Haier MRV II User manual

Haier MRVⅡAir Conditioning
Haier MRVⅡcan be used in a large combination
with multiple outdoor units, it is only one system
and is the second generation of Haier C-MRV
product. Major features are energy saving,
intelligent control and precise temperature control,
for R410A system, that is more friendly for
environment as well.
To regulate the installation, commissioning and
maintenance procedure, and ensure the working
quality, also to improve the working efficiency, we
make this guide for reference.
This regulation is applicable for Haier A/C Elec.
Corp. Ltd.

Index
Part 1 Installation regulation------------------------------------------3
Part 2 Commissioning & Maintenance for R22 system---- 22
Part 3 Debugging & Maintenance for R410Asystem--------85
Part 4 Wiring diagram------------------------------------------------136
Part 1 Installation regulation
1. Installation flowchart-------------------------------------------------------4
2. Equipment delivery---------------------------------------------------------5
3. Outdoor installation--------------------------------------------------------6
4. Indoor installation----------------------------------------------------------8
5. Piping work------------------------------------------------------------------12
6. Water drainage pipe installation--------------------------------------14
7. Insulation treatment------------------------------------------------------15
8. Electric wiring--------------------------------------------------------------16
9. Pipe cleaning work--------------------------------------------------------18
10. Leakage test---------------------------------------------------------------19
11. Evacuation-----------------------------------------------------------------20
12. Additional Refrigerant Charging------------------------------------21
13. Trial operation-------------------------------------------------------------22
14. Transfer to user-----------------------------------------------------------23
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Part 1
1 Installation flowchart
Take training for the user
Every unit should run normally
Recharge the refrigerant due to
the actual pipe length and the
size
Vacuum should be below 75
mmHg
Keep the pressure at 28kgf/cm
for 24 hours
Keep clean in the pipe
Select the proper cable and wire
It should be done for the whole
piping system
After installation
15. Transfer to the user
14. Debugging and trial running
13. Additional refrigerant charging
12. Evacuation
11. Leakage testing
10. Cleaning operation
9. Electric installation
8. Heat insulation
Pay attention to the gradient
Keep dry, clean and hermetic
Prevent the ventilation in short
circuit. Easy for maintenance
Confirm the model to avoid the
mis-installation
Confirm the person responsible
for each process
Prepare the material,equipment
and worker's training
Confirm the selected model,
position, pipe size, layout direction
Important points
in installation
7. Condensate water drainage
6. Refrigerant pipe layout
5. Outdoor installation
4. Indoor installation
3. Working distribution
2. Working preparation
1.Engineering drawing
before installation
Process
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Part 1
2 Equipment delivery
2.1 After the equipment is delivered to the site, all relative persons should
join the unpacking and checking work.
2.2 Pay attention to the below points when unpacking:
a. Check the equipment name, model, specification and the quantity, etc.
b. Suspend the equipment to the site or near the site before unpacking
the unit. Forbidden to suspend the unit after unpacking to avoid being
damaged.
c. When unpacking, do not operate wildly to avoid being damaged.
d. Check if the accessories are complete due to the packing list after
unpacking. Any question, contact the after-sale persons.
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Part 1
3 Outdoor installation
3.1 The unit should be placed far away the flammable, explosive or oily
place.
3.2 The noise and the outlet air should not affect the neighbors.
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3.3 There should be enough space for air inlet, air outlet and
maintenance around the unit. Fluent ventilation and good heat release. If
there is obstacle above the unit, it must be over 2m away from the air
outlet, or there should be extended duct.
3.4 The floor and the steel bracket should be strong enough to afford the
1.5 times heavier than the unit running weight. The floor and the steel
bracket should be horizontal.

Part 1
3.5 The bottom of steel bracket should be made from 6# channel steel.
3.6 The floor should be over 100mm higher than the ground, and there
should be the drainage around to ensure the unit not being immersed in
the water.
3.7. The unit should be fixed firmly with the anti-vibration cushion.
3.8. The outdoor should be as near the indoor as possible. Shorten the
pipe and decrease the bend pipe. Pipe length can not exceed the
permitted range.
3.9 Avoid the dangerous place which could be easily damaged by
monsoon, typhoon and earthquake, if possible, do not install the unit in
the air.
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Part 1
4 Indoor installation
A. With the shortest refrigerant pipe, and convenient to connect with
distributing pipe and water pipe. Water pipe should keep a 1% gradient
at least.
B. The place for indoor unit installation should be strong enough to
afford the unit weight and running shake.
C. Preset a checking hole near the indoor unit, and there should be
enough space for maintenance, and convenient to maintain or change
the PCB and motor.
D. Ensure air return and air discharging fluent, and prevent ventilation
in short circuit , also air return duct and air outlet duct is necessary.
E. Before installation, please check if the unit appearance has been
damaged or the other abnormal after being unpacked. Also please check
if the accessories are complete, and the accessories should be
transferred to the special person for proper preservation.
F. The unit should be fixed firmly to avoid falling and shaking. After
installing the indoor unit, please check it with a gradienter to ensure the
indoor unit is horizontal.
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Part 1
4.1 Wall mounted unit installation
installation figure:
mounting plate
gas pipe
liquid pipe
indoor side outdoor side
through-wall hole
wall thickness
through-wall hole section
adhesive tape
fresh air pipe
heat insulation
4.1.1 Fix the mounting plate, set the through-wall hole: install the unit on
smooth wall beside beam and pillar. Firstly , fix the mounting plate on the
wall with a steel nail ,use a thread with a screw ,drop it down vertically
from the central top of the mounting plate,(or you can use a gradienter)to
find the horizontal place and fix it. Drill holes in the wall according to the
wall mounting plate’s position , put plastic sleeve into the hole, then
fasten the plate securely with 4*25 screw .
4.1.2 Make through-wall hole : make a throughout hole in the wall , after
installation , please seal it with putty or gesso.
4.1.3 Hang the unit body onto the upper notches of the mounting
plate ,move the body from side to verify its secure fixing.
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Part 1
4.2 Cassette unit installation
air outlet air outlet
air inlet
4.2.1 To ensure the air conditioner working effect, the installation height
should be less than 3m.
4.2.2 After installation on the ceiling ,check the unit’s horizontal level ,use
a gradienter to check it.
4.2.3 Set a checking hole bigger than 400*400mm for checking and
maintenance .
4.3 ESP duct unit installation
Ceiling
Air return
A
Building roof
Air return box
Air supply duct Unit
Air outlet
grille
Air supply
Unit
Air return
Air return box
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Part 1
4.3.1 The indoor unit can be installed on the ceiling, which height is no
more than 3m.
4.3.2 Install the unit with suspending pole, check if the installation place
can bear the unit.
4.3.3 Fix the indoor unit to the suspending bolt, if necessary, it is possible
to suspending the unit to the beam, etc.
4.3.4 Adjust the horizon with a gradienter or by the following method.
Make adjustment so that the relation between the lower surface of the
unit and water level in the hose becomes what is shown in the figure.
PVC pipe
0~5 mm
(0~0.2")
Piping side
Water level
make the piping side slightly lower.
Supply water
4.3.5 Notice for high static pressure duct unit
4.3.5.1 In order to reduce the noise level of the working room , it is better
not to install indoor unit in the working room ,especially for the room
where need a strict noise level. Indoor unit can be installed in a special
room or stair well, and connect with working room by air sending duct and
air return duct.
4.3.5.2 High static pressure duct unit is designed for duct type air
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Part 1
sending,
it must connect with air sending and air return duct ,it is forbidden to blow
air into working room directly, otherwise the noise level will be so high
due to the high fan speed from the air outlet .
4.3.5.3 Connection between indoor unit and duct should be soft, and
connect a static pressure box out of unit to avoid shaking and noise pass
through the duct.
4.3.5.4 The design for air sending/return duct, static pressure box, and air
sending/return outlet should be done by the design organization with
relative competency to ensure indoor unit air sending character matches
the duct .
5 Piping work
Refrigerant pipe is made of phosphorus deoxidized copper seamless
steel pipe , weld them together with copper or phosphorus welding rod.
When carrying out this work please comply with the followings strictly :
dry ,clean, hermetic. Therefore, note the below items during working:
5.1 After cutting off the pipe refer to dimensions, blow it with nitrogen for
cleanness. For the pipe which diameter is over 25mm, the pipe inside
need to be cleaned with duster cloth for dust and copper scraps.
5.2 Cover the both ends of the pipe to prevent the dust , vapor and
impurity into the pipe.
5.3 Do not execute the piping work in the rain, moist air and water may
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Part 1
cause system block.
5.4 When welding the pipe, please blow nitrogen to prevent oxidation,
pressure of nitrogen flow is about 0.02Mpa , otherwise the oxid layer on
pipe inside will clog the pipe or damage the compressor.
5.5 Welding connection needs a changeable diameter pipe, the pipe
inserted depth is : 10 mm : below φ19mm ; 15mm: above φ22mm
5.6 When working on the end of the pipe with metal saw or file, do not let
the copper scrap into the pipe.
5.7 The flared type pipe made by expansion tools must conform to the
relative standard, if not, it must be reworked.
5.8 For flared type connection ，please daub some freeze oil on inside
and outside of pipe to avoid pipe bend.
5.9 Refrigerant pipe should be installed horizontally or vertically and as
short as possible ,protect the exposed part with ornament board. To avoid
wrong connection, the pipe need to be marked every other end, set a
bracket exclusively at the joint between piping and unit , do not make unit
afford any weight .
5.10 Branch pipe should be installed in horizontal or vertical direction,
otherwise that will affect the air conditioner effect.
Horizontal
Right
Floor
Wrong Floor
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Part 1
Vertical
Wrong Right
Floor
Floor
6 Water drainage pipe installation
6.1 Drain pipe should keep a 1% gradient at least towards water outlet
direction and as short as possible, if the pipe is made of hard PVC, then
set a suspender at interval of 2 meters to avoid the pipe bend.
For Cassette & Ceiling concealed unit
Suspension
bolts
Heat
insulation Downgrade
of 1/100 or more
1.5m ~ 2m
6.2 Drain pipe diameter shall be equal or larger than that of indoor
unit ,normally drained water and forcedly drained water could not gather
together to one system.
6.3 Check if water drainage is smooth after installation, if the horizontal
drain pipe is too long , please set an air discharge hole at interval of 5
meters.
6.4 To avoid the drain pan distortion, the connection between drain pipe
and unit should be soft.
6.5 For the indoor unit whose pressure at condensing water drain pipe
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Part 1
connection part is negative (cassette, ceiling concealed type) ,please
install a water return pipe for drain pipe.
6.6 Test the drain pipe after installation. Seal the water outlet of drain pan
and charge water to 2/3 part. Check the drain pan two hours later, if
there is no leakage, open the water outlet to ensure if the water drainage
is fluent and if the drain pipe connection is tight.
7 Insulation treatment
7.1 If the insulating layer of condensing water pipe is made of rubber, its
thickness should be over 10mm.
7.2 If the insulating layer of refrigerant pipe is rubber pad insulation pipe,
its thickness should be over 15mm, if the material of insulation layer is
fiberglass, the thickness should be over 20mm.
7.3 To do the refrigerant pipe insulation work , the straight pipe should be
done firstly, for the welding joint and the others that can be done after
checking work, then finish all the insulation work.
7.4 The gas pipe and liquid pipe should be treated separately
7.5 The joint of insulating material should be glued to ensure there is no
gap, wrap insulating material with adhesive tape, be not too tight and no
sense of looseness.
7.6 The pipe inside the ceiling needs not to be wrapped if unnecessary,
only stick the control cable with adhesive tape on the outer of insulating
layer, for R410A system, please refer to the below picture:
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Part 1
R22system: R410Asystem:
Connection wire
Liquid pipe
Heat insulator
Gas pipe
Adhesive tape
over 20cm
Connection wire
Liquid pipe
Heat insulator
Gas pipe
Adhesive tape
8 Electric wiring
Air conditioner electric wiring should comply with the relative articles
in GB5024-96.
8.1 Electric wiring work should be done by the qualified electricians.
8.2 Indoor and outdoor unit should be grounded reliably, grounding
resistance should be less than 4Ω.
8.3 All the power cables and signal cables should pass through the wire
tube or wire groove. Power cable and signal wire should not go through
the same wire tube.
8.4 All cables must be copper core. Power cable and signal wire shall
keep a certain distance (about 200mm), or be laid on both sides of
refrigerant pipe , do not wind each other, fixing by this way can avoid
communication disturbance.
8.5 Power supply for indoor and outdoor can be different and supply the
power separately, but the indoor units connected with one outdoor should
use one power supply.
8.6The circuit breaker should be installed for every outdoor unit, the
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Part 1
breaker’s capacity should be 1.5 times of outdoor’s max. running current
8.7 Indoor unit of the same outdoor system should use one power supply.
8.8 The recommended power cable is BV.BVR and V V cable ,do not use
YZW cable.
8.9 Signal wire must be double core shielded wire(1.5mm2) ,shielded
layer should be connected continuously on indoor unit and be insulated
with adhesive tape, grounded at single point on outdoor unit.
Communication wire is forbidden as O type.
8.10 When power cable over 10mm2is connected to the terminal block,
the cable terminal should be O type.
8.11 All the electric wires should not touch the refrigerant pipe directly,
because the insulating layer will get aging due to heat , then it will leak
and cause injury accident.
8.12 Power cable of 10HP outdoor unit should not be under 6mm2.
8.13 Power cable of indoor unit should not be under 2.5 mm2
8.14The wire between wired controller and indoor unit is 0.5 mm2RVV,
polar connection. For the salve units in group control, only connect the
terminal B, C.
8.15 Central control wire is 1.5 mm2 2-core shielded wire. Terminal P, Q
of communication bus line between indoor and outdoor is no polarity.
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Part 1
9 Pipe cleaning work
Blow nitrogen is one way to clean impurity from pipe
Note: If you did not blow nitrogen when welding pipe , this method
can not clean the oxid on the pipe wall .
Connect the nitrogen with unit system via pressure relief valve,
adjust the valve to 5Kg/cm2, supply nitrogen to system, seal the pipe end
by hand or others , when the pipe pressure getting too high to be sealed ,
open the pipe quickly, repeat this procedure four or five times, the
impurity can be cleaned basically.
9.1 For MRV system , because the pipe is too thick , the cleaning work
should be carried segment by segment.
9.2 When cleaning the pipe , please ensure the pressure is high enough
and clean for some times, if the impurity can not be cleaned completely,
the filter in system and electric expansion valve will be clogged.
9.3 When opening the pipe please make sure to do it safely, prevent the
impurity blew out from hurting people.
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Part 1
10 Leakage test
Connect nitrogen tank, pressure relief gauge, gauge manifold and
refrigerant system in turn, charge nitrogen to system both on high and
low pressure sides at same time, notice items:
10.1 Please must test system by nitrogen , do not use any other gas.
10.2 It is better to do the leakage test before connecting with outdoor unit,
because the stop valve of outdoor unit may leak due to welding or outside
force, then nitrogen will go into outdoor circle system.
10.3 Apply pressure both on gas and liquid sides at same time, pressure
charging work can be done by two or three steps , at first apply a lower
pressure to system, if no big leakage be found ,then apply a higher
pressure.
10.4 Check the welded joint and flared joint with suds one by one. If leaks,
air bubble will come out.
10.5 After leakage test, place the unit for 24 hours, if the pressure does
not go down, there is no leakage.(Environment temperature will affect
system pressure, generally , when the environment temperature changes
1 degree, system pressure will change 0.1 Kg/cm2.)
10.6 If the system pressure goes down over 0.3 Kg/cm2 within 24 hours,
and no obvious leakage position can be found ,please check again
segment by segment , reduce the checking area.
10.7 After finding out the leakage and execute relative treatment , please
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Part 1
apply the pressure again and observe for another 24 hours.
11 Evacuation
Connect the vacuum and refrigerant system via gauge
manifold ,draw out the air and moisture with vacuum pump from the pipe ,
then make system get vacuum and dry.
Important points:
11.1 Please must use vacuum pump to evacuate system, forbid to use
refrigerant to pile out the air from system.
11.2 The propositional vacuum pump is 40L/min, vacuum pointer should
be below -755mmHg.
11.3 It is better to operate evacuation treatment repeatedly , after 2 hours’
evacuation, charge some refrigerant to system , then evacuate for
another 2 hours, repeat to do it 2 or 3 times, the system can reach a high
vacuum level.
11.4 The vacuum should be maintained often to ensure it can reach high
vacuum level.
11.5 Because the electric expansion valve may be close, evacuation
work should be done both from high pressure and low pressure sides.
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Part 1
12 Additional Refrigerant Charging
When the unit out of factory ,refrigerant charging amount is exclude
the refrigerant in the pipe , so after installation the piping, additional
refrigerant should be charged on site.
12.1 Connect the refrigerant tank, gauge manifold to high pressure and
low pressure stop valve via flexible hose in turn, open tank valve and pile
out the air in the pipe.
12.2 Additional charging amount should accord to the diameter and the
length of liquid pipe , final additional charging amount should be
marked on the outdoor nameplate.
12.3 Please must charge the additional refrigerant while weighing, forbid
to estimate according to current or voltage.
12.4 Additional refrigerant should be charged after evacuation or when
the system running in cooling mode.
12.5 Refrigerant should be charged into liquid pipe as liquid state ,if the
system is running in cooling mode , refrigerant should be gas state, or
compressor may be damaged.
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