Daikin FVFC71AV16 User manual

DA
SPLIT SYSTEM

INSTALLATION MANUAL
Air Conditioner
F loo r Standing type
INDOOR
FVFC 71 AV 1 6
FVFC 1 00AV 1 6
FVFC 1 40AV 1 6
OUTDOOR
RZVF 71BS V 1 6
RZVF 1 00 BS V 1 6
RZMF 1 40 BS V 1 6
Page No.
Installation Manual I DU .......... 01- 2 3
Installation Manual O DU ......... 2 4-60
R-32 Sp e A Condioner

English

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CONTENTS
OUTLINE DIMENSIONS
INDOOR UNIT.................................................................................... 2
ABOUT INSTALLATION
1 SAFETY PRECAUTIONS................................................................... 3
2 BEFORE INSTALLATION .................................................................. 5
3 CHOOSING AN INSTALLATION SITE............................................... 6
4 INDOOR UNIT INSTALLATION.......................................................... 7
5 ELECTRICAL WIRING CONNECTION.............................................13
6 REFRIGERANT PIPING WORK....................................................... 14
ABOUT OPERATION
1 CONTROLLER PART NAMES AND FUNCTIONS........................... 18
2 OPERATING INSTRUCTION............................................................ 19
3 INDICATOR LIGHTS......................................................................... 20
4 TROUBLESHOOTING...................................................................... 21
5 OVERALL CHECKING...................................................................... 22
6
OPERATING RANGE
SERVICE AND MAINTENANCE....................................................... 22
22
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OUTLINE DIMENSION
INDOOR UNIT [FVFC]
All dimensions are in mm
F
A
B
D
E
C
IJK
H
L
G
Dimension
Model ABCDEFGHIJKL
71A 514 254 1850 676 859 600 270 242 73 77 31 34
100/140A 514 254 1850 676 859 600 350 322 73 77 115 34
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DAIKIN AIR CONDITIONER
INSTALLATION MANUAL
Read the precautions in this manual
carefully before operating the unit. This appliance is filled with R32.
• The precautions described herein are classified as WARNING and CAUTION.
They both contain important information regarding safety. Be sure to observe all precautions without fail.
• Meaning of WARNING and CAUTION notices.
WARNING
Failure to follow these instructions properly may result in personal injury or loss of life.
CAUTION Failure to observe these instructions properly may result in property damage or personal injury,
which may be serious depending on the circumstances.
• The safety marks shown in this manual have the following meanings:
Be sure to follow the instructions. Be sure to establish an earth connection. Never attempt.
• After completing installation, conduct a trial operation to check for faults and explain to the customer how to operate
the air conditioner and take care of it with the aid of operation manual.
WARNING
• Ask your dealer or qualified person to carry out installation work. Do not attempt to install the air conditioner yourself. Improper
installation may result in water leakage, electric shocks or fire.
• This appliance is intended to be used by expert or trained users in shops, in light industry and on farms, or for commercial use
by lay persons.
• This appliance is not intended for use by persons, including children, with reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by
a person responsible for their safety.
• Children should be supervised to ensure that they do not play with the appliance.
• Install the air conditioner according to the instructions given in this manual. Incomplete installation may cause water leakage,
electrical shock, or fire.
• Be sure to use only the specified accessories and parts for installation work. Failure to use the specified parts may result in the
unit falling, water leakage, electric shocks or fire.
• Install the air conditioner on a foundation strong enough to withstand the weight of the unit. A foundation of insufficient
strength may result in the equipment falling and causing injury.
• Electrical work must be performed in accordance with relevant local and national regulations and with instructions in this
installation manual. Be sure to use a dedicated power supply circuit only. Insufficiency of power circuit capacity and improper
workmanship may result in electric shocks or fire.
• Be sure to use a dedicated power circuit. Never use a power supply shared by another appliance.
• Use a cable of suitable length. Do not use tapped wires or an extension lead, as this may cause overheating, electric shocks
or fire.
• Make sure that all wiring is secured, the specified wires are used, and that there is no strain on the terminal connections or
wires. Improper connections or securing of wires may result in abnormal heat build-up or fire.
• When wiring the power supply and connecting the wiring between the indoor and outdoor units, position the wires so that
the control box lid can be securely fastened. Improper positoning of the control box lid may result in electric shocks, fire or
overheating terminals.
• After connecting interconnecting and supply wiring, be sure to shape the cables so that they do not put undue force on the
electrical covers or panels. Install covers over the wires. Incomplete cover installation may cause terminal overheating,
electrical shocks, or fire.
• When installing or relocating the air conditioner, be sure to bleed the refrigerant circuit to ensure it is free of air, and use only
the specified refrigerant (R32). The presence of air or other foreign matter in the refrigerant circuit cause abnormal pressure
rise, which may result equipment damage and even injury.
• If refrigerant gas leaks during installation, ventilate the area immediately.
Toxic gas may be produced if the refrigerant comes into contact with fire.
• After completing installation, check for refrigerant gas leakage.
Toxic gas may be produced if the refrigerant gas leaks into the room and comes into contact with a source of fire,
such as a fan heater, stove or cooker.
• Be sure to switch off the unit before touching any electrical parts.
SAFETY PRECAUTIONS
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WARNING
• During pump down, stop the compressor before removing the refrigerant piping. If the compressor is still running and
stop valve is open during pump-down, air will be sucked in when the refrigerant piping is removed, causing abnormal
pressure in refrigeration cycle, which may result equipment damage and even injury.
• During installation, attach the refrigerant piping securely before running the compressor. If the refrigerant pipes are not attached
and the stop valve is open when compressor is running, air will be sucked in when the refrigerant piping is removed, causing
abnormal pressure in refrigeration cycle, which may result equipment damage and even injury.
• Be sure to earth the air conditioner.
Do not earth the unit to a utility pipe, lightning conductor or telephone earth lead. Imperfect earthing may result in
electric shocks.
• Be sure to install an earth leakage breaker. Failure to install an earth leakage breaker may result in electrical shocks, or fi r e .
• All electrical wiring must not touch the water piping or any moving parts of the fan motors.
• Confirm that the unit has been switched OFF before installing or servicing the unit.
• Disconnect from the main power supply before servicing the air conditioner unit.
• DO NOT pull out the power cord when the power is ON.
This may cause serious electrical shocks which may result in fire hazards.
• Keep the indoor and outdoor units, power cable and transmission wiring, at least 1m from TVs and radios, to prevent distorted
pictures and static.
Depending on the type and source of the electrical waves, static may be heard even when more than 1m away.
• Do not use means to accelerate the defrosting process (if applicable) or to clean, other than those recommended by the
manufacturer.
• The appliance must be stored in a room without continuously operating ignition sources (for example: open flames, an
operating gas appliance or an operating electric heater).
• Do not pierce or burn.
• Be aware that refrigerants may not contain an odour.
• The appliance must be installed, operated and stored in a room with a floor area larger than Xm2(refer to “Special Precaution
when dealing with R32 Unit”). In case it is not satisfy minimum floor area, it requires to install at good ventilation room.
• NOTE: The manufacturer may provide other suitable examples or may provide additional information about the refrigerant
odour.
CAUTION
• While following the instructions in this installation manual, install drain piping to ensure proper drainage and insulate piping to
prevent condensation. Improper drain piping may result in indoor water leakage and property damage.
• Tighten the flare nut according to specified method such as with a torque wrench. If the flare nut is too tight, it may crack after
prolonged use, causing refrigerant leakage.
• Do not overcharge the unit.
Overcharge will cause over-current or damage to the compressor.
• Ensure that the unit’s panel is closed after service or installation.
Unsecured panels will cause the unit to operate noisily.
• Sharp edges and coil surfaces are potential locations which may cause injury hazards.
Avoid from being in contact with these places.
• Before turning off the power supply set the remote controller’s ON/OFF switch to the “OFF” position to prevent the nuisance
tripping of the unit. If this is not done, the unit’s fans will start turning automatically when power resumes, posing a hazard to
service personnel or the user.
• Make sure to provide for adequate measure in order to prevent the outdoor unit be used as a shelter by small animals. Small
animal making contact with electrical parts can cause malfunctions, smoke or fire. Please instruct the customer to keep the
area around the unit clean.
• The temperature of refrigerant circuit will be high, please keep the inter-unit wiring away from copper pipes that are not
thermally insulated.
• Only qualified personnel can handle, fill, purge and dispose of the refrigerant.
• Do not install the air conditioner in places such as the following:
a. Where there is mist of oil, oil spray or vapour for example a kitchen. Resin parts may deteriorate, and cause them to fall out or
water to leak.
b. Where corrosive gas, such as sulfurous acid gas, is produced. Corrosion of copper pipings or brazed parts may cause the
refrigerant to leak.
c. Where there is machinery which emits electromagnetic waves. Electromagnetic waves may disturb the control system, and
cause malfunction of the equipment.
d. Where flammable gases may leak, where carbon fibre or ignitable dust is suspended in the air or where volatile flammables,
such as thinner or gasoline, are handled. If the gas should leak and remained around the air conditioner, it may cause ignition
and a fire to break out.
• Do not install in places filled with smoke, gas, chemicals, etc. There is a possibility that the sensors inside the indoor unit could
detect these and display a refrigerant leak abnormality (only for R32 refrigerant).
• This unit is equipped with a refrigerant leak detector for safety. To be effective, the unit must be electrically powered at all times
after installation, other than short service intervals (only for R32 refrigerant).
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BEFORE INSTALLATION
• Make sure to use R32 refrigerant before the installation work. Otherwise, the unit cannot operate normally.
• Do not throw away the accessories required for installation until the installation is finished.
• Be sure to instruct the customer how to properly operate the system (particularly the cleaning of air filter, operation
method, temperature adjusting method) showing the attached operation and installation manual to the person.
• Do not install the unit where the atmosphere is salty such as near the seaside, where the voltage frequently
fluctuates or in a vehicle or a boat.
1
ACCESSORIES
• Check the following accessories are included in the indoor unit.
AWireless Remote
Controller
1
BScrews
2
CRubber Bush (for power
cable knock out hole)
2
DOperation manual
1
EInstallation manual
1
2
CHECKLIST
a. Item to be checked after completion of installation work.
Items to be checked In case of defection Check
column
Is the indoor unit fixed firmly? The unit may drop, vibrate or make noise.
Is the gas leak test finished? It may result in insufficient cooling.
Is the unit fully insulated? Condensate water may drip.
Does drainage flow smoothly? Condensate water may drip.
Does the power supply voltage correspond
to that shown on the name plate? The unit may malfunction or the component burn out.
Are wiring and piping correct? The unit may malfunction or the component burn out.
Is the unit safely grounded? Dangerous at electric leakage.
Is wiring size according to specifications? The unit may malfunction or the component burn out.
Is something blocking the air outlet or inlet
of either the indoor or outdoor units? It may result in insufficient cooling.
Are refrigerant piping length and additional
refrigerant charge noted down? The refrigerant charge in the system is not clear.
b. Item to be checked at delivery.
Items to be checked Check column
Have you explained how to operate the air conditioner showing the
operation and installation manual to the customer?
Have you handed the operation and installation manual to customer?
c. Points for explanation about operations.
The items with WARNING and CAUTION marks in the instruction manual are the items pertaining to
possibilities for bodily injury and material damage in addition to the general usage of the product. Accordingly, it is
necessary that you make a full explanation about the described contents and also ask your customers to read the
instruction manual.
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CHOOSING AN INSTALLATION SITE
• Before choosing the installation site, obtain user approval.
Indoor Unit
The indoor unit should be sited in a place where:
• The restrictions on installation specified in the indoor
unit installation drawing are met.
• The foundation is strong enough to support the
weight of the unit and the floor is flat to prevent
vibration and noise generation.
• The space around the unit is adequate for servicing
and the minimum space for air inlet and air outlet is
available.
•Drain water can be properly drained.
•Both air intake and exhaust have clear paths met.
•The unit is not in the path of direct sunlight.
•The unit is away from the sources of heat or steam.
•There is no source of machine oil vapour (this may
shorten indoor unit life).
•Cool air is circulated through out the room.
•The unit is away from electronic ignition type
flourescent lamps (inverter or rapid start type). As
these may shorten the remote controller range.
•The unit is at least 1 metre away from any television
or radio set (unit may cause interference with the
picture or sound).
•Do not install the units at or near doorway.
•Do not operate any heating apparatus too close to the
air conditioner unit or use in room where mineral oil,
oil vapour or oil, steam exist, this may cause plastic
part to melt or deform as a result of excessive heat or
chemical reaction.
•When the unit is used in kitchen, keep flour away from
going into suction of the unit.
•This unit is not suitable for factory used where cutting
oil mist or iron powder exist or voltage fluctuates
greatly.
•Do not install the units at area like hot spring or oil
refinery plant where sulphide gas exists.
•Ensure the color of wires of the outdoor unit and
the terminal markings are same to the indoors
respectively.
• IMPORTANT : DO NOT INSTALL OR USE THE AIR
CONDITIONER UNIT IN A LAUNDRY ROOM.
• Do not use joined and twisted wires for incoming
power supply.
• The equipment is not intended for use in a potentially
explosive atmosphere.
•The piping length between indoor unit and outdoor
unit is within the allowable limit.
Wireless Remote Controller
• Do not expose the remote controller to direct sunlight
(this will hinder receiving signals from the indoor
unit).
• Turn on all the fluorescent lamps in the room, if any,
and find the site where remote controller signals are
properly received by the indoor unit (within 7 metres).
CAUTION
Do not install the unit at altitude over 2000m for
both indoor and outdoor.
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INDOOR UNIT INSTALLATION
1
INSTALLATION DIAGRAM
Indoor Unit
Outdoor Unit
Air Discharge
Air Intake
Air Intake
Wrap the insulated pipe with the
finishing tape from bottom to top
Figure A
Air Discharge Louver
Indicator Lights
Air Intake Grille
Air Filters
(Inside Air Intake Grille)
Signal Receiver
2
INSTALLATION CLEARANCE
Standard Mounting
Ensure that the overhead supports are strong enough to hold the weight of the unit. Position the hanger rods (wall
mounting bracket for floor standing), and check for its alignment.
Also, check that the hangers are secured and the base of the fan coil unit is leveled in both horizontal directions.
Figure B
50mm or more 50mm or more
Please ensure that the following steps are taken:
– The drain pipe slope shall be kept at least 1:100.
– Provide clearance for easy servicing and optimal air flow as shown in Figure B.
–The indoor unit must be installed such that there is no short circuit of the cool discharge air with the warm return
air.
–Do not install the indoor unit where there is direct sunlight shining on the unit. The location should be suitable for
piping and drainage installation. The unit must be a large distance away from the door.
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3
INDOOR UNIT INSTALLATION
Fixing Procedure
• Fix the indoor unit by using embedded bolt, etc. to prevent falling down of the vertically-long shaped unit.
1. Detach the air intake grille.
Remove the screw (Right, Left, total 2) holding the grille. Then, (1) lean the grille forward you, and (2) lift upward
and out. Refer Figure C.
Figure C
)
)
M4 x 12 Screw
Front Panel
Grille stopper
Intake grille
2. Install the indoor units.
< Method 1 >
Fix the bracket with the attached screws to the top panel as shown in Figure D.
Then fix the indoor unit to the wall surface.
Figure D
All dimensions are in mm
Bracket for installation
330
2-7 X 15 slot
18
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< Method 2 >
Fix the indoor unit to the floor with Anchor bolts (to be locally procured) using fixing holes (x4) on the bottom frame.
Figure E
All dimensions are in mm
Fixing Hole (x 4)
Bottom frame
<Bottom>
260
57, (79)
144, (202)
* Dimension in ( ) for 40-60 models.
For more safety precaution, fix the indoor unit with < Method 1 > and < Method 2 > during installation.
Piping and Drain Hose Installation.
• Detach the pipe retainer,
< In case of left or right piping >
1. Open the holes on the Right (Left) side panel. (Refer to Figure F).
2. Pass refrigerant pipes, drain pipes, and unit wiring through the hole on the side panel.
Figure F
Bottom frame
Side Panel
Through hole (left and right side panel, rear panel)
Through hole for wiring (left and right side panel)
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< In case of rear piping >
1. Open the holes on the rear panel. (Refer to Figure G).
2. Pass refrigerant pipes, drain pipes, and unit wiring through the hole on the rear panel.
< In case of downward piping >
1. Cut holes in the indicated area of the bottom frame. (Refer to Figure G).
2. Pass refrigerant pipes, drain pipes, and unit wiring through the hole on the bottom frame.
Figure G
Bottom panel
Insulation for fitting
Pipe retainer
Rear panel
Knock-out hole
Drain hose inside
the unit
Fix using the cable tie
Cut holes here
After rigging pipes and wiring, lock down the refrigerant pipes, drain hose inside the unit, indoor-out-door unit.
Transmission wiring and grounding line, in the piping guide.
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Drain Piping Work
1. Rig the drain piping.
Rig the drain line to ensure proper drainage. Also, observe the following to prevent leaks.
Figure H
Liquid pipe
Gas pipe
Drain hose inside
the unit
Fan housing
Bottom Frame
Anchor hose here
Drain hose (Procure in field).
Vinyl Tube (Pipe size 20mm).
• Bundle the drain hose to the refrigerant pipes as shown at right or take other means to anchor it down,
so as not to apply pressure to the hose inside the unit. This is necessary to prevent the drain hose from
disconnecting and to ensure proper insulation. Keep the drain hose sloping at a minimum 1/100 gradient,
to prevent air pockets.
• Condensate can form on the hose and leak from the unit. Therefore, definitely insulate the hose in at
least the below two places.
• All hose in the room and inside the unit.
• At connection between the unit’s drain hose and building drain pipe.
2. After rigging the drain hose, check that drainage flows smoothly and that water does not leak
from connections.
• Carefully pour approximately 1,000cc of water through the air discharge outlet so that it falls directly
onto the heat exchanger at an angle without splashing. (Refer to Figure I).
* If water is poured too fast or it water pressure is too high, the water will pass through the heat exchanger
and drip on the fan motor below it.
* If water gets on the inner front wall, it will leak onto the floor.
Figure I
Heat
exchanger
Air discharge
outlet
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Intake Grille
Intake grille must be installed as step below.
1. Hook the air intake grille on the groove on the unit’s bottom frame in order of (1) -> (2). (Refer to Figure J).
Figure J
2. Fit the grille stopper (front panel) into the groove on the air intake grille and lock the grille down in its
original place by screw. (Refer to Figure K).
M4 x 12 Screw Front Panel
Grille stopper
Intake grille
Figure K
If the unit needs to be service, steps below shall be followed:
1. Confirm that the unit had been switched off before servicing the unit.
2. Use screwdriver to unlock the screw on the intake grille.
3. Install the intake grille and screw the grille stopper after service and make sure the unit is proper install.
Filter Cleaning work
1. Take out the filter from the unit in order of (1) -> (2). (Refer to Figure L).
Figure L
2. Clean the filter, either use a vacuum cleaner, or wash them in water and dry in the shade.
3. Re-insert the filter to the original position.
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ELECTRICAL WIRING CONNECTION
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• All wires must be firmly connected.
• Make sure all the wire do not touch the refrigerant piping, compressor or any moving parts.
• The connecting wire between the indoor unit and the outdoor unit must be clamped by using provided cord anchorage.
• In the case when protected pipes are used, use H05VV-U4G for the connecting wire between the indoor unit and the
outdoor unit. Use H07RN-F when protected pipes are not used.
• Make sure no external pressure is applied to the terminal connectors and wires.
• Make sure all the covers are properly fixed to avoid any gap.
• Use round crimp-style terminal for connecting wires to the power supply terminal block. Connect the wires by matching
to the indication on terminal block. (Refer to the wiring diagram attached on the unit).
Attach insulation sleeve
Electric wire
Round crimp-style terminal
•Transmission wire must be routed at least
50mm away from the power cable.
•Transmission wire should be a shielded wire.
WARNING
• Use the correct screwdriver for terminal screws tightening. Unsuitable screwdrivers can damage the screw head.
• Over tightening can damage the terminal screws.
• Do not connect wire of different gauge to same terminal.
• Keep wiring in an orderly manner. Prevent the wiring from obstructing other parts and the terminal box cover.
•For wiring connection between INDOOR and OUTDOOR unit, see Outdoor installation manual and wiring diagram.
Connect wires of the same
gauge to both side.
Do not connect wires of the
same gauge to one side.
Do not connect wires
of different gauges.

14
REFRIGERANT PIPING WORK
• For the outdoor unit refrigerant piping, refer to the installation manual attached to the outdoor unit.
1 FLARING THE PIPE END
1) Cut the pipe end with a pipe cutter.
2) Remove burrs with the cut surface facing downward so that
the chips do not enter the pipe.
3) Put the flare nut on the pipe.
4) Flare the pipe.
5) Check that the flaring is properly made.
• Do not use mineral oil on flared part.
• Prevent mineral oil from getting into the system as this
would reduce the lifetime of the units.
• Never use piping which has been used for previous
installations.
• Only use parts which are delivered with the unit.
• Do never install a drier to this R32 unit in order to
guarantee its lifetime.
• The drying material may dissolve and damage the
system.
• Incomplete flaring may cause refrigerant gas leakage.
WARNING
Do not reuse joints which have been used once already.
CAUTION
Make sure that the
flare nut is fitted.
Flare’s inner surface
must be flaw-free.
The pipe end must
be evenly flared in
a perfect circle.
Check
(Cut exactly at
right angles.)
Remove burrs.
Set exactly at the position shown below.
Die
A
Pipe Size,
mm (in)
A (mm)
Flare Tool for
R32/R410A Conventional flare tool
Clutch-type Clutch-type
(Ridgid-type)
Wing-nut type
(Imperial-type)
6.4 (1/4") 0-0.5 1.0-1.5 1.5-2.0
9.5 (3/8") 0-0.5 1.0-1.5 1.5-2.0
12.7 (1/2") 0-0.5 1.0-1.5 2.0-2.5
15.9 (5/8") 0-0.5 1.0-1.5 2.0-2.5
19.1 (3/4") 0-0.5 1.0-1.5 2.0-2.5
Flaring
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2 REFRIGERANT PIPING
1) Use the flare nut fixed to the main unit. (To prevent cracking of the flare nut by aged deterioration.)
2) To prevent gas leakage, apply refrigeration oil only to the inner surface of the flare. (Use refrigeration oil for R32.)
3) Use torque wrenches when tightening the flare nuts to prevent damage to the flare nuts and gas leakage.
CAUTION
Align the centres of both flares and tighten the flare nuts 3 or 4 turns by hand. Then tighten them fully with the torque wrenches.
[Apply oil]
Do not apply refrigeration
oil to the outer surface.
Flare nut
Apply refrigeration oil to the
inner surface of the flare.
Do not apply refrigeration oil to the flare nut
to avoid tightening with excessive torque.
Torque wrench
Spanner
Pipe union
Flare nut
[Tighten]
1. Cautions on pipe handling
1) Protect the open end of the pipe against dust and
moisture.
2) All pipe bends should be as gentle as possible.
Use a pipe bender for bending.
Pipe Size, mm (in) Torque, Nm/(ft-lb)
6.4 (1/4") 18 (13.3)
9.5 (3/8") 42 (31.0)
12.7 (1/2") 55 (40.6)
15.9 (5/8") 65 (48.0)
19.1 (3/4") 78 (57.6)
2. Selection of copper and heat insulation materials
When using commercial copper pipes and fittings, observe the following:
1) Insulation material: Polyethylene foam
Heat transfer rate: 0.041 to 0.052W/mK (0.035 to 0.045kcal/(mh •˚C))
Refrigerant gas pipe’s surface temperature reaches 110˚C max.
Choose heat insulation materials that will withstand this temperature.
2) Be sure to insulate both the gas and liquid piping and to provide insulation
dimensions as below.
Piping size, mm (in) Minimum bend
radius
Piping
thickness
Thermal insulation
size
Thermal insulation
thickness
6.4 (1/4") 30mm or more 0.8mm
(C1220T-O)
I.D. 8-10mm
10mm Min.
9.5 (3/8") 30mm or more I.D. 12-15mm
12.7 (1/2") 40mm or more I.D. 14-16mm
15.9 (5/8") 50mm or more 1.0mm
(C1220T-O)
I.D. 16-20mm
19.1 (3/4") 50mm or more I.D. 20-24mm
Inter-unit wire
Liquid pipe
Liquid pipe
insulation
Drain hose
Finishing tape
Gas pipe
insulation
Gas pipe
3) Use separate thermal insulation pipes for gas and liquid refrigerant pipes.
Be sure to
place a cap.
If no flare cap is
available, co ver the
flare mouth with tape to
keep dirt or water out.
Wall
Rain

15
WARNING
Prior to installation, ensure risk of ignition is minimised and avoid working in confined space. Ensure adequate
ventilation is available by opening windows or doors.
• When flared joints are reused indoors, the flare part shall be re-fabricated.
• Avoid installation of the air conditioner in a place where there is danger of exposure to continuously
operating open flames (for example an operating electric heaters).
• Any person who is involved with working on or breaking into a refrigerant circuit should hold a current
valid certificate from an industry-accredited assessment authority, which authorises their competence
to handle refrigerants safely in accordance with an industry recognised assessment specification.
• Checking for presence of refrigerant
The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the
technician is aware of potentially flammable atmospheres. Ensure that the leak detection equipment being
used is suitable for use with flammable refrigerants, i.e. nonsparking, adequately sealed or intrinsically
safe.
• Presence of fire extinguisher
If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fire
extinguishing equipment shall be available to hand. Have a dry powder or CO2fire extinguisher adjacent
to the charging area.
• No ignition sources
All possible ignition sources, including cigarette smoking, should be kept sufficiently far away from the
site of installation, repairing, removing and disposal, during which flammable refrigerant can possibly be
released to the surrounding space. “No Smoking” signs shall be displayed.
• The following checks shall be applied to installations:
–marking to the equipment continues to be visible and legible. Markings and signs that are illegible
shall be corrected;
–refrigeration pipe or components are installed in a position where they are unlikely to be exposed to
any substance which may corrode refrigerant containing components, unless the components are
constructed of materials which are inherently resistant to being corroded or are suitably protected
against being so corroded.
• Initial safety checks shall include:
–that capacitors are discharged, this shall be done in a safe manner to avoid possibility of sparking
–there shall be no live electrical components and wiring are exposed while charging, recovering or
purging the system;
• Repair to intrinsically safe components
Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not
exceed the permissible voltage and current permitted for the equipment in use.
Replace components only with parts specified by the manufacturer.
• Leak detection methods
Ensure that the detector is not a potential source of ignition (for example a halide torch) and is suitable for
the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant
(for R32, LFL is 13%) and shall be calibrated to the refrigerant employed and the appropriate percentage
of gas (25 % maximum) is confirmed.
Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing
chlorine shall be avoided as the chlorine may react with the refrigerant and corrode the copper pipe-work.
If a leak is suspected, all naked flames shall be removed/extinguished. If a leakage of refrigerant is found
which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of
shut off valves) in a part of the system remote from the leak. Oxygen free nitrogen (OFN) shall then be
purged through the system both before and during the brazing process.
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• Removal and evacuation
When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures
shall be used. However, it is important that best practice is followed since flammability is a consideration.
The following procedure shall be adhered to:
• remove refrigerant;
• purge the circuit with inert gas;
• evacuate;
• purge again with inert gas;
• open the circuit by cutting or brazing.
The refrigerant charge shall be recovered into the correct recovery cylinders. The system shall be “flushed”
with OFN to render the unit safe. This process may need to be repeated several times. Compressed air or
oxygen shall not be used for this task. Flushing shall be achieved by breaking the vacuum in the system with
OFN and continuing to fill until the working pressure is achieved, then venting to atmosphere, and finally
pulling down to a vacuum. This process shall be repeated until no refrigerant is within the system. When
the final OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to
take place. This operation is absolutely vital if brazing operations on the pipe-work are to take place. Ensure
that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation available.
• Labelling
This unit shall be labelled ‘de-commissioned and emptied of refrigerant’.This label shall be dated and signed.
Ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.
• Charging procedures
In addition to conventional charging procedures, the following requirements shall be followed.
–Ensure that contamination of different refrigerants does not occur when using charging equipment.
Hoses or lines shall be as short as possible to minimise the amount of refrigerant contained in them.
– Cylinders shall be kept upright.
–Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
– Label the system when charging is complete (if not already).
– Extreme care shall be taken not to overfill the refrigeration system.
Prior to recharging the system it shall be pressure tested with OFN. The system shall be leak tested on
completion of charging but prior to commissioning. A follow up leak test shall be carried out prior to leaving
the site.
Decommissioning
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment
and all its detail. It is recommended good practice that all refrigerants are recovered safely. Prior to the task
being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of
reclaimed refrigerant. It is essential that electrical power is available before the task is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure ensure that:
• mechanical handling equipment is available, if required, for handling refrigerant cylinders;
• all personal protective equipment is available and being used correctly;
• the recovery process is supervised at all times by a competent person;
• recovery equipment and cylinders conform to the appropriate standards.
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of
the system.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with manufacturer’s instructions.
h) Do not overfill cylinders. (No more than 80 % volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
j) When the cylinders have been filled correctly and the process completed, make sure that the cylinders
and the equipment are removed from site promptly and all isolation valves on the equipment are closed off.
k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned
and checked.
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Recovery
When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good
practice that all refrigerants are removed safely. When transferring refrigerant into cylinders, ensure that
only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cylinders
for holding the total system charge are available. All cylinders to be used are designated for the recovered
refrigerant and labelled for that refrigerant (i.e. special cylinders for the recovery of refrigerant). Cylinders
shall be complete with pressure relief valve and associated shut-off valves in good working order. Empty
recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions concerning the equipment
that is at hand and shall be suitable for the recovery of flammable refrigerants. In addition, a set of calibrated
weighing scales shall be available and in good working order. Hoses shall be complete with leak-free
disconnect couplings and in good condition. Before using the recovery machine, check that it is in satisfactory
working order, has been properly maintained and that any associated electrical components are sealed to
prevent ignition in the event of a refrigerant release. Consult manufacturer if in doubt.
The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and
the relevant Waste Transfer Note arranged. Do not mix refrigerants in recovery units and especially not in
cylinders.
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable
level to make certain that flammable refrigerant does not remain within the lubricant.The evacuation process
shall be carried out prior to returning the compressor to the suppliers. Only electric heating to the compressor
body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried
out safely.
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CONTROLLER PART NAMES AND FUNCTIONS
Cooling Model
TIMER
SWING
FAN
FAN
AUTO
FAN
DRY
TURBOMODE
KEY LOCK
1
5
4
7
2
3
6
COOL
TURBO
SWING
1
OPERATION MODE SELECTOR BUTTON
5
TEMPERATURE SETTING BUTTON
Press the button to select OPERATION MODE
(Cool/Dry/Fan)
Press the button to decrease set temperature in °C or °F
2
TURBO BUTTON
6
FAN SPEED CONTROL BUTTON
Press the button to active/deactivate TURBO function Press the button to select fan speed, High/Medium/Low,
of your choice
3
SWING BUTTON
7
ON/OFF BUTTON
Press the button to active/deactivate SWING function Press the button and the system will start.
Press the button again and the system will stop.
4TEMPERATURE SETTING BUTTON
Press the button to increase set temperature in °C or °F
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