Rinnai Brivis DONSC10Z71 User manual

Brivis ICE Inverter
INSTALLATION INSTRUCTIONS
OUTDOOR INDOOR
Brivis System Models
Outdoor
Indoor
DONSC10Z71
DINLU10Z7
DONSC13Z71
DINLU13Z7
DONSC15Z71
DINLU15Z7
DONSC17Z71
DINXU17Z7
PLEASE READ THESE INSTRUCTIONS CAREFULLY BEFORE
INSTALLING & USING THIS PRODUCT

2
Table of Contents
1.0 INTRODUCTION .....................................................................................................................................3
1.1 Brivis ICE R410a Inverter Range ............................................................................................................3
1.2 Safety / Warnings ....................................................................................................................................3
1.3 Codes / Regulations ................................................................................................................................3
2.0 COMPONENTS .......................................................................................................................................4
2.1 Indoor Unit (Cooling Coil) ........................................................................................................................4
2.2 Starting Collars ........................................................................................................................................5
2.3 P-Trap ......................................................................................................................................................6
2.4 Outdoor Unit ............................................................................................................................................7
3.0 TYPICAL INSTALLATION......................................................................................................................8
4.0 INDOOR UNIT INSTALLATION .............................................................................................................9
4.1 Location .................................................................................................................................................10
4.2 Condensate Drain / Safety Tray ............................................................................................................10
4.3 Minimum Service Access.......................................................................................................................10
4.4 Electrical Connection .............................................................................................................................11
4.5 System and Ductwork Design ...............................................................................................................11
4.6 Brivis Heater Thermistor position (if applicable)....................................................................................11
4.7 Filtration .................................................................................................................................................11
4.8 General Arrangement Drawings ............................................................................................................12
5.0 OUTDOOR UNIT INSTALLATION .......................................................................................................13
5.1 Location .................................................................................................................................................13
5.2 Electrical Connection .............................................................................................................................13
5.3 Thermostat Control Wiring.....................................................................................................................13
5.4 Wiring Diagrams ....................................................................................................................................14
5.5 General Arrangement Drawings & Clearance Requirements Outdoor Unit ..........................................17
6.0 REFRIGERATION CHARGE & PIPE-WORK.......................................................................................18
6.1 Piping Design.........................................................................................................................................19
6.2 Pipe-work connection ............................................................................................................................20
6.3 Expelling the air with the vacuum pump................................................................................................21
6.4 Charging the system..............................................................................................................................22
7.0 START-UP AND COMMISSIONING.....................................................................................................23
7.1 Sequence of Operation..........................................................................................................................24
7.2 Cooling Capacity....................................................................................................................................25
7.3 Specifications.........................................................................................................................................26
7.4 Commissioning Sheet............................................................................................................................27
Specifications subject to change without notice. © 2018 Brivis Climate Systems Pty. Ltd.

3
INSTALLATION, START-UP & MAINTENANCE
INSTRUCTIONS
1.0 INTRODUCTION
Read all instructions before proceeding with the installation and start up.
•This equipment must be installed in accordance with all relevant regulatory authority and industry requirements.
•Only qualified, licensed technicians shall perform works on these units; failure to do so will result in warranty being
void.
•Definitions:
“Shall” indicates a mandatory requirement of this manual
“Should” indicates a recommended requirement of this manual
•Deviation from these instructions, may at the discretion of Brivis, void the warranty. As a result, the homeowner and
or installer may be charged a fee for non-product warranty related call outs. Also note that failure to comply with these
instructions may preclude Brivis from being able to service the appliance.
THE USER SHOULD RETAIN THIS MANUAL FOR FUTURE REFERENCE.
1.1 Brivis ICE R410a Inverter Range
The Brivis Inverter ICE series is a refrigerated cooling split only type air conditioner designed for connection to compatible
Brivis Ducted Gas Heaters. Brivis Inverter ICE utilises the heating system’s ductwork and air circulation fan to distribute
cool, filtered refrigerated air.
ICE
Outdoor Model
ICE
Indoor Model
Nominal Cooling
Capacity - kW
Recommended Brivis
Gas Ducted Heater Model
DONSC10Z71
DINLU10Z7
10
Refer to latest Brivis Gas Ducted Heater
Specifications for Maximum Recommended
Add-On Cooling Capacity
DONSC13Z71
DINLU13Z7
13
DONSC15Z71
DINLU15Z7
15
DONSC17Z71
DINXU17Z7
17
Table 1 – Brivis ICE Models and Heater Compatibility
•Some heaters may require a transition to modify its starting collar (pop) size to suit the inlet pop size of the ICE
indoor coil. DO NOT REDUCE POP SIZES ON INDOOR COIL or HEATER.
•Ensure minimum specified air quantity requirements passes through the ICE cooling coil at all times
•Ductwork and fittings must be sized to handle the total cooling airflow through the system on either whole home or
zoned basis.
1.2 Safety / Warnings
The unit is designed to provide safe and reliable service when operating within design specifications. To avoid injury to
personnel and damage to equipment or property when operating the equipment, the following safe practices should be
observed as a minimum.
•Check the unit weight to be sure the lifting equipment is adequate
•Disconnect power to the unit before working on it
•Do not remove access panels or doors until fans have completely stopped
•Do not enter a fan cabinet while the fan is running
•Protect materials when welding or flame cutting. Use suitable cloth to contain sparks. Have a fire extinguisher at
hand and ready for immediate use
•Do not place articles on or against this appliance
•Do not use or store flammable materials near this appliance
•Do not spray aerosols in the vicinity of this appliance while it is in operation
•Do not modify this appliance
Note: The communication cable installed between the indoor coil and outdoor unit shall be:
1. Field supplied
2. 2-core shielded cable
3. Earthed at the CDU end, refer to Fig.14
Failure to do so may prevent the correct operation of the unit

4
1.3 Codes / Regulations
Brivis ICE units must be installed, serviced or repaired in accordance with these instructions and related regulations, codes,
standards, and authorities. These include but may not be limited to:
•Ozone Protection and Synthetic Greenhouse Gas Management Regulations 1995
•AS/ NZS 1677.2 - Australian Standard, Refrigeration systems, safety requirements for fixed applications
•AS 4211.3 Gas recovery or combined recovery and recycling equipment
•HB 276-2004 : A Guide to Good Practice for Energy Efficient Installation of Residential Heating, Cooling & Air
Conditioning Plant & Equipment
•AS 4254 - Ductwork for air-handling systems in buildings
•Local Electricity Authority
•Local Building Regulations
•Environment Authorities
•Building Code of Australia (BCA)
•Brivis “SuperSizeGuide”
It is recommended the Brivis “SuperSizeGuide” be followed in estimating cooling requirements and for system design that
will result in efficient installation and provide a higher level of comfort and economical operation.
Brivis assumes no responsibility for equipment installed in violation of any code or regulations and these installation
instructions.
2.0 Components
Upon receiving units, inspect for damage and ensure appliances match your order. In the event of damage, or incorrect delivery, notify
supplier immediately. Brivis accepts no responsibility for installation of damaged or incorrect units.
2.1 Indoor Unit (Cooling Coil)
Remove packaging from unit and any protective foam packing from coils and pipes. Indoor units are shipped with a holding
charge of dry nitrogen. Check to confirm the holding charge. For lifting details refer to the General Arrangement drawings.
•Brivis Inverter ICE indoor units shall be installed only downstream of a heater
•Brivis Inverter ICE is not designed for installation on a marine craft, houseboat, or any similar environment.
Fig. 1a – DINXU Indoor Cooling Coil
P-Trap
Assembly
Access
Plate
Power Cord &
Plug
Electric Box

5
Fig. 1b – DINLU Indoor Cooling Coil
2.2 Starting Collars
Insert starting collar (pop) into the hole in pop plate, ensuring pop flange is placed over the inner supply air wall of the
cabinet. Spread the pop flange to fit tight in the cabinet’s hole with the notch side of the collar over lapping the other.
Secure the pops with the rivets supplied.
Fig. 2a – DINXU Indoor Unit Starting Collar Assembly
P-Trap
Assembly
Access Plate
Power Cord &
Plug
Electric
Box
Pop
flange
Rivets
(Supplied)

6
Fig. 2b – DINLU Indoor Unit Starting Collar Assembly
2.3 P-Trap
The Indoor Unit incorporates an evaporator drip tray and is supplied with a 20mm Female Pressure Pipe drain spigot, which
is to be connected to the "P" trap.
•Always install the “P” trap as close to the unit as possible
•Fill the "P" trap with water during installation before starting unit, to prevent air movement through the drainpipe
•Ensure trap contains water at all times
•Adjust the level of the unit to ensure that the condensate drains from the evaporator drip tray (approx. 10 - 15mm
incline from back to front)
Important Note
•Before installing and commissioning the P-Trap, check to ensure that all joints are sound, including
the preformed U-Bend.
Fig. 3 - “P” TRAP ASSEMBLY
Fig. 4 - “P” TRAP INSTALLATION
Pop
flange
Rivets
(Supplied)

7
2.4 Outdoor Unit
Fig. 5 - Outdoor Units
DONSC10Z71
DONSC13Z71, 15Z71 & 17Z71

8
A. Ensure 1m minimum, or preferably 2½ times
the duct diameter, STRAIGHT duct length
before any take-offs occur
B. Ensure 1m minimum STRAIGHT duct between the
Gas Ducted Heater and ICE coil unit
C. Safety Drain Tray (field supplied), independently
drained
D. Working Platform (field supplied)
E. Unit Mounts (field supplied) to be fitted under unit
F. P Trap Assembly (supplied) on primary condensate
drain – fit as close as possible to unit
G. Condensate drain pipe to be pitched down and to be
terminated in an approved manner as specified by
local codes
H. Terminate the Safety Drain Tray in a position so as not
to cause a nuisance, but where the home owner can
see if water is dripping. Instruct owner to contact
Installer or Brivis if Safety Drain Tray outlet drips water
I. Electric box with standard 10 A power plug
•Run 2 core shielded communication cable from
indoor coil electric box
(Terminals Q, P) to the outdoor unit (S1,S2).
•Run 24VAC from the heater into the indoor coil
electric box (Terminals A1, A2)
3.0 TYPICAL INSTALLATION
Fig. 6 - Typical Indoor Unit Installation
Fig. 7 - Typical Under Floor Installation
A. Ensure 1m minimum, or preferably 2½ times the
duct diameter, STRAIGHT duct length before any
take-offs occur
B. Ensure 1m minimum STRAIGHT duct between the
Gas Ducted Heater and ICE coil unit
C. Safety Drain Tray (field supplied), independently
drained
D. Working Platform (concrete slab)
E. Unit Mounts (field supplied) to be fitted under unit
F. P Trap Assembly (supplied) on primary
condensate drain – fit as close as possible to unit
G. Condensate drain pipe to be pitched down and to
be terminated in an approved manner as specified
by local codes
H. Terminate the Safety Drain Tray in a position so
as not to cause a nuisance, but where the home
owner can see if water is dripping. Instruct owner
to contact Installer or Brivis if Safety Drain Tray
outlet drips water
I. Electric box with standard 10 A power plug
•Run 2 core shielded communication cable from indoor coil electric box
(Terminals Q, P) to the outdoor unit (S1,S2).
•Run 24VAC from the heater into the indoor coil electric box (Terminals A1, A2)
IMPORTANT NOTE
1. Ensure unit is sitting on something that is ‘weather/waterproof’
2. Make sure there is adequate ventilation to help prevent condensation
3. Ensure the P-Trap and drain are working effectively
4. Always mount the coil on (field supplied) supports to create an air gap to prevent moisture/condensation
5. Always mount coil over safety tray

9
4.0 INDOOR UNIT INSTALLATION
•Indoor coils are supplied with a nitrogen holding charge ranging from 400kPa to 700kPa
•Connect a suitable pressure gauge to the indoor coil valve to ensure the internal pressure is at least 400kPa
•If the measured pressure is less than 400kPa, check and if necessary repair any leaks found before proceeding
•Remove the nitrogen holding charge by connecting a charging line with valve depressor
•For SWEAT connection: Sweat off the liquid & suction pipe blanking plates and proceed to pipe up in line with section
6.0 (Refrigeration Charge & Pipe-work)
•For FLARE connection: Un-screw the flare connection, remove the plastic seal and proceed with section 6.0
(Refrigeration Charge & Pipe-work)
•Some heaters may require a transition to modify its starting collar (pop) size to suit the inlet pop size of the ICE indoor
coil. DO NOT REDUCE POP SIZES ON INDOOR COIL or HEATER
•Ensure minimum specified air quantity requirement passes through the ICE cooling coil at all times
•Ductwork and fittings must be sized to handle the total cooling airflow through the system on either whole home or
zoned basis
•24 volt control wiring shall be installed from the indoor coil electric box (Terminals A1, A2) to the Heater (StarPro
series) or to Brivis Thermostat as required
•The electric box has standard 10 A power cord and plug , please do not cut or modify the cord
•2 core shielded communication cable shall be installed from the indoor unit (Terminals Q, P) to the outdoor unit
(S1,S2). One end of the shield has to be earthed.
•If the Brivis Heater requires a remote thermistor installed in the supply air ductwork, position it in the supply air starting
collar (discharge pop) of the cooling coil (see Section 4.6)
.

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4.1 Location
•Choose a location that is suitable for refrigeration piping and condensate drainage
•Allow adequate provision is made for service access
•Indoor Coil Unit is not weatherproof and should be installed so that there is no chance of direct sunlight, water or
moisture coming into contact with the outer casing
•Where the unit is installed in the roof or ceiling space ensure the building structure is capable of supporting the unit’s
weight – do not suspend unit from support handles
•Brivis Inverter ICE indoor units shall be installed only downstream and at least 1m distance from heater’s main supply
air outlet and always before the first duct branch-take-off fitting
•Never put the Indoor Coil Unit in the Return Air part of the duct system, this may result in condensation forming in the
Heater, causing corrosion and damage to vital components
•Ensure a minimum of 1m, or preferably 2½ times the duct diameter of straight ductwork, is installed immediately
downstream of the Indoor Coil Unit before any fitting, divergence or branch-take-offs occur. Failure to do so may
compromise airflow, system performance and reliability
.
4.2 Condensate Drain / Safety Tray
•A non-flexible drainpipe shall be installed for the primary condensate run-off with a continuous downward grade away
from the unit of not less than 1:50
•When the indoor unit is installed in a roof or ceiling space, an additional field-supplied Safety Drain Tray shall be
installed under the Indoor Unit
•Safety Tray must also be separately drained, arranged to terminate in a position where the home owner can see if
water is dripping from the outlet. Please instruct the end user to call their Installer or Brivis Service should they notice
water dripping from the Safety Tray drain outlet
4.3 Minimum Service Access
For servicing, a minimum clearance of 600mm must be provided in front of the access panel side of the unit for its entire
length.
•Where installed on a platform in the roof space, the platform should also extend 600mm out in front of the access
panel side of the unit for its entire length
•A 600mm wide platform is required to connect between the indoor unit and the access opening or the ducted heating
unit for the purpose of access
•Adequate lighting should be installed, such as permanent artificial lighting with switch located at roof access opening
•Duct work should not be installed across the platform preventing safe access
Fig. 8b – DINLU Indoor Service Clearances
Fig. 8a – DINXU Indoor Service Clearances
AIR FLOW
ELEC
BOX
ACCESS
PANEL
PLATFORM
600mm
PLATFORM
600mm
AIR FLOW
ELEC
BOX
ACCESS
PANEL

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4.4 Electrical Connection
•The electric box has standard 3 m, 10 A power cord and plug; do not cut or modify the cord
•24 Volt control wiring shall be installed from the indoor coil electric box (Terminals A1, A2) to the Heater (StarPro
series) or to Brivis Thermostat as required
•2 core shielded communication cable shall be installed from the indoor unit to the outdoor unit. One end of the cable
has to be earthed. See Fig.14.
The unit is pre-wired with a 3-pin plug and lead, and should be plugged into a standard 10 Amp 220 to 240 Volt fixed
switched socket outlet adjacent to the unit, in a convenient location so it can be turned OFF quickly and easily.
The electricity supply must be 220 to 240 Volts at 50 Hz, and from an authorised power supplier. Generators should never
be used, as their output may be incompatible with, or prone to damage the unit’s electronic components.
4.5 System and Ductwork Design
Good duct design and sizing are essential to every Brivis ICE cooling system. Use the Brivis “SuperSizeGuide”, Brivis size,
or HB276 for guidance. In general:
•The ductwork system shall be designed to ensure the minimum recommended cooling airflow as specified in the
technical data, is capable of being supplied at all times.
•Ductwork should be airtight and have a minimum insulation rating as specified by local codes; under no
circumstances should it be less than a rating of R1.0
•It should also be properly sized, and curves and bends should be smooth enough to ensure that the air flows through
efficiently, quietly and with minimal resistance
•The registers and diffusers should be large enough and of good design. They should minimise noise, while providing
the correct distribution pattern
•The positive return air system should be fitted with a grille large enough to accept the full air capacity of the system at
low noise levels
•Adequate air filtration must be provided
•If the system uses high level outlets (e.g. ceiling diffusers), then the return air inlet should be at a low level
4.6 Brivis Heater Thermistor position (if applicable)
•Mount heater thermistor in the discharge (outlet) pop of the cooling coil
•Drill a 3/4” (20mm) diameter hole through the top of the evaporator coil’s outlet pop
•Carefully insert the thermistor assembly (probe end first) into this hole and secure using the two screws provided
•Ensure that the thermistor plug is facing upwards and is accessible for servicing
•Connect the thermistor extension lead from the heater to the thermistor assembly and ensure that the plug is
connected securely
•Ensure that the thermistor extension lead is secured to timbers or duct outer casing to prevent damage
4.7 Filtration
A filter must be fitted into the system, and should be easily accessible for regular cleaning. Please refer to the guidelines
for return air filter grilles accompanying the Gas Ducted Heater.
Note: A qualified electrician must install the 220 to 240 Volt wiring according to local regulations.
Note: It is important that all ductwork and fittings be insulated. It is mandatory under some building codes to also install
fire rated duct. Check with your local authority.

12
4.8 General Arrangement Drawings
Fig. 9 - Indoor Unit Dimensions – Model DINXU17Z7
Fig. 10 - Indoor Unit Dimensions Models - DINLU10Z7, DINLU13Z7 & DINLU15Z7
902
540
40
823
657
538
50
678
362
811
748
777
549

13
5.0 OUTDOOR UNIT INSTALLATION
5.1 Location
•The unit must be installed in accordance with relevant authority requirements.
•The unit should not be accessible to general public
•Do not install the unit where there is a possibility it will present a noise problem for either the home owner or
neighbours, or exceed the noise guidelines as set down by local or state legislation or regulatory bodies.
•Avoid positioning unit in direct sunlight
•The unit must be installed in an area that is well ventilated - avoid positions where condenser air may be recirculated
•The location shall easily support the outdoor unit’s weight
•Locate the outdoor unit as close as possible to the indoor unit
•Allow for drainage of rainwater
•Ensure minimum clearances, as outlined in the Outdoor Unit Clearances drawing, Fig. 16 (Section 5.5), are
maintained
Mounting at ground level:
•The unit shall be mounted and fastened on to a solid, level foundation
•Apply rubber “waffle pad” or similar between the unit feet and the foundation if required
Mounting on the roof:
•Ensure that the weight of the unit is not excessive for the design of the roof structure
•Unit shall be mounted onto either a suitably designed metal frame or timber blocks, ensuring that there is an insulating
membrane such as rubber “waffle pad” between the roof structure and the frame for vibration elimination
•Metal frame or timber supports must be of sufficient size and length to prevent the unit tipping over in high winds.
5.2 Electrical Connection
All electrical work shall be carried out by a qualified and licensed electrician. The installation shall comply with current
relevant standards, wiring rules and local authority requirements. Means for disconnection (i.e. isolating switch and circuit
breaker) shall be incorporated according to wiring rules. Wiring sizing is the responsibility of the installer as it depends on
the conditions and regulations applicable to each installation site. Refer to the electrical drawings and specifications for
electrical data.
The electrical installation requirements are generally as follows:
•The outdoor unit shall be supplied directly from a distribution board.
•An external isolating switch shall be installed adjacent to the Outdoor Unit.
•Short circuit protection for the unit shall be supplied at the main switchboard Wire fuses shall not be used - check SAA
Wiring Rules for “Protection” sizing and cable sizes. Refer to specification sheet for circuit breaker sizing.
•Do not drill into the cabinet as critical internal components may be damaged during this process.
•Avoid running the control/communication cables near sources of electromagnetic interference such as electrical
motors, transformers, high current cables etc. Use shielded cable and earth it on one end.
•Ensure that power supply is adequate.
•2 core shielded communication cable, earthed at one end (see Fig. 14) shall be run between the indoor coil electric
box and the outdoor unit.
5.3 Thermostat Control Wiring
•All control wiring is 24 Volt, and is required to be installed between the indoor coil electric box (Terminals A1, A2) and
the Gas Ducted Heater or programmable Controller in accordance with the wiring instructions supplied with the Brivis
Gas Ducted Heater.
•For any other make of heater (Non- Brivis) contact the heater’s manufacturer.
•Minimum control circuit wire size is 1.0mm2with a maximum of 1.5mm2
Note: There is time delay built into the Outdoor Condensing Unit to prevent compressor short cycling on rapid calls from
the thermostat for cooling. Time delays providing this protection are built into the recommended Brivis Controllers.

14
5.4 Wiring Diagrams
Fig. 11 – Typical Indoor Unit Wiring Diagram (DINXU & DINLU SERIES)

15
Brivis Networker
INDOOR UNIT ELECTRIC BOX
NG-2A
G W R
Electronic Control Module
C Y
TSTAT
TW1 TW2
ZONE /
ADD-ON
ZONE A
ZONE B
M
Fn
A1
A2
Fig. 12 – Wiring Circuit for Brivis StarPro Series Heaters with Brivis ICE Add-On
Using Brivis Networker
StarPro model heaters can be configured for zoning and/or Add-On Refrigerative Air Conditioning. For more information
regarding connection to a StarPro unit please refer to the associated heater installer’s manual.
Your zoning requirements may require a 'Brivis Network 516 module' (Brivis Part No. B023178), please refer to the
associated heater installer’s manual.
Fig. 13 – Wiring Circuit for Brivis Classic Series Heaters with Brivis ICE Add-On
Using Brivis Programmable Thermostat
Note:
For Brivis ICE Add-On connection to a Brivis BX5 StarPro heater, a ‘Brivis Network 516 module’ (Brivis Part
No. B023178) must be fitted.
Note: For Brivis ICE Add-On connection to a Brivis Classic heater (CC3, 2PWN, or BX3) an additional relay
‘ACC LOOM ADD-ON RELAY CLASSIC’ (Brivis Part No. B063283) must be fitted.
Contact Brivis Technical Support for information on superseded Brivis Heaters.
Relay Wires
PCB Wires
Field Supplied Wires
To Add-On Cooling Unit
For connection refer to the installation manual
accompanying the Add-On cooling unit.
Heater
Control
Board
0
1
3
4
2
7
6
8
W
R
Relay
B063283
240V
Active
Terminal
Block
Brown
Red
Red
HEATER
Programmable
Thermostat
R
Y
G
W
White
Fan speed terminal block
Common (B)
Low (R)
Medium (W)
High (Br)
Blue
*
For Brivis Classic 2PWN units the ‘
Fan speed terminal block
’ is inside the fan housing. The RED wire from the heater PCB
extends to the ‘Fan speed terminal block’ with a BROWN wire quick connect fitting.This BROWN wire shall be joined to the
RED wire supplied with ADD-ON relay, i.e. terminal 4.
*

16
Fig. 14 – Shielded Communication Cable Between Indoor and Outdoor Units

17
5.5 Dimensional Drawings & Clearance Requirements Outdoor Unit
W
H
W1
H
B
D
A
A
B
D
W1
W
Fig. 15 – Outdoor Unit Dimensions
Table 2 – Brivis ICE Inverter Outdoor Unit Dimensions
MODEL
Size
W
D
H
W1
A
B
DONSC10Z71
10
946
410
810
1030
673
403
DONSC13Z71
13 / 15 / 17 952 415 1333 1045 634 404
DONSC15Z71
DONSC17Z71

18
Fig. 16 – Outdoor Unit Clearances
6.0 REFRIGERATION CHARGE & PIPE-WORK
WARNING:
•Both indoor and outdoor units come delivered under positive pressure
•The Outdoor Unit is charged with sufficient R410a refrigerant for an interconnecting pipe run of 15m actual length
•The indoor unit is pressurised with 400kPa to 700kPa dry nitrogen
•Pipe end blanking plates must not be removed until the installer is sure the plates are not under positive pressure
•A suction accumulator and oil separator has been fitted in the outdoor units
•Read all instructions and notes below before starting installation
•For flare connections please refer to section 6.2.
CAUTION:
•Use new, clean and sealed refrigeration grade pipe suitable for R410a
•Keep pipe ends sealed, both before and during installation, to avoid entry of moisture
•Suspend pipes with hangers or straps and seal openings around pipe penetrations with flexible material
•Consider pipe expansion and leave space between pipes and adjacent structures
•Use brazing shields where required
•When brazing in the vicinity of valves likely to be affected by heat, they shall be lagged with a wet cloth
•All brazing operations must be completed with a small steady stream of nitrogen passing through the pipe-work to
limit scale build up and moisture contamination
•Never use the unit compressor as a vacuum pump

19
6.1 Piping Design
•Pipe-work shall be installed in a manner which prevents drainage of liquid into the compressor and ensures
adequate oil return
•During operation, temperature of gas pipe and liquid pipe shall be over-heating or over-cooling extremely.
Therefore, it is necessary to carry out insulation; otherwise it shall debase the performance of unit and burn
compressor.
•The burning performance of the insulation material should be over 120°C.
•The insulation materials should be also chosen according to the local law.
•The thickness of insulation layer shall be above 10mm.If in hot or wet environment place, the layer of insulation
should be thicker accordingly
•Both the liquid and vapour line shall be separately insulated
•Be sure not to bind the insulation material over tight, it may extrude out the air in the material to cause bad
insulation and cause early aging of the material.
•Pipes should be run as directly as possible between indoor and outdoor units
•If the indoor coil is located above the condensing unit the suction line shall have a loop at the evaporator
outlet to prevent refrigerant drainage into the compressor during off cycle (see Fig. 17)
•If the evaporator is located below the condensing unit, then the suction riser shall be U-Trapped at 3m above
ground level (see Fig 17)
•Avoid burying pipes below ground. If necessary, they shall be insulated and encased in a PVC pipe, sealed at
both ends where the pipe exits above ground. The buried distance shall not exceed 5 metres and a liquid line
solenoid valve, interlocked with the compressor, shall be located adjacent to the indoor unit.
•Care should be taken if running pipe-work within wall cavities as this may lead to transmission of refrigerant noise
into the occupied space. The use of mufflers or oil separator can help reduce potential pulsation in the discharge
line
Fig. 17 – Piping Diagram

20
6.2 Pipe-work connection
Sweat connection:
•Locate the suction & liquid pipe service valves in the compressor compartment by removing the service access
panel
•Check that the service valves are tightly closed (Service Ball valves have been provided for suction and liquid
lines)
•Wrap each valve in turn with a wet cloth prior to sweating off its associated blanking plate (Flare nut connection is
fitted on some of the indoor units to avoid brazing)
•Braze the interconnecting liquid and suction pipes from the indoor unit
•Pressurise the indoor unit & pipe-work again with dry nitrogen and check for any brazed joint leaks. Repair as
necessary but ensure the system is not under pressure prior to brazing
•With the indoor unit pressure again released, evacuate to a vacuum pressure of 100 microns minimum
•Disconnect the vacuum pump whilst retaining the system vacuum
•Open the liquid line valve fully first, and then the suction line valve
Flare connection:
•Cut the pipe with pipe cutter
•Insert the flare nut into the pipe and flare the end
•Refer to the following table for the dimension of flare nut spaces:
Pipe Gauge Tightening Torque
Flare Dimensions ‘A’
Minimum
(mm)
Maximum
(mm)
Ø 6.4
14.2 ~ 17.2 N.m
(144 ~ 176 kgf.cm)
8.3 8.7
Ø 9.5
32.7 ~ 39.9 N.cm
(333 ~ 407 kgf.cm)
12.0 12.4
Ø 12.7
49.5 ~ 60.3 N.m
(504 ~ 616 kgf.cm)
15.4 15.8
Ø 15.9
61.8 ~ 75.4 N.m
(630 ~ 770 kgf.cm)
18.6 19.0
Ø 19.0
97.2 ~ 118.6 N.m
(990 ~ 1210 kgf.cm)
22.9 23.3
Table 3 – Flare Dimensions and Flare Tightening Torque
•Connect the indoor unit first and then the outdoor unit.
•Bend the refrigerant pipe in the correct way to prevent damage.
•The bending angle should not exceed 90°.
•The preference is to place any bends in the middle of the pipe. The larger the bending radius the
better, as it reduces internal pressure drop.
•Do not bend pipe more than is necessary.
•When connecting the flare nut, coat the flare both inside and outside with approved oil and
initially tighten by hand 3 or 4 turns before tightening firmly.