Rasonic Air Conditioner Installation Instruction

Required Tools for Installation

• Philips screw driver
• Level gauge
• Electric drill, hole core drill (ø70 mm)
• Hexagonal wrench (4 mm)
• Spanner
• Pipe cutter
• Reamer
• Knife
• Gas leak detector
• Measuring tape
• Thermometer
• Megameter
• Multimeter
• Torque wrench (with specific values: 18 N·m, 42 N·m, 55 N·m, 65 N·m, 100 N·m)
• Vacuum pump
• Gauge manifold

Safety Precautions

Read the following "SAFETY PRECAUTIONS" carefully before installation.

Electrical work must be installed by a licensed electrician. Use the correct rating of the power plug and main circuit for the model.

WARNING: Indicates possibility of causing death or serious injury.

CAUTION: Indicates possibility of causing injury or damage to properties only.

Symbols:

• Symbol with white background: PROHIBITED
• Symbol with dark background: Must be carried out

Carry out test running to confirm no abnormality occurs after installation. Explain operation, care, and maintenance to the user and remind them to keep the operating instructions.

General Warnings:

• Do not install the unit in excessive oil fume areas (kitchen, workshop).
• Keep away from heat sources or steam.
• Ensure good air circulation, no obstacles blocking airflow.
• Choose a location where drainage is easy.
• Consider noise prevention.
• Do not install near a doorway.
• Ensure required spaces from walls, ceiling, fences, etc.
• Indoor unit height: at least 1.8 m.
• If an awning is built over the outdoor unit, ensure it does not obstruct heat radiation.
• Avoid locations where animals or plants could be affected by hot air discharge.
• Do not place obstacles that could short-circuit discharged air.
• If piping length exceeds limits, additional refrigerant may be needed (refer to table).
• Do not install outdoor unit near veranda handrail; risk of children climbing.
• Do not use unspecified, modified, joint, or extension cords for power supply. Do not share outlets with other appliances.
• Do not tie up power supply cord in a bundle; may cause abnormal temperature rise.
• Do not insert fingers or objects into the unit; high-speed fan may cause injury.
• Do not sit or step on the unit; risk of falling.
• Keep plastic bags away from small children to prevent suffocation.
• Do not let any substance other than specified refrigerant (e.g., air) mix into the refrigeration cycle; can cause abnormal high pressure, explosion, or injury.
• Do not add or replace refrigerant other than specified type; may cause product damage, burst, or injury.
• For R410A models, use R410A specified piping, flare nuts, and tools. Using R22 parts may cause abnormally high pressure and explosion/injury.
• Copper pipes for R410A must be > 0.8 mm thick.
• Amount of residual oil should be less than 40 mg/10 m.
• Engage authorized dealers/specialists for installation. Incorrect installation can cause water leakage, electrical shock, or fire.
• Install according to these instructions strictly.
• Use attached accessories and specified parts only; otherwise, risk of set falling, water leakage, fire, or electrical shock.
• Install at a strong and firm location that can withstand the unit's weight.
• Follow local national wiring standards and regulations for electrical work. Use an independent circuit and single outlet.
• Do not use joint cable for indoor/outdoor connection. Use specified cable and connect tightly. Clamp cable to prevent external force on terminals.
• Ensure control board cover is fixed properly; otherwise, risk of fire or electrical shock.
• Recommended to install with Earth Leakage Circuit Breaker (ELCB) or Residual Current Device (RCD) with 30mA sensitivity at 0.1 sec or less.
• Install refrigerant piping properly before running the compressor. Operation without piping/valves open can cause air suck-in, abnormal pressure, explosion, or injury.
• During pump down, stop the compressor before removing refrigeration piping.
• Tighten flare nuts with a torque wrench according to specified methods. Over-tightening can cause flare breakage and refrigerant leakage.
• Confirm no refrigerant gas leakage after installation. Refrigerant contact with fire may generate toxic gas.
• Ventilate if refrigerant gas leaks during operation.
• Equipment must be properly earthed. Do not connect earth line to gas pipe, water pipe, lightning rod earth, or telephone; risk of electrical shock.

General Cautions:

• Do not install where flammable gas may leak; risk of fire.
• Do not release refrigerant during piping work, re-installation, or repair.
• Take care of liquid refrigerant; it may cause frostbite.
• Do not install in a laundry room or location where water may drip from the ceiling.
• Do not touch sharp aluminum fins; sharp parts may cause injury.
• Carry out drainage piping correctly; improper drainage can cause water entry and furniture damage.
• Select an installation location that is easy for maintenance.

Power Supply Connection:

• Use power supply cord 3 x 1.5 mm² (1.0 ~ 2.0HP) or 3 x 2.5 mm² (2.5HP), type designation 60245 IEC 57 or heavier.
• Power supply point should be easily accessible for disconnection.
• Permanent connection may be prohibited in some countries.
• Connection to receptacle: Use an approved 15A (1.0 ~ 2.0HP) or 20A (2.5HP) power plug with an earth pin.
• Connection to circuit breaker: Use an approved 16A (1.0 ~ 2.0HP) or 20A (2.5HP) circuit breaker. It must be a double pole switch with a minimum 3.0 mm contact gap.

Installation Work: It may require two people.

Attached Accessories

Indoor/Outdoor Unit Installation Diagram

This section contains diagrams illustrating the overall installation process. Key elements include:

• Indoor Unit Installation: Shows placement on a wall, required clearances from walls, ceiling, and other obstacles. Details dimensions for the installation plate and the location of the piping hole relative to the plate.
• Outdoor Unit Installation: Shows placement on a solid base (concrete or rigid frame) and required clearances.
• Piping and Cable Connections: Illustrates how to connect the refrigerant pipes and electrical cables between the indoor and outdoor units.
• Drainage: Shows how to connect the drain hose and ensure proper water flow.
• Cutting and Flaring: Depicts the process of preparing copper pipes for connection, including cutting, deburring, and flaring.
• Front Grille Removal: Shows how to remove the front grille for servicing.

Installation Steps

1. 1. SELECT THE BEST LOCATION

   Indoor Unit:

   • Avoid excessive oil fume areas (kitchen, workshop).
   • Keep away from heat sources or steam.
   • Ensure good air circulation, no obstacles blocking airflow.
   • Choose a location where drainage is easy.
   • Consider noise prevention.
   • Do not install near a doorway.
   • Ensure required spaces from walls, ceiling, fences, etc.
   • Install at a height of at least 1.8 m.

   Outdoor Unit:

   • If an awning is used, ensure it doesn't obstruct heat radiation.
   • Avoid locations where animals or plants could be affected by hot air discharge.
   • Maintain required spaces from walls, ceiling, fences, etc.
   • Do not place obstacles that could short-circuit discharged air.
   • If piping length exceeds limits, additional refrigerant may be needed (refer to table).

2. 2. HOW TO FIX INSTALLATION PLATE (Indoor Unit)

   The mounting wall must be strong and solid.

   • Ensure the installation plate is positioned with adequate clearance (e.g., >1 unit width from left/right walls, >2 unit height from ceiling).
   • Specific dimensions for installation plate and hole center are provided for different models:
     • PV9**, PV12**: Plate dimensions A=470mm, B=90mm, C=380mm, D=420mm. Hole center measurements provided.
     • PV18**, PV24**: Plate dimensions A=605mm, B=95mm, C=550mm, D=550mm. Hole center measurements provided.
   • Mount the plate horizontally using at least 5 screws. Use anchor bolts for concrete walls.
   • Drill piping hole (ø70 mm), slightly slanting towards the outdoor side. Hole center is determined by specific measurements (e.g., 128 mm from edges).

3. 3. TO DRILL A HOLE IN THE WALL AND INSTALL A SLEEVE OF PIPING

   • Insert the piping sleeve into the drilled hole.
   • Fix the bushing to the sleeve.
   • Cut the sleeve to protrude about 15 mm from the wall.
   • Seal the opening with putty or caulking compound.
   • CAUTION: Use sleeve in hollow walls to prevent damage from mice biting cables.

4. 4. INDOOR UNIT INSTALLATION

   This step involves physically mounting the indoor unit onto the installation plate.

   • Right Rear Piping: Pull out indoor piping, install unit, secure it, insert connection cable.
   • Right and Right Bottom Piping: Similar steps, ensuring proper cable and piping routing.
   • Embedded Piping: Replace drain hose, bend embedded piping carefully (using a spring bender), pull connection cable, cut/flare piping, install unit, connect piping, insulate, and secure.
   • Power Supply Cord Arrangement: Excess cord length should be managed behind the chassis without bundling. Ensure the cord is not clamped or stretched between the unit and the plate.
   • Hook the indoor unit onto the upper portion of the installation plate until it clicks securely.
   • To remove the unit, push a marking at the bottom and pull slightly.

5. 5. CONNECT THE CABLE TO THE INDOOR UNIT

   Connection cable between indoor and outdoor units should be approved, polychloroprene sheathed flexible cord (e.g., 3 x 1.5 mm² or 3 x 2.5 mm²).

   • Do not use joint connection cables.
   • Strip wires correctly (10 ± 1 mm conductor length, no loose strands).
   • Connect cables to the terminal board, ensuring the earth wire (Yellow/Green) is longer for safety.
   • Secure the cable with a holder.
   • WARNING: Risk of fire from joining wires; use complete wires without joining.
   • Ensure proper earthing.

6. 6. PIPING INSULATION

   • Insulate pipe connection portions as shown in diagrams. Wrap insulated pipe ends to prevent water ingress.
   • If drain hose or piping is in a room where dew may form, use additional insulation (e.g., POLY-E FOAM, 6 mm thickness or more).

7. 7. CUTTING AND FLARING THE PIPING

   • Cut pipes using a pipe cutter and remove burrs with a reamer.
   • Turn piping end down to avoid metal powder entering the pipe.
   • Make flare after inserting the flare nut onto the copper pipe.
   • Check flare finish for even thickness and shine. Improper flaring (inclined surface, cracked, uneven thickness) can cause gas leakage.

8. 8. HOW TO TAKE OUT FRONT GRILLE

   Steps involve removing caps and screws to detach the front grille for servicing. Reverse order for reinstallation.

9. CHECK THE DRAINAGE

   • Open front panel and remove air filters.
   • Pour a glass of water into the drain tray-styrofoam.
   • Ensure water flows out from the drain hose.

10. EVALUATION OF THE PERFORMANCE

    • Operate unit in cooling/heating mode for at least 15 minutes.
    • Measure intake and discharge air temperatures.
    • Ensure temperature difference is > 8°C (Cooling) or > 14°C (Heating).

11. AUTO SWITCH OPERATION

    • AUTO OPERATION MODE: Press and release AUTO switch within 5 seconds.
    • TEST RUN OPERATION: Press and hold AUTO switch for 5-8 seconds (audible "pep" sound indicates start).
    • REMOTE CONTROLLER RECEIVING SOUND ON/OFF: Press AUTO switch continuously for 5 seconds (within first 20 sec of Test Run) until "pep pep" sound, then press again to toggle ON/OFF. Long "peep" = ON, short "pep" = OFF.

12. DISPOSAL OF OUTDOOR UNIT DRAIN WATER

    • If using a drain elbow, unit should be on a stand > 5 cm tall.
    • Avoid drain elbow if ambient temperature is < 0°C for extended periods to prevent freezing.

13. Pump Down Method When Reuse Existing Piping (R22 Model) for R410A Model

    WARNING: Compressor oil from R22 models is incompatible with R410A models and can damage the compressor.

    • Purpose of Pump Down: To collect mixed refrigerant and oil into the outdoor unit.
    • Procedure: Operate unit in cooling for 10-15 mins, close 2-way valve, wait 3 mins, close 3-way valve, then remove unit.
    • If pump down fails, flush piping with R410A refrigerant.
    • Reuse of R22 piping is dangerous due to oil; only use if unavoidable (e.g., concealed piping) and after proper pump down.

14. 1. SELECT THE BEST LOCATION (OUTDOOR UNIT)

    Covered in step 1.1.

15. 2. INSTALL THE OUTDOOR UNIT

    • Fix the unit firmly and horizontally on a concrete or rigid frame using bolt nuts (ø10 mm).
    • If installing on a roof, ensure stability against wind and earthquakes.
    • Refer to diagrams for model-specific dimensions (A, B, C, D) for placement.
    • For PV9**/PV12**: A=474mm, B=87mm, C=18.5mm, D=261mm.
    • For PV18**/PV24**: A=540mm, B=160mm, C=18.5mm, D=330mm.

16. 3. CONNECT THE PIPING

    AIR PURGING METHOD IS PROHIBITED FOR R410A SYSTEM.

    • Prepare pipes: cut, remove burrs, flare.
    • Connect piping to indoor unit: Align center, tighten flare nut by hand, then with torque wrench to specified values.
    • Connect piping to outdoor unit: Align center, tighten flare nut by hand, then with torque wrench to specified values.
    • Piping Size and Torque Specifications:

    • Piping Size	Torque
      6.35 mm (1/4")	[18 N·m (1.8 kgf·m)]
      9.52 mm (3/8")	[42 N·m (4.3 kgf·m)]
      12.7 mm (1/2")	[55 N·m (5.6 kgf·m)]
      15.88 mm (5/8")	[65 N·m (6.6 kgf·m)]
      19.05 mm (3/4")	[100 N·m (10.2 kgf·m)]

17. 4. EVACUATION OF THE EQUIPMENT

    WHEN INSTALLING AN AIR CONDITIONER, BE SURE TO EVACUATE THE AIR INSIDE THE INDOOR UNIT AND PIPES.

    • Connect charging hose to low side of charging set and service port of 3-way valve.
    • Connect center hose to vacuum pump.
    • Turn on vacuum pump; gauge should move to -76 cmHg (-0.1 MPa). Evacuate for approximately 10 minutes.
    • Close low side valve, turn off pump. Check gauge for movement (should not move for 5 mins).
    • Disconnect hose. Tighten service port caps (18 N·m).
    • Remove valve caps, open both 2-way and 3-way valves using a 4mm hexagonal wrench.
    • Mount valve caps. Check for gas leakage.
    • If gauge needle doesn't move, check for leaks at connections and retighten.
    • WARNING: Do not release refrigerant during piping work. Liquid refrigerant can cause frostbite.

18. 5. CONNECT THE CABLE TO THE OUTDOOR UNIT

    • Remove control board cover by loosening the screw.
    • Use approved connection cable (e.g., 3 x 1.5 mm² or 3 x 2.5 mm²).
    • Connect cable to terminal board, secure with holder (clamper).
    • Attach control board cover back.
    • Refer to indoor unit instructions for wire stripping and connection requirements.
    • WARNING: Ensure proper earthing. Earth wire (Yellow/Green) should be longer for safety.

19. 6. PIPING INSULATION

    Carry out insulation at pipe connection portion as mentioned in Indoor/Outdoor Unit Installation Diagram. Wrap insulated piping end to prevent water ingress.

    If drain hose or connecting piping is in a room where dew may form, increase insulation with POLY-E FOAM (6 mm thickness or above).

20. CUTTING AND FLARING THE PIPING

    Cut pipes using a pipe cutter and remove burrs with a reamer. Turn piping end down to avoid metal powder entering the pipe. Make flare after inserting the flare nut onto the copper pipes. Check flare finish for even thickness and shine. Improper flaring can cause gas leakage.

21. CHECK ITEMS

    • Is there any gas leakage at flare nut connections?
    • Has the heat insulation been carried out at flare nut connection?
    • Is the connection cable being fixed to terminal board firmly?
    • Is the connection cable being clamped firmly?
    • Is the drainage ok? (Refer to "Check the drainage" section)
    • Is the earth wire connection properly done?
    • Is the indoor unit properly hooked to the installation plate?
    • Is the power supply voltage complied with rated value?
    • Is there any abnormal sound?
    • Is the cooling/heating operation normal?
    • Is the thermostat operation normal?
    • Is the remote control's LCD operation normal?