Kelvinator 18000Btu/h User manual

INVERTER SPLIT - TYPE
ISSUE No.: 2 DATE: 04/09/08 P/No.: 2020323A2868

1
CONTENTS
Contact an authorised service technician for repair or maintenance of this unit.
Contact an authorised installer for installation of this unit.
The air conditioner is not intended for use by young children or infirmed persons without supervision.
Young children should be supervised to ensure that they do not play with the air conditioner.
If the power cord is to be replaced, replacement work shall be performed by authorised personnel only.
Installation work must be performed in accordance with the national wiring Standards by authorised
personnel only.
Take care not to catch fingers on the fan when adjusting vertical louvres.
This air conditioner may use R22, R407C or R410A refrigerant (Confirmed before installation)
!CAUTION
IMPORTANNT NOTES
SAFETY PRECAUTIONS
Warning .........................................................................................................................................2
Operating temperature ..................................................................................................................2
BEFORE INSTALLATION
Tools needed for installation ...................................................................................................... ... .3. .
Items required for installing the unit ................................................................................................3
Typical installation......................................................................................................................... .4...
REFRIGERANT PIPE CONNECTION
Refrigerant pipe connection ....................................................................................................... 10.
Inside you will find many helpful hints on how to install and test the air conditioner properly.
Read This Manual
TEST RUNNING
Test running ...................... .........................................................................................................22
AIR PURGING
Air purging ...................................................................................................................................20
Satety and leakage check ...........................................................................................................22
ELECTRICAL WORK
Connecting the cable to the indoor unit ......................................................................................17
Connecting the cable to the outdoor unit ....................................................................................18
INSTALLATION
Installation .....................................................................................................................................5
CHECKING THE DRAINAGE AND FORMING THE PIPING
Checking the drainage ................................................................................................................19
Forming the piping ......................................................................................................................19

!
2
SAFETY PRECAUTIONS
OPERATING TEMPERATURE
50 27 34 -15

65
Clip Anchor
Seal (See page 10 for details)
16.0mm
3
Cable Tie (5~10)
Insulation materials
BEFORE INSTALLATION
Tools needed for installation
Items required for installing the unit
(See page 10 for details)

Connecting
pipe Assembly
Inst allatio n Plate
Self-tapping Screw A Clip Anchor
Loop the
connective
cable.
C
B
A
60cm above
60cm above
10cm above
100cm above
6
12cm above
Air Filter
Air Outlet
20cm above
12cm above
15cm above
1
2
3
Mole than 1.7m
Lessthan 2.3m
4
BEFORE INSTALLATION
Typical installation
(If applicable)

2
2
5
INSTALLATION
Read completely then follow step by step.
Indoor unit
Outdoor unit
Rooftop installatiom
Installation
Fig.1
Fig.2

15
15
15
18
Capacity is based on standard length and maximum allowance
length is on the basis of reliability.
Oil trap should be installed every 5~7 metres.
When the connecting pipe is longer than 5 metres, additional
refrigerant should be added into the unit according to the
above table through the service port on the “LO” valve on
outdoor unit.
24
28 40
40
Indoor unit installation
Fig.4
Note :
1. Fit the Installation Plate
1). Fit the installation plate horizontally
on structural parts of the wall with
spaces around the installation plate.
2). If the wall is made of brick, concrete or
the like, drill eight (8) 5mm diameter holes
in the wall. Insert Clip anchor for appropriate
mounting screws.
3). Fit the installation plate on the wall with eight
(8) type “A” screws.
Correct orientation
of Installation Plate
Fit the Installation Plate and drill holes in the wall according to the wall structure and corresponding
mounting points on the installation plate.
(Dimensions are in “mm” unless otherwise stated)
6
Piping length elevation
8
10
10
8
820
20
20
25
25
5/8
16.0mm
3/8
9.53mm
5/8
16.0mm
3/8
9.53mm
21 40
10 25
5/8
16.0mm
3/8
9.53mm
INSTALLATION
Fig.3

7
2. Drill a hole in the wall
1. Determine hole positions according to
the diagram detailed in Fig.5. Drill
one (1) hole ( 65mm) slanting slightly
to outdoor side.
2. Always use wall hole conduit when
drilling metal grid, metal plate or the like.
Indoor
Outdoor
5-7mm
Fig.6
A
40
B
Right rear side
refrigerant
pipe hole 65
Installation plate
Indoor unit outline
Left rear side
refrigerant
pipe hole 65
150mm or more to ceiling
120mm or more
to wall
120mm or more
to wall
7,000 & 9,000Btu/h model: (A: 710, B: 250)
12000Btu/h model: (A: 790, B: 265)
90
40
45
150mm or more to ceiling
Indoor unit outline Installation plate
305
Right rear side
refrigerant
pipe hole 65
Left rear side
refrigerant
pipe hole 65
120mm or more
to wall
120mm or more
to wall
850
45
90
45
45
18,000Btu/h model
INSTALLATION
Wall
150mm or more from the ceiling
Indoor Unit Outline
120mm or more
from the wall
380
Hooked Part
380
998
120mm or more
from the wall
322
67
130
65
65
130
50
50
22
Fig.5
21,000 & 24,000 Btu/h models
Above 120 from
the wall
Above 120 from
the wall
Above 150 from
the ceiling
325
55
95
95
55
1250
815 257
178
55
58
Pipe hole
Hooked Part Hooker Part
Pipe hole
Indoor unit outline
28,000Btu/h model
Fig s 5’

8
1. For the left-hand and right-hand piping, remove the pipe cover from the side panel.
2. For the rear-right-hand and rear-left-hand piping, install the piping as shown. Bend the
c pipe to be laid at a height of 43mm or less from the wall.onnecting
3. Fix the end of the c pipe. (Refer to Tightening Connection in REFRIGERANT
PIPING CONNECTION)
onnecting
Connecting pipe
Indoor unit outline
C pipeonnecting
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43
1. Pass the piping through the hole in the wall.
2. Put the upper claw at the back of the indoor unit on
the upper hook of the installation plate, move the
indoor unit from side to side to see that it is securely
hooked.
3. Piping can easily be made by lifting the indoor unit
with a cushioning material between the indoor unit
and the wall. Remove cushioning material after finish
piping.
4. Push the lower part of the indoor unit up on the wall,
Then move the indoor unit from side to side, up and
down to check if it is hooked securely.
Fig.10
4. Indoor unit installation
Fig.8
Fig.9
3. Pipe and Drainage InstallationConnecting
1. Run the drain hose sloping downward. Do not install the drain hose as illustrated below.
2. When connecting an extension drain hose, insulate the connecting part of the extension
drain hose with a shield pipe, do not let the drain hose become slack.
Fig.7
Right-hand piping
Side Part cover
Left-hand piping
Rear-right piping
Rear-left piping
Do not block water flow with a rise.
Do not put the end of the
drain hose into water.
Upper Hook
Lower Hook
Cushioning
material
INSTALLATION

9
5. Piping and wrapping
Bundle the tubing, connecting cable, and
drain hose with tape securely and
evenly as shown in Fig.11.
Because the condensed water from rear
of the indoor unit is gathered in ponding
box and is piped out of room. Do not put
anything else in this box.
Indoor unit
Connecting
pipe
Pipe room
Ponding box
Wrapping belt
Connecting
cable
Drain hose
Fig.11
Connect the indoor unit first, then the outdoor unit.
Do not allow the piping to be exposed out from the back of the indoor unit.
Be careful not to let the drain hose become slack.
Heat insulate the c piping.
Be sure that the drain hose is located at the lowest side of the bundle. Locating
at the upper side can cause drain pan to overflow inside the unit.
Never cross connect or inter wind the power wire with any other wiring.
Run the drain hose sloped downward to drain out the condensed water smoothly.
onnecting
CAUTION
Install the outdoor unit on a rigid base to prevent noise and vibration.
Select the air outlet direction so that discharged air is not blocked.
In the case where the installation location is exposed to strong winds,
make sure the fan operates properly by putting the unit lengthwise along the wall
or by using a shield to minimise wind exposure.
Especially in windy areas, install the unit to minimise exposure to wind.
For suspended installations, the installation bracket should follow with technique
requirement in the installation bracket diagram. The installation wall should be solid
brick, concrete or of same construction,
or reinforced to minimise movement or vibration.
The connection between the wall bracket and the
air conditioner should be firm, stable and reliable.
Ensure there lare no obstacles which block
flow air.
Strong
wind
Fig.12
Outdoor unit installation
Outdoor unit installation precautions
INSTALLATION

REFRIGERANT PIPE CONNECTION
Securing of outdoor unit
Anchor the outdoor unit with
a bolt and nut 10 or 8 tightly
and horizontally on a concrete
or rigid mount.
If a drain elbow is used, the unit should be placed
on a stand which is taller than 3cm.
If the unit is used in an area where temperature
falls below 0 C for 2 or 3 days in succession, it
is recommended not to use a drain elbow, as the
drain water may freeze and the fan will not rotate.
Fit the seal into the drain elbow, then insert
the drain joint into the base pan hole of the
outdoor unit, rotate 90 to secure. Connect
the drain joint with an extension drain hose
(Locally purchased), in instances where you
need to drain condensed water away from the unit.
O
Drain joint installation
Seal
Drain joint
Base pan hole of
outdoor unit
Seal
Drain pipe
Refrigerant pipe connection
Oblique
90 C Roughness
Burr
Main cause for refrigerant leakage
is due to defects in the flaring work.
Carry out correct flaring work
using the following procedure:
A: Cut the pipes and the cable.
1. Use the piping kit accessory (if applicable) or pipes
purchased locally.
2. Measure the distance between the indoor and the outdoor unit.
3. Cut the pipes a little longer than the measured distance.
4. Cut the cable 1.5m longer than the pipe length.
1. Flaring work
Fig.14
A
B
Air inlet
Air outlet
Air inlet
Fig.13
B: Burr removal
1. Completely remove all burrs from the cut
cross section of pipe/tube.
2. Face the end of the copper pipe/tube in a
downward direction as you remove burrs in
order to avoid burrs dropping into the tubing.
Pipe
Reamer
Fig.15
Fig.16
Model
18000Btu/h
A(mm)
530
B(mm)
290
21000Btu/h
24000Btu/h
Face down
10
560 335
590 333

Bar
Copper pipe
Clamp handle Red arrow mark
Cone
Yoke
Handle
Bar
"A"
C: Putting flare nut on
Remove flare nuts attached to indoor and
outdoor unit, then put them on pipe/tube
having completed burr removal (Note: It is not
possible to put them on after flaring work).
Flare nut
Copper tube
Fig.17
Fig.18
D: Flaring work
Firmly hold copper pipe in a die according
to the dimension shown in the table below.
Carry out flaring work using flaring tool as
shown below.
Caution
Align the center of the pipes.
Sufficiently tighten the flare
nut with fingers, and then tighten
it with a spanner and torque wrench
as shown.
Tightening Connection
Excessive torque can break nut
depending on installation conditions.
Fig.19
Indoor unit tubing Flare nut Pipings
Outer diam.
(mm)
A(mm)
Max. Min.
6.35 1.3 0.7
9.53
1.6 1.0
12.7
1.8 1.0
12.7
1.8 1.0
Outer
diam.
Tightening
torque (Kg.m)
Additional tightening
torque (Kg.m)
6.35
12.7
9.53
16.0
2.4 2.2
7.5 8.0
16.0
5.0 5.5
3.0 3.5
1.6 2.0
11
REFRIGERANT PIPE CONNECTION

Smooth all round
Improper flaring
Even length
all round
Tubing retainer
Rear l eft
Fron t
Rear right
Drain hose
Piping
Connecting cable
For Rear Right Piping
Connetion of pipes - Indoor
:
:
REFRIGERANT PIPE CONNECTION
12
Check
E:

Insert the piping, drain hose and the
connecting cable into the piping hole.
Tubing retainer
Connecting
cable
:
:
:
:
:
REFRIGERANT PIPE CONNECTION
13

Tubing retainer
14
For Rear Left Piping
:
:
:
:
REFRIGERANT PIPE CONNECTION

:
:
:
:
REFRIGERANT PIPE CONNECTION
15

Connection of pipes - outdoor
Tubing retainer
Connecting
cable
:
:
:
:
:
7.5 8
REFRIGERANT PIPE CONNECTION
16
.

17
ELECTRICAL WORK
Terminal block of indoor unit
9000Btu/h model
18000Btu/h model
all models according to diagram
To outdoor unit
Cord clamp
L N S
To outdoor unit
1 2(N) S
24000Btu/h model
28000Btu/h model
18
24
28 2.5
16A
16A
20A
Electrical box
cover
Front Panel
10mm
40mm
Code wire
The supply voltage must be consistent with
the rate voltage of the air conditioner.
Connect the cable to the indoor unit
NOTE: Before performing any electrical work, turn off the main power to the system.
Connect the cable to the indoor unit
1.5
1.5
1.0
10A
21 16A 1.5
12000Btu/h model
21000Btu/h model
6

LS
N
Wire connector of outdoor unit
Wire -holding board
40mm
10mm
Connect the cable to the outdoor unit
:
:
:
:
ELECTRICAL WORK
7
18

Checking the drainage
CHECKING THE DRAINAGE AND FORMING THE PIPING
Downward
slope
Water
leakage
Water
leakage
Water
leakage
Ai r
Do n ot
ra ise
Ac cum ulate d
dr ain w ater
Tip of drain hose
dipp ed i n water
Di tch
Less than
50mm gap
:
:
:
:
Forming the piping
19
:
B
.