Hitachi RAM-90NP5E User manual

SPLIT UNIT AIR CONDITIONER
INSTALLATION MANUAL
Outdoor Unit
RAM-90NP5E
●Carefully read through the procedures of proper
installation before starting installation work.
●The sales agent should inform customers regarding
the correct operation of installation.
Tools Needed For Installation Work
SAFETY PRECAUTION
●Read the safety precautions carefully before operating the unit.
●The contents of this section are vital to ensure safety. Please pay special attention to the following sign.
WARNING ........ Incorrect methods of installation may cause death or serious injury.
CAUTION ......... Improper installation may result in serious consequence.
Be sure that the unit operates in proper condition after installation. Explain to customer the proper way of
operating the unit as described in the user’s guide.
!
!
WARNING
!
CAUTION
!
● Flare nut must use a torque wrench without fail. Tighten with the specified tightening torque. If the flare nut is
tightened too much, after a long period of time, the flare nut breaks, Gas leakage, stagnation, touching fire, rarely
cause ignition.
● Sharp bending of the pipe use the polyethylene rod, bend not crushed the pipe. Gas leakage from the crushed part,
stagnation, touching fire, rarely cause ignition.
● Please request your sales agent or qualified technician to install your unit. Water leakage, short circuit or fire may
occur if you do the installation work yourself.
● Please observe the instructions stated in the installation manual during the process of installation. Improper installation
may cause water leakage, electric shock and fire.
● A brazed, welded, or mechanical connection shall be made before opening the valves to permit refrigerant to flow
between the refrigerating system parts. A vacuum valve shall be provided to evacuate the interconnecting pipe and/
or any uncharged refrigerating system part.
● Mechanical connectors used indoors shall comply with ISO 14903. When mechanical connectors are reused indoors,
sealing parts shall be renewed. When flared joints are reused indoors, the flare part shall be re-fabricated.
● Refrigerant tubing shall be protected or enclosed to avoid damage.
● Make sure that the units are mounted at locations which are able to provide full support to the weight of the units.
If not, the units may collapse and impose danger.
● Observe the rules and regulations of the electrical installation and the methods described in the installation manual
when dealing with the electrical work. Use power cables approved by the authorities of your country.
● Be sure to use the specified wire for connecting the indoor and outdoor units. Please ensure that the connections
are tight after the conductors of the wire are inserted into the terminals. Improper insertion and loose contact may
cause over-heating and fire.
● Please use the specified components for installation work. Otherwise, the units may collapse or water leakage,
electric shock and fire may occur.
● Be sure to use the specified piping set for R32. Otherwise, this may result in broken copper pipes or faults.
● When installing or removing an air conditioner, only specified refrigerant (R32) shall be allowed, do not allow air or
moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally
high so that a rupture may be caused.
● Be sure to ventilate fully if a refrigerant gas leak while at work. If the refrigerant gas comes into contact with fire,
a poisonous gas may occur. Be aware that refrigerants may not contain an odour.
● After completion of installation work, check to make sure that there is no refrigeration gas leakage. If the refrigerant
gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas
may occur.
● Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified
air conditioner technician or electrician. Improper repairs may result in water leakage, electric shock and fire, etc.
FOR SERVICE PERSONNEL ONLY
The Choice of Mounting Site (Please note the following matters and obtain permission from customer before installation).
Dimension of Mounting Stand
of the Outdoor unit
(unit : mm)
Names of Outdoor Components
●A circuit breaker or fuse must be installed. Without a circuit breaker or fuse the danger of electric shock exists.
The external switch shall be incorporated to completely disconnect from power supply. It should disconnect all
poles, and a contact separation of at least 3mm must be present.
●Do not install the unit near a location where there is flammable gas. The outdoor unit may catch
fire if flammable gas leaks around it.
● Do not install the indoor unit in a machine shop or kitchen where vapor from oil or its mist flows to the indoor
unit. The oil will deposit on the heat exchanger, thereby reducing the indoor unit performance and may deform
and in the worst case, break the plastic parts of the indoor unit.
●Please ensure smooth flow of water when installing the drain hose.
●Piping shall be suitable supported with a maximum spacing of 1m between the supports.
( mark is tool exclusive use for R32)
●+–Screwdriver ●Measuring Tape ●Knife
●Saw ●Pipe Cutter ●Hexagonal Wrench Key ( 4mm)
●Power Drill (ø 65mm ~ ø 80mm) Vacuum Pump
●Pliers or Wrench ●Torque Wrench Vacuum
Pump Adaptor ●Flare Tool Gas Leakage Detector
Manifold Valve Charge Hose ●Reamer ●File
Figure showing the Installation of Outdoor Unit.
● This unit is chargeless up 35m pipe length.
● Installation of pipe length less than minimum pipe length
requirement (3 meters) may generate an abnormal sound.
CAUTION
< IA0000: A >
This symbol shows that this
equipment uses a flammable
refrigerant.
If the refrigerant is leaked, together
with an external ignition source,
there is a possibility of ignition.
This symbol shows that the
Operation Instructions should be
read carefully.
This symbol shows that a service
personnel should be handling this
equipment with reference to the
Installation Manual.
This symbol shows that there
is information included in
the Operation Manual and/or
Installation Manual
WARNING
CAUTION
CAUTION
CAUTION
!
BURST HAZARD
Do not allow air, etc. to
get into refrigerant cycle
(piping)
RISK OF EXPLOSION
Compressor must be
stopped before removing
refrigerant pipes.
All service valve must be
fully closed after pumping
down operation.
WARNING
●Do not use means to accelerate the defrosting process or to clean, other than those recommended by the
manufacturer. Any unfit method or using incompatible material may cause product damage, burst and serious
injury.
●The appliance/pipe-work shall be stored in a well ventilated room with indoor floor area larger than Amin [refer
to Table 1] and without any continuously operating ignition source. Keep away from open flames, any operating
gas appliances or any operating electric heater. Else, it may explode and cause injury or death.
●The appliance/pipe-work shall be installed, and/or operated in a room with floor area larger than Amin [refer to
Table 1] and keep away from ignition sources, such as heat/spark/open flame or hazardous areas such as gas
appliances, gas cooking, reticulated gas supply systems or electric cooking appliances, etc.
●Do not pierce or burn as the appliance/pipe-work is pressurized. Do not expose the appliance/pipe-work to heat,
flame, sparks, or other sources of ignition. Else, it may explode and cause injury or death.
WARNING
!
Table 1: Minimum Floor area of the room A
min
(m
2
)
Minimum Floor Area of the room
A
min
(m
2
)
RAF-**RXE
RAD-**QPE
RAD-**RPE
RAI-**RPE
RAK-**QPE
RAK-**RXE
RAK-**RPE
Max
refrigerant
charge
amount
(kg)
Max
Piping
Length
(m)
Outdoor
Model
RAM-90NP5E 35 2.40 5.49 3.68 3.68 49.42
WARNING
!
●The Outdoor unit must be mounted at a location which can support
heavy weight. Otherwise, noise and vibration will increase.
CAUTION
!
●Do not expose the unit under direct sunshine or rain. Besides,
ventilation must be good and clear of obstruction.
●The air blown out of the unit should not point directly to animals
or plants.
●The clearances of the unit from top, left, right and front are
specified in figure below. At least 3 of the above sides must be
open air.
●Be sure that the hot air blown out of the unit and noise do not
disturb the neighbourhood.
●Do not install at a location where there is flammable gas, steam,
oil and smoke.
●The location must be convenient for water drainage.
●Place the Outdoor unit and its connecting cord at least 1m away
from the antenna or signal line of television, radio or telephone.
This is to avoid noise interference.
●Do not install outdoor unit facing strong wind direction. It may
damage the fan motor.
●Do not install the outdoor unit in a place where small animals
may build their nests. If small animal goes inside the unit and
touches the electrical parts, failure of the unit, smoke or fire may
be caused. Request your customer to keep the surrounding of
the unit is clean.
OUTDOOR UNIT
1. Proper place for installation
1.1 Outdoor unit
(1) Keep the space around the unit for maintenance and avoiding the effects of hindrance for normal ventilation of the
unit.
(2) The northern or eastern side of the building is better to install. At the installation on the southern or western side
unavoidably, some blind should be set up for the unit. (In this case, the blind must not obstruct the ventilation of
the unit.)
(3) You’d better not put the unit at a place where is full of dirt and at a place where is wet in the rain.
(4) Place as near as possible to the indoor unit.
(5) Install the unit in a stable place to minimize vibration or noise.
(6) After arranging the cords and pipes, secure them in place.
●This appliance must be earthed.
●Power is supplied through outdoor unit, do not connect power source to indoor unit.
WARNING
!
2. In the electrical installation a separator with a contact gap of more than 3mm has to be installed. During cleaning or service
the set has to be switched off with this separator.
Height difference
Height difference between indoor units should not be
more than 5m.
Piping length
(L1 + L2 + L3 + L4 + L5) = Maximum 75m
Minimum piping length for each indoor unit is 3m.
Maximum piping length for one indoor unit is 25m.
In case the pipe length is more than 35m, add refrigerant
R32 at 15 gram per every meter exceeds
Flare adaptor for piping
The flare adaptor for piping is required
depending on combination of indoor units.
● ø9.52 (3/8”) ➝ø 12.7 (1/2”)
Parts number TA261D-4 001
● ø12.7(1/2”) ➝ø 9.52 (3/8”)
Parts number TA261D-6 002
One unit of 1.5kW, 1.8kW, 2.5kW, 3.5kW or 5.0kW
(5kW unit: Optional flare adaptor for piping is necessary.)
One unit of 1.5kW, 1.8kW, 2.5kW, 3.5kW or 5.0kW
(5kW unit: Optional flare adaptor for piping is necessary.)
One unit of 1.5kW, 1.8kW, 2.5kW, 3.5kW or 5.0kW
(5kW unit: Optional flare adaptor for piping is necessary.)
One unit of 1.5kW, 1.8kW, 2.5kW, 3.5kW or 5.0kW
(1.8kW-3.5kW unit: Optional flare adaptor for piping is necessary.)
One unit of 1.5kW, 1.8kW, 2.5kW, 3.5kW or 5.0kW
(1.8kW-3.5kW unit: Optional flare adaptor for piping is necessary.)
Drain Pipe
1
3
Bush
QtyNo. Item
10
11
!
** is refering to indoor model name.
Please face this side (suction side)
of the unit to the wall.
Please remove side cover
when connecting the piping
and connecting cord.
Pull downward
BASE
CONDENSED WATER DISPOSAL OF OUTDOOR UNIT
There are holes on the base of Outdoor unit for condensed water to exhaust.
In order to flow condensed water to the drain, the unit is installed on a stand or a block so that the unit is 100mm above the ground as shown
figure. Join the drain pipe to one hole.
At first insert one portion of the hook to the base (Portion A), then pull the drain pipe in the direction shown by the arrow while inserting the
hook into the base. After installation, check whether the drain pipe cling to the base firmly.
When Using and Installing In Cold Areas
When the air conditioner is used in low temperature and in snowy conditions, water from the heat exchanger may freeze on the base surface
to cause poor drainage. When using the air conditioner in such areas, do not install the bushings. Keep a minimum of 250mm between the
drain hole and the ground. When using the drain pipe, consult your sales agent.
For more details, refer to the installation Manual for Cold Areas.
DRAIN PIPE
100 mm ABOVE
BUSH DRAIN PIPE
Do not use this valve. For factory use only.
Mount the Outdoor unit on stable ground to prevent vibration and increase of noise level.
Decide the location for piping after sorting out the different types of pipe available.
When removing side plate, pull the handle after releasing the hook by pulling it downward.
To the outdoor unit, up to five indoor units can be connected until the total value of each units’s capacity reaches
15.5 kW.
The pipe connection ports of the outdoor unit and connectable indoor units are shown above.
[Outdoor unit installation]
CAUTION
● Make sure to connect to two or more indoor units.
!
CAUTION
!

< IA0000: A >
Preparation of Pipe
1
●Use a pipe cutter to cut
the copper pipe.
●Jagged edge will cause leakage.
●Point the side to be trimmed downwards during trimming to prevent
copper chips from entering the pipe.
●Before flaring, please put on the flare nut.
Pipe Connection
2
INSTALLATION OF REFRIGERATING PIPES AND AIR REMOVAL
CAUTION
!
●Recommend to use
R32 flaring tool.
CAUTION
!
In case of removing flare nut of an Indoor unit, first
remove a nut of small diameter side, or a seal cap of
big diameter side will fly out. Prevent water from entering
into the piping when working.
Trimming tool
Copper pipe
Die
Die
Copper pipe
Flare nut
Torque
wrench
Wrench
Removal Of Air From The Pipe And Gas Leakage Inspection
Gas Leakage Inspection
Please use gas leakage detector
to check if leakage occurs at the
connection of Flare nut as shown
on the right.
If gas leakage occurs, further tighten
the connection to stop leakage. (Be
sure to use R32 detector)
3
Outer
Diameter
mm (inch)
6.35 (1/4")
9.52 (3/8")
12.70 (1/2")
1.0 ~ 1.5
1.0 ~ 1.5
1.0 ~ 1.5
Clutch type
A (mm)
1.5 ~ 2.0
1.5 ~ 2.0
1.5 ~ 2.5
Wing nut type
Thickness
(mm)
0.8
0.8
0.8
0.0 ~0.5
0.0 ~0.5
0.0 ~0.5
Flare tool for R32
Clutch type
Conventional flare tool
Outer
dia.of pipe
6.35 (1/4")
9.52 (3/8")
12.70 (1/2")
6.35 (1/4")
9.52 (3/8")
12.7 (1/2")
6.35 (1/4”)
9.52 (3/8”)
12.7 (1/2”)
15.87 (5/8”)
Spindle
Valve
head cap
Torque N·m
(kgf
·
cm)
14.0 – 18.0 (140 ~ 180)
33.0 – 42.0 (330 ~ 420)
50.0 – 62.0 (500 ~ 620)
19.6 – 24.5 (200 ~ 250)
19.6 – 24.5 (200 ~ 250)
29.4 – 34.3 (300 ~ 350)
12.3 – 15.7 (125 ~ 160)
3.92~5.88 (40~60)
9.80~10.78 (100~110)
Small dia. side
Large dia. side
Valve core cap
Small dia. side
Large dia. side
Small dia. side
Large dia. side
●Prevent moisture from entering pipe connection.
●Refrigerating machine oil not be applied to the outside of
the flare.
When refrigerating machine oil is applied to the outside of
the flare, excessive tightening of the flare nut, cracking of
the flare nut, destruction of the flare and gas leakage may
occur.
●When using the control valve, do not use deteriorated
packing. And, do not overtighten the steering wheel.
Gas leakage from the service valve part, stagnation, touching
fire, rarely cause ignition.
CAUTION
CONNECTION OF POWER CORD
Procedures of Wiring
Detail of Cutting the Connecting Cord
●The naked part of the wire core should be 10 mm and fix it to the terminal tightly. Then try to pull the individual wire to check if
the contact is tight. Improper insertion may burn the terminal.
●Be sure to use only wire specified for the use of air-conditioner.
●Please refer to the manual for wire connection and the wiring technique should meet the standard of the electrical installation.
●There is an AC voltage drop between the LN terminal if the power is on. Therefore, be sure to remove the plug from its socket.
WARNING
!
WARNING
!
●Leave some space in the connecting
cord for maintenance purpose and be
sure to secure it with the cord band.
●Secure the connecting cord along the
coated part of the wire using the cord
band. Do not exert pressure on the wire
as this may cause overheating or fire.
!
WARNING ●THIS APPLIANCE MUST BE EARTHED.
1. Installation procedure and notice
Especially, the selection of installation place need great care for the split type air conditioner, because it is very difficult to move
from place to place after the first installation.
1.1 Wiring
(1) Those terminal blocks for connecting the indoor and outdoor cables should be installed starting from the righthand side, in a
sequence of 1, 2, 3, 4, 5; in accordance with the units’ numbering system, as illustrated in the diagram. The left hand-most
terminal block is for the power supply connection use.
(2) Connect the electrical wiring between the Indoor and Outdoor unit, as shown in Fig. 1-1. Never connect the wiring by
mistake.
In case of wrong connection, the unit does not operate properly and it may cause malfunction.
(3) The connecting cord must be fixed by the band which is located near the terminal board.
1.2 Connection of the connecting cords and power cord
(1) Cut off the connecting cord, the power cord and strip the insulation of the wire, as shown in Fig. 1-2.
(2) Connect the connecting cord and power cord to the terminal board. (Fig. 1-3-2)
(3) Fix the connecting cords and power cord with steel band certainly. (Fig. 1-3-2)
Fig. 1-1
Fig. 1-2
WARNING
●If you cannot attach the side cover due to the connecting cord, press the connecting cord in direction to
the front panel to fix it.
●Be sure that the hooks of the side cover is fixed in certainly. Otherwise water leakage may occur and
this causes short circuit or faults.
●The connecting cord should not touch to service valve and pipes. (It becomes high temperature in heating
operation.)
Wiring of The Outdoor Unit
●Please remove the side cover for wire connection.
!
Checking for the electric source and the voltage range
●Before installation, the power source must be checked and necessary wiring work must be completed. To make the wiring
capacity proper, use the wire gauges list below for the lead-in from a pole transformer and for the wiring from a switch board
of fuse box to the main switch and outdoor unit in consideration of the locked rotor current.
●Do not connect wrongly at terminal “1 2 3” of indoor and outdoor unit.
To avoid misconnection, please refer attached terminal label as shown in Fig. 1-3-1.
●To avoid connecting cord scratch or clamp by side cover, it must be fix by band as shown in Fig. 1-3-2.
●Investigate the power supply capacity and other electrical conditions at the
installation location.
Depending on the model of room air conditioner to be installed, request the
customer to make arrangements for the necessary electrical work etc.
The electrical work includes the wiring work up the outlet. In localities where
electrical conditions are poor, use of a voltage regulator is recommended.
Circuit Breaker
25A
Bind connecting cords to make them
fit between the convex sections.
Grounding rod (optional)
(Earth wire and grounding rod are not supplied. Please use optional
items below.)
IMPORTANT
Type of grounding rod
SP-EB-2
Length
900mm
Cable length
up to 25m
Wire cross-section
2.5mm2
IMPORTANT
Fig. 1-3-2
CAUTION
Note:
●Outdoor supply cords shall not
be lighter than polychloroprene
sheathed flexible cord with code
designation 60245 IEC 57.
!
Connect the power
supply earth cord at
this earth screw.
After remove the
screw and cover,
put the connecting
cables and fix the
cover with screw.
Fig. 1-3-1
Arrange power cord so they do
not touch service valve.
CAUTION
!
This system integrates 5 sub-systems of piping with 1 pair of service valves installed. That pair will be used for air purging and pumping
down operations. Furthermore, due to valves are not installed to cover up the connecting mouths, there is a need for all unutilized
connecting mouths to be tightly covered up by seal caps and flared nuts.
CAUTION: Should all unutilized connecting mouths are not tightly covered up by seal caps and flared nuts, there will be potential gas
leaks occurring.
1. Air purging by using vacuum pump
Remove the valve cap from the service valves located at both the large and small pipe rims.
After removing the valve cap of the valve core of the service valves located at the large pipe rim, connect the charging
hose A.
After connecting the vacuum suction pump adaptor, connect the charging hose B to the adaptor.
During relocation or at any one time when the air conditioner unit is removed and re-installed, there is a possibility
of getting a closed electric-powered valve. Should the electric-powered valve be closed, even with air purging being
conducted, certain amount of air is still trapped within that area, hence, there is a need to open up the electric-powered
valve to do an air purging. Under such circumstances, before using the vacuum-suction pump, the main power supply
(LN terminal) should be connected to enable a complete opening up of the valve. After connecting the power supply for
approximately 90 seconds, the valve will be fully opened up, after which disconnect the power supply and start using the
vacuum suction pump.
(Refer to “Power Supply Terminal Connections” in regards to the LN terminal)
CAUTION: Ingress of air during the operating cycle may cause increase in pressure and other breakdowns.
Switch off the outdoor unit’s power supply
Shutting off via the manifold valve handle Hi, the handle Lo will open up and operate the vacuum pump that will run a
vacuum suction for approximately 60 minutes.
Upon a full shut off via the manifold valve handle Lo, the vacuum pump will stop operating.
Check to ensure that there is no gas leakage.
After removing the charging hose A, rotate the service valve spindles (2 units on both sides) in an anti-clockwise
direction to fully open up.
Reinstall the cap nuts to their original positions and tighten them to their specified torque values.
Disconnect the charge hose from the service valve.
Tighten the valve cap of valve core.
[Torque 12.3 - 15.7 N·m (125 - 160 kgf·cm)]
Attach the valve cap to the spindles of each large and small dia. pipe side service valves.
Tighten the valve cap of the spindle.
[Torque 19.6 - 24.5 N·m (200 - 250 kgf·cm)]
FINAL STAGE OF INSTALLATION
1
● The connected terminals should be completely sealed with heat insulator
and then tied up with rubber strap.
● Please tie the pipe and power line together with vinyl tape as shown in
the figure showing the installation of Indoor and Outdoor units. Then fix
their position with holders.
● To enchance the heat insulation and to prevent water condensation, please
cover the outdoor part of the drain hose and pipe with insulation pipe.
● Completely seal any gap with putty.
Power Source And Operation Test
2
Power Source
CAUTION
!
●Please use a new socket. Accident may occur due to the
use of old socket because of poor contact.
●Please plug in and then remove the plug for 2 – 3 times.
This is to ensure that the plug is completely plugged into
the socket.
●Keep additional length for the power cord and do not render
the plug under external force as this may cause poor contact.
●Do not fix the power cord with U-shape nail.
Operation Test
●Please ensure that the air conditioner is in normal operating
condition during the operation test.
● Explain to your customer the proper operation procedures as
described in the user’s manual.
●If the indoor unit does not operate, check to see that the
connections are correct.
Insulation material for pipe connection
Putty
Putty
Sleeve of
protection pipe
CAUTION
●Trial run should be conducted on one unit at a time
to check for incorrect wiring of connecting cord.
!
Pump Down Method When Reuse
Existing Piping (R410A Model) for
R32 Model
●Compressor oil of R410A model is insoluble in
compressor oil of R32 model. The mixing of
compressor oil may cause damage of compressor.
Possibility of Mixing
●Reuse of piping of R410A model is dangerous
because of its compressor oil.
●When reuse piping of R410A model, pump down
must be carried out properly to ensure compressor
oil which is remained inside piping is collected away.
Reuse of piping R410A model only apply if previous
model is Hitachi and proper pump down method is used.
CAUTION
!
To Reuse Old Piping
●Piping of R410A model can be reused only when air-
conditioner is properly pumped down.
●The purpose of pump down is to collect back the
compressor oil (which is mixed with refrigerant and
circulating inside refrigeration cycle) properly into the
outdoor unit of air conditioner.
!