721 510 951 1066 401 342 281
B015HD 46Kg 1181 1126 721 510 951 1066 401 342 281
B016HD 49Kg 1301 1246 721 510 1071 1186 401 342 295
B019HD 53Kg 1301 1246 721 510 1071 1186 401 342 295

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 9
Dimensions & Clearances
INDOOR UNIT CLEARANCES
Clearance Options for Maintenance
(Mandatory) Fan Removal Clearances Options
Unit
A A + B C D
B007HD 500 500 500 450
B009HD 500 500 500 450
B012HD 500 850 850 450
B015HD 500 850 850 450
B016HD 500 850 850 450
B019HD 500 850 850 450

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 10
Unit Installation
Unit insta llation
INDOOR INSTALLATION

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 11
Unit Installation
Indoor Unit Location
The indoor unit is designed for installation
within a ceiling/roof space or other
compartment, where there is no influence
from outdoor conditions.
While selecting the location, the following
conditions must be assured:
a) The location should assure free flow of the
return air into the unit without interference.
b) The unit should not be installed close to
rooms where noise should be avoided
(bedrooms, children rooms, etc).
c) Consider air distribution from the unit to
the rooms and select a suitable location
for even air flow.
d) Avoid obstacles which may restrict the run
air intake or the discharge supply air flow.
e) If installing the unit on a platform ensure
that the structure is capable of supporting
the indoor unit and platform.
NOTE: The indoor unit should not be installed
outside.
Notes for Installation
a) The return-air duct should be as short as possible, with full acoustic lining inside. The cross
section at the duct connection to the unit shall be equal to that of the unit.
b) The distance between the return air grille and the air intake on the unit must be as short as
possible.
Design and prepare in advance easy access for servicing as follows:
c) The minimum height clearance for the installation is 410 mm.
d) Allow the access to the electrical control box to facilitate its easy removal by opening the cover
(fastened by 4 screws).
e) A distance of 500 mm must be kept to allow access to the electrical service panel. For the
maintenance of fan and motor see indoor unit clearances. See Page 7.
1. Insulated Acoustic ducting
2. Discharge air grilles
3. Transition duct – air off
4. Suspended hanging option –
indoor fan coil
5. Indoor Fan Coil
6. Platform Option – Indoor fan coil
7. Transition duct – air on
8. Return air grille
9. Electrical Box

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Page 12
Unit Installation
Floor or Platform Mounting
1. Create a platform using bearers and
chipboard. Place the unit platform over load
bearing walls or on strategically located
trusses in the roof space.
2. Place serrated rubber pads or isolating
springs under each corner of the unit to
minimize / eliminate any noise transmission.
Suspension Mounting
Use the accessory kit – P/n 6601905 Hanging
Bracket Kit. For installation detailed see the
instructions supplied with this accessory kit.
1. Fasten the hanging brackets to the indoor coil.
2. Use field supplied threaded rod to suspend the
unit.
M10 or greater is recommended to brace the unit
mounting.
3. Fix the threaded rod to a structurally sound part of
the roof or concrete pad.
Check with local and national building codes and
or a structural engineer as to the fixing of the unit
or building support structure if applicable.
4. Secure the indoor fan unit to the threaded rods
ensuring all fasteners are secure and tight.
Failure to correctly secure the suspension
brackets and threaded rod to the indoor unit
could cause it to fall and inflict injury or damage.
Leveling the Unit
1. Adjust the level of the unit as required. The
drainpipe end of the unit must be lower by at
least 5mm for good drainage.
2. Take care not to damage the drain tubes or
coil when lifting to adjust unit level
3. For suspension mounting units, tighten the
locking nuts once the revised position is
determined.

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 13
Unit Installation
OUTDOOR UNIT

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 14
Unit Installation
CONDENSER INSTALLATION
Installation on flat surface (roof, ground, etc)
Install outdoor unit support in a position elevated at
least 100 mm on a concrete pad, concrete block or
wooden beams, in order to allow free water flow
underneath.
1. Outside the building
2. Outdoor Unit
3. Floor
4. Concrete slab or equivalent
5. Wall
6. Anchor bolts
7. Serrated Rubber / Waffle Pad 40x80 mm
INTERCONNECTING TUBING
The tubing between the indoor and outdoor units consist of two copper tubes and an electric cable
routed through a 60-mm wall opening. In addition, a drainage hose is installed between the indoor
unit and the closest drainage point. Connect both sections, taking the shortest, most direct route.
1. Outside wall
2. Gas (Vapor) Line
3. Liquid Line
4. Electric Cable
5. Inside wall
6. Incline Angle

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 15
Unit Installation
Installation Notes
1. When laying the tubing for the installation, make sure that
the ends are sealed to prevent penetration of dirt, moisture
etc. To prevent dust or moisture from entering the tubes,
seal them with caps or masking tape. It is recommended
to clean the inside space of the tubes with nitrogen before
connecting them to the unit.
2. Whenever possible, avoid passing tubes through hot
zones, such as walls next to ovens, chimneys, etc. In
such cases, additional insulation or other means of
protection should be employed.
3. Tubing route shall be kept in straight lines as much as
possible. When installing, keep the number of tube bends
to a minimum. If bends are necessary, perform them only
by using professional tube benders and not manually.
4. Make sure that tubing is insulated on its entire length,
including tube end and quick connectors, or flare-nuts, to
avoid tube “sweating” and water dripping from it.
5. Tubing shall be of refrigerant grade, without any damage.
Tube inside walls must be kept absolutely clean prior to
and during installation operations.
6. The Gas line shall be individually insulated with a minimum
9mm (3/8”) thick closed cell pipe insulation.
7. For diameters, length of liquid and gas lines, and height
difference, see the table below for each model. If the
liquid or gas tube diameters differs from the corresponding
flare connector diameter (mounted on the unit), use a
suitable reducing union for this purpose.
NOTE: it is not a requirement to insulate the liquid line unless
it is exposed to direct sun or extreme ambient temperatures.
Unit Interconnecting Tubing Table
TUBING LENGTH, UP TO – (IN METRES, ONE WAY)UNIT
MODEL
CONNECTING
LINE
10 15 20 25
MAXIMUM
TUBING
LENGTH
MAXIMUM
HEIGHT
DIFFERENCE
B007RS Gas
Liquid
15.88mm (⅝”)
9.58mm (⅜”)
15.88mm (⅝”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)
-
- 20M 10M
B009RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)”
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 10M
B012RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)”
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B015RS Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B016RT Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”) 25M 15M
B019RT Gas
Liquid
19.05MM (¾”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
22.23mm (⅞”)
9.58mm (⅜”)
25M 15M

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Page 16
Unit Installation
Recommendation for Interconnection Tubing Installation
Three possible versions are schematically illustrated:
1) The outdoor unit installed above the indoor unit – such installation requires an oil trap in the
gas line at the lowest point of the riser. The radius of the oil trap should be as short as
possible. Horizontal runs of liquid line should follow the gas line (except for trap). In case the
insulation must be partially removed for installation purposes, it is imperative that lines be fully
insulated with after the installation has been completed.
2) The units are installed at the same level – no
trap is required.
3) The outdoor unit is installed below the indoor
unit – such installation requires an inverted gas
line trap to be installed at the indoor unit. The
top of the trap must be greater than the height of
the indoor unit.
1. Air
2. Outdoor Unit
3. Gas Line
4. Liquid Line
5. Indoor Unit
1. Air
2. Liquid Line
3. Gas Line
4. Oil trap every 3m
5. Indoor Unit
6. Outdoor Unit
1. Air
2. Indoor Unit
3. Liquid Line
4. Gas Line
5. Outdoor Unit

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Page 17
Unit Installation
PIPE INSTALLATION
WARNING
This paragraph describes the necessary steps for setting the unit into operation. Be sure to
follow the instructions, to assure proper functioning of the air conditioner.
The outdoor unit is pre-charged with the correct amount of refrigerant. In extended runs, for
additional refrigerant charge please refer to the outdoor unit name plate. This process shall be
performed only by qualified refrigeration technicians with a professional charging set.
Flare Preparation
a) Cut the tube, using a tube cutter.
Make sure that the cut is perpendicular
to the tube axis. Ensure the pipe is de-
burred and free of metal shavings
b) Slip the flare-nut over the tube, secure
the tube in the flaring tool and perform
the flare on the tube end. The tube
projection length (A) from the flaring
block varies with tube diameter and
shall be set as indicated in the table.
c) Apply few drops of refrigeration oil to
the tube before flaring.
Pipe Welding Preparation
The indoor / outdoor unit final connections are made
using flared couplings. Where welded joints are
required the following are the requirements.
1. Keep piping capped at ends when storing,
handling and installing.
2. Use locally supplied, sealed, clean, refrigeration
grade copper piping only.
3. Using a flat surface, hold down the pipe at one
and roll out the requirements.
NOTE: Take care not to dent, flatten or damage
the pipe.
4. Use only a rotating wheel pipe cutter to cut the
tube.
5. Use only a de-burring tool to de-bur the pipe ends.
Flare Depth (A)
A (mm) TUBE OD
1.3 9.58mm (⅜”)
1.9 15.88mm (⅝”)
2.1 19.05mm (¾”)
1. Copper Tube
2. Flaring Tool

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 18
Unit Installation
Pipe Welding
Take care when using brazing flame torch, ensure that hot pipes or flame do
not cause a fire
1. Use quality brazing rod suitable for copper to copper joins on refrigeration grade tubing.
2. Before brazing wrap a wet cloth around pipes next to the indoor unit to prevent hot pipes
from melting foam insulation in the unit. Make sure the flame or heat from the flame does
not contact the unit casing or wiring, or damage will occur
3. Heat the pipe up as per the
illustration
4. Use nitrogen gas for flowing
though piping during pipe
brazing. If oxygen, acetylene or
fluorocarbon gas is used, it will
cause an explosion or poisonous
gas.
5. Use a regulator valve when
nitrogen gas flowing is performed
during brazing. The gas pressure
should be maintained within 0.03
to 0.05Mpa. If an excessively
high pressure is used, it will
cause an explosion.
Connecting the tubes
1. Connect and tighten the flare nuts to the
refrigeration valves on the outdoor unit and
to the male connectors of the indoor unit.
2. Coat the flared surfaces lightly with
refrigeration oil to improve sealing.
Note: First manually tighten the flare nuts,
and then use a wrench. See table for
tightening torque values.
3. Check for leaks. Use leak detect solution or
soap solution for leak testing. An electronic
leak detector is recommended.
Tube (Inches)
Flare Sizes 9.58mm (⅜”) 15.88mm (⅝”) 19.05mm (¾”)
Torque (N.M.) 40-45 70-75 80-85

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 19
Unit Installation
EVACUATION AND SETTING IN OPERATION
a) Connect two charging hoses from the charging set to the outdoor unit as shown in the diagram
below.
b) Connect the centre hose of the charging set to a vacuum pump.
c) CAUTION - turn on the vacuum pump and make sure that the low pressure gauge reading
moves from 0 kPa to -100 kPa; then evacuate the system for a further 10 minutes.
If gauge needle does not move from 0 kPa to -100 kPa, this indicates a leak. Take the
following measures: tighten all connections; if leaking stops when the tubing connections are
tightened, proceed from step c. If leaking persists even after connections are tightened, detect
the leak and repair it; be sure to proceed only after all leaks have been eliminated.
d) Close the valves of both the gas and liquid sides of the charging set and turn off the vacuum
pump. Make sure that the gauge needle does not move for about 5 minutes.
e) Disconnect the charging hoses from the vacuum pump and from the service ports of both the
three-way valves.
f) Replace the service port and valve caps of both tree-way valves and tighten them with a torque
wrench; see table of torque values listed on the previous page.
CAUTION
When performing the following steps, avoid any exposure to the service valve ports; remember
that the system is under pressure.
g) Remove the valve caps from the service valves. Position both valves to “open” using a 5mm
Hex/Allen key wrench. Open each valve by rotating the centre spindle in an anti-clockwise
direction until fully back seated.
h) Replace valve caps of both service valves. Check for gas leakage with a leak detector or
soapy water.
1. Charging Set
2. Vacuum Pump
3. Outdoor Unit
4. Service Port
5. Valve Cap
6. 3-Way Gas Valve
7. 3-Way Liquid Valve
8. Valve Cap
9. Indoor Unit
10. Gas Flare Connection
11. Liquid Flare Connection

DUCTED REVERSE CYCLE REFRIGERATED AIR CONDITIONING
Page 20
Unit Installation
ADDITIONAL CHARGE
1. Add 57 grams per meter of 9.53 (3/8”) liquid line over and above the specified system pre-
charged length. See the unit name plate for this information. DO NOT exceed the maximum
equivalent pipe length on each unit.
2. Service port on the liquid service valve is not supplied on all units.
1. Valve Protection Plug
2. Insert 5mm Hex / Allen key to
open/close the Refrigerant Valve
3. Valve Protection Cap
4. Refrigerant Valve
5. Service Port cap
6. Flare Nut
7. Valve Mounting Bracket
8. Copper Tube
DRAIN LINE INSTALLATION
a. It is recommended to prepare a drainage
point with rigid 20mm plumbing pressure
PVC pipe tube by a qualified technician.
b. The drain run must be installed with a
constant minimum down slope of 2% and
equipped with a trap, at the indoor unit.
c. Install a “P” trap in the main drain.
d. Use the 25mm flexible plastic coupling
hose provided to connect from the indoor
unit primary drain point to the “P” trap
and drain pipe. Secure with clamps.
e. To check the system, fill the condense
tray with water and verify its free flow
through the drain line.
Verify that no leaks are present from the
drain line or unit.