40MBDQ Ducted Slim Ductless System

Table of Contents

• Safety Considerations
• Introduction
• Installation Requirements
• Dimensions
• Installation Clearances Horizontal Installations
• Maintenance Clearances
• Installation
• Step 1 - Check Equipment
• Step 2 - Mount Unit
• Step 3 - Installing Ductwork
• Step 4 - Condensate Drain Installation
• Step 5 - Electrical Connections
• Wiring
• Electrical Data
• Connection Diagrams
• Step 6 - Refrigerant Piping
• Wireless Remote Controller Installation
• Wired Remote Controller Installation
• Start-Up
• Step 7 - Setting Static Pressure or Automatic Airflow
• Fan Performances at Varying Static Pressures
• System Checks
• Troubleshooting
• Advanced Service and Installation Functions

Safety Considerations

Improper installation, adjustment, alteration, service, maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal injury or property damage.

Consult a qualified installer, service agency, or your distributor or branch for information or assistance. The qualified installer or agency must use factory-authorized kits or accessories when modifying this product. Refer to the individual instructions packaged with kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing and work gloves. Have a fire extinguisher available. Read these instructions thoroughly and follow all warnings or cautions included in the literature and attached to the unit. Consult local building codes and the current editions of the National Electrical Code (NEC) NFPA 70.

In Canada, refer to the current editions of the Canadian Electrical Code CSA C22.1. Recognize safety information.

This is the safety-alert symbol ?. When you see this symbol on the unit and in instruction manuals, be alert to the potential for personal injury.

WARNING: The 9K and 12K units are for single room applications only.

WARNING: ELECTRICAL OPERATION HAZARD. Failure to follow this warning could result in personal injury or death. Before installing or servicing unit, always turn off all power to the unit. There may be more than one disconnect switch. Turn off the accessory heater power if applicable. Lock out and tag switch with a suitable warning label.

WARNING: EXPLOSION HAZARD. Failure to follow this warning could result in death, serious personal injury, and/or property damage.

Never use air or gases containing oxygen for leak testing or operating refrigerant compressors. Pressurized mixtures of air or gases containing oxygen can lead to an explosion.

CAUTION: EQUIPMENT DAMAGE HAZARD. Failure to follow this caution may result in equipment damage or improper operation.

Do not bury more than 36 in. (914 mm) of refrigerant pipe in the ground. If any section of pipe is buried, there must be a 6 in. (152 mm) vertical rise to the valve connections on the outdoor units. If more than the recommended length is buried, refrigerant may migrate to the cooler buried section during extended periods of a system shutdown. This causes refrigerant slugging and could possibly damage the compressor during the start-up process.

Introduction

The Ducted Slim models are R-410A fan coils designed with application flexibility in mind. The 9K-48K sizes can be mounted horizontally or vertically (upflow) while the 58K size can be mounted only horizontally. A rear and bottom return is available for field modification on the 9K-48K sizes to match the different applications.

All these fan coils have a DC fan motor with variable speeds for efficiency and comfort. The static pressure can be manually set up or use the constant air volume control.

The ducted fan coil unit is shipped with a condensate lift pump providing a maximum lift of 29.5in (750mm).

Diagram Description (Fig. 3 - Indoor Unit Representation): Shows an indoor unit with an air outlet, air inlet, air filter, drain hose, refrigerant connecting pipe, and screw connection points.

Diagram Description (Fig. 1 - Sizes 09K - 48K): Illustrates the 09K-48K unit, noting it can be mounted vertically as well as horizontally.

Diagram Description (Fig. 2 - Size 58K): Illustrates the 58K unit.

Note: Read the entire instruction manual before starting the installation. Images are for illustration purposes only. Actual models may differ slightly.

Accessories

The system is shipped with the following accessories. Use all of the installation parts and accessories to install the system. Improper installation may result in water leakage, electrical shock and fire, or cause the equipment to fail. Keep the installation manual in a safe place and do not discard any other accessories until the installation work has been completed.

Table 1 - Accessories

Notes: If the outdoor unit is higher than the indoor unit, prevent rain from flowing into the indoor unit along the connection pipe by creating a downward arc in the connection pipe before it enters the wall and enters the indoor unit. Doing so helps ensure rain drips from the connection pipe before it enters the wall.

Piping and the interconnecting wiring are field supplied.

Fig. 3 is a sketch. Different models may differ slightly.

Table 2 - Indoor Unit Model Numbers

Installation Requirements

• Confirm that the ceiling or wall can support the unit's weight.
• Confirm there is enough room within the false ceiling for installation and maintenance. The false ceiling should be horizontal and leveled.
• Install the unit in a location within the room that allows uniform airflow in all directions.
• Do not install the indoor units near a direct source of heat such as direct sunlight or a heating appliance.
• Allow sufficient space for airflow and unit servicing. Refer to Fig. 7 for minimum required distances between the unit and the walls or ceilings.
• All wiring and refrigerant lines must be at least 3 ft. (1m) away from all electromagnetic interference (televisions, radios, etc.) sources. Interference is still possible even if this distance is maintained.
• Ensure the hanger is strong enough to withstand the unit's weight.
• If the indoor unit is installed in an unconditioned space, running for long periods of time when the temperatures are outside the recommended indoor unit operation ranges, you are advised to seal all the corners of the indoor unit to prevent any leakage and add insulation material (1/2 to 3/4 in (10-20 mm)) to the entire surface of the indoor unit to avoid condensation or heat transfer.

Diagram Description (Fig. 4 - Insulation Material): Shows insulation material being applied to a unit.

Note: Nuisance sweating may occur if the unit is installed in a high humidity environment with low airflow.

Table 3 - Operating Range

If the unit is installed outside the operating range, it is recommended to install a return air temperature button sensor. See "RETURN AIR ARRANGEMENT (SIZES 09K-48K ONLY)" on page 10.

Note: DO NOT install the indoor or outdoor units in a location with special environmental conditions. For those applications, contact your Ductless representative.

WARNING: Securely install the indoor unit on a structure that can sustain its weight. If the structure is too weak, the unit may fall and cause personal injury, unit and property damage, or death. DO NOT install the indoor unit in a bathroom or laundry room as excessive moisture can short the unit and corrode the wiring.

CAUTION: Install the indoor and outdoor units, cables and wires at least 3.2 ft (1m) from televisions or radios to prevent static or image distortion. Depending on the appliances, a 3.2 ft (1m) distance may not be sufficient. If the indoor unit is installed on metal, it must be electrically grounded.

Dimensions

Provides detailed dimensions for various unit sizes (9K through 58K) in tables and diagrams.

Table 4 - Indoor Unit Dimensions

This table lists dimensions (A through M, H1, H2, W1, W2) for each unit size (9K to 58K) in inches and millimeters, along with refrigerant pipe locations and operating weight.

Diagram Description (Fig. 5 - Indoor Unit Sizes 09K - 48K): Shows a diagram of the 09K-48K unit with labels for various components and dimensions, including outside air intake, air filter, hanger brackets, electric control box, drain pipe, liquid/suction lines, and air inlet/outlet ports. It notes these are blow-through systems.

Diagram Description (Fig. 6 - Indoor Unit Size 58K): Shows different views (bottom, left, rear, front, top, right) of the 58K unit, noting it is a draw-through system.

Installation Clearances

Installation Clearances Horizontal Installations

Diagram Description (Fig. 7 - Installation Clearances): Illustrates required clearances around the indoor unit for horizontal installation, showing distances for the left side, right side, ceiling opening size, and maintenance space.

Maintenance Clearances

Provides service access for inspection purposes.

Diagram Description (Fig. 8 - Maintenance Clearances): Depicts the necessary clearances for maintenance access, including bottom return/blower/motor service, filter service, coil connection, condensate drain piping, condensate pump service, sensor service, and PCB board service. It also shows the required size for an access panel.

Table 5 - Maintenance Clearances

This table specifies the 'B' dimension clearance requirement for unit sizes 9K through 58K, ranging from 11.81in (30cm) to 15.75in (40cm).

Note: If installed above a fixed ceiling, utilize a ceiling access panel the length and width of the unit, otherwise the blower components and/or entire unit cannot be removed. If a single access panel is desired, minimum dimensions are provided.

Installation

Step 1 - Check Equipment

Unpack the unit and move to the final location. Remove the carton, taking care not to damage the unit. Inspect the equipment for damage prior to installation. File a claim with the shipping company if the shipment is damaged or incomplete.

Locate the unit rating plate which contains the proper installation information. Check the rating plate to ensure the unit matches the job specifications.

CAUTION: Ensure the ceiling grid is supported separately from the unit. The ceiling grid must not be supported by any part of the unit or any associated wiring or piping work.

Ceiling Mounting Options

Different ceiling types call for different mount applications.

• Wood: Place wood mounting across the roof beam, then install hanging screw bolts. Diagram Description (Fig. 11 - Wood Mounting): Shows wood mounting across a roof beam with hanging screw bolts.
• New Concrete Bricks: Inlay or embed screw bolts. Diagram Description (Fig. 12 - New Concrete Bricks): Shows two methods for embedding screw bolts in new concrete: blade shape insertion and slide insertion.
• Original Concrete Bricks: Use an embedding screw bolt, crock, and stick harness. Diagram Description (Fig. 13 - Original Concrete Bricks): Shows a steel bar with an embedding screw bolt for pipe hanging.
• Steel Roof Beam Structure: Install and use the supporting steel angle. Diagram Description (Fig. 14 - Steel Roof Beam): Shows a steel roof beam structure with hanging screw bolts and supporting angle steel.

Step 2 - Mount Unit

The unit can stand or lie on the floor, or hang from the ceiling or the wall. Allow adequate space for wiring, piping, and servicing of the unit. The 09K-48K size units can be mounted horizontally or vertically (upflow). The 58K units can be mounted horizontally.

Diagram Description (Fig. 9 - Unit mounted horizontally): Shows a unit mounted horizontally.

Diagram Description (Fig. 10 - Unit mounted vertically (upflow)): Shows a unit mounted vertically (upflow).

IMPORTANT: When the unit is installed over a finished ceiling and/or a living area, building codes may require the installation of a field-supplied secondary condensate pan under the entire unit. Some localities may allow as an alternative, the running of a separate, secondary condensate line. Consult the local codes for additional restrictions or precautions.

CAUTION: The unit body must be completely aligned with the hole. Ensure the unit and the hole are the same size before moving on.

Hanging and Securing the Unit

Provide adequate space for wiring, piping, and servicing of the unit (see "Installation Requirements" on page 4 and "Maintenance Clearances" on page 7).

1. Mark and Drill Holes to Hang and Install the Bolts

Mark the location of the four hanger bolt holes on the ceiling based on the indoor unit's dimensional drawing. Drill four holes into the ceiling and install the four suspension bolts securing the bolt using the washers and nuts (field supplied). Use a Ø 0.39in (10mm) all-threaded rod.

Diagram Description (Fig. 15 - Bracket Positions): Shows the placement of bracket positions relative to the unit's length (L) and width (M).

Table 6 - Bracket Positions Dimensions

This table provides the 'L' and 'M' dimensions for bracket positions for various unit sizes.

2. Install the Hanger Bolts

Diagram Description (Fig. 16 - Install the Hanger Bolts): Illustrates installing hanger bolts with anchors.

3. Mount and Secure the Unit

THIS STEP REQUIRES TWO PEOPLE. Lift the indoor unit to mount and secure it. Insert the suspension bolts into the unit's hanging holes. Fasten the bolts with the washers and nuts provided.

Mount the indoor unit onto the hanging screw bolts with a block. Position the indoor unit with a level indicator to prevent leaks.

Adjust the unit's height until the bottom is level with the false ceiling. Leave enough space to provide an adequate pitch for the drain.

Secure the unit in position with lock nuts and washers on both sides of the mounting bracket. Ensure the threaded rod does not extend more than 2 in. below the mounting brackets (see Fig. 18).

Diagram Description (Fig. 17 - Suspension bolt): Shows a suspension bolt with washers and nuts.

Diagram Description (Fig. 18 - Secure the Unit): Illustrates securing the unit with shockproof cushion, screw nut, washer, and overhang part.

Step 3 - Installing Ductwork

Return Air Arrangement (Sizes 09K-48K Only)

Based on the return air conditions in the field, the factory configured rear return arrangement of the unit may be modified to allow bottom return.

To modify:

1. Remove the Air Inlet Flange/filter rack and ventilation panel. Diagram Description (Fig. 19 - Remove the Air Inlet Flange): Shows removal of the air inlet flange.
2. Install the seal on the bottom inlet.
3. Swap the position to change the rear return to a bottom return arrangement installing the Air Inlet flange and the filters. Diagram Description (Fig. 20 - Change the Rear Return): Shows the modified return air arrangement.
4. Install the filter brackets to lock the filter in place. Diagram Description (Fig. 21 - Install the Filter Brackets): Shows filter bracket installation.

Diagram Description (Fig. 23 - Installing Duct): Illustrates connecting return and supply air ducts to the unit.

Outside Air Connection

If needed, a knockout for the outside air duct connection is located on the side of the unit downstream of the air filter. Follow the recommendation to field supply and field install a booster fan on the duct work used for outside air. A relay to energize a booster fan may be powered by the connection on the PCB board CN43. This connection is 230 volt AC and rated for 200 watts.

Note: The manufacturer recommends NOT powering the fan motor by this circuit.

The output of the NEW FAN (CN43) is powered ON while the indoor fan is active.

Note: The amount of outside air is dependent upon different factors such as the booster fan, outside air duct work type and length, static pressure, etc. Refer to the local IAQ specifications for the outdoor air quantities and control.

Return Temperature Sensor: A button sensor (p/n 40VM900009 - sold separately) may be used for situations where an indoor ducted unit is reading an inaccurate room temperature due to installation factors. The button sensor kit has a length of 66ft (20m). Replace the factory T1 sensor, which can be found inside the indoor unit. The sensor may be installed on the wall or ceiling. Airflow must be considered for accurate sampling.

Diagram Description (Fig. 22 - Button Sensor): Shows the button sensor with dimensions.

Note: A temperature compensation correction may be necessary depending on the installation location of the unit. Consult the wireless remote controller's service manual for advanced steps on temperature compensation.

Diagram Description (Fig. 24 - Outside Air Connection Sizes 18K-58K): Shows connection sizes for 18K-58K units.

Diagram Description (Fig. 25 - Outside Air Connection Sizes 09K-12K): Shows connection sizes for 09K-12K units.

Step 4 - Condensate Drain Installation

The condensate pipe is used to drain water away from the unit. Improper installation may cause unit and property damage. The unit is supplied with a drain adapter allowing the use of a field supplied 3/4 in. PVC Schedule 40 drain pipe. When installing the condensate piping, keep in mind the following details and follow these recommendations:

Note: When installing drains, adhere to the local sanitation codes.

• The ducted slim indoor unit is supplied with a condensate lift pump that is capable of lifting water 29.5in. (750mm).
• Ensure the highest point in the condensate piping is as close to the unit as possible (see Fig. 28).
• Ensure the condensate piping slopes downward in the direction of the condensate flow, with a minimum gradient of 1/100.
• When multiple units are connected to a common condensate drain, ensure the drain is large enough to accommodate the volume of condensate from all the units. Consider the recommendation to install an air vent in the condensate piping to prevent air lock.
• Do not install condensate piping where exposure to freezing temperatures is possible.
• To prevent the pipe from sagging, hangers should be spaced every 36 in (91.44cm). Be sure to follow local codes.
• If the drainpipe outlet is higher than the body's pump joint, provide a lift pipe for the indoor unit's exhaust outlet.
• Do not install the lift pipe higher than 21in. (55cm) from the center line of the pump outlet pipe. The distance between the unit and the lift pipe must be less than 8in (20cm). An incorrect installation could allow water to flow back into the unit and flood.
• To prevent air bubbles, keep the drain hose horizontal or slightly upward. See letter (A) Figure 28.

CAUTION: Insulate all piping to prevent condensation, which could lead to water damage. If the drainpipe is bent or installed incorrectly, water may leak and cause a water-level switch malfunction.

In HEAT mode, the outdoor unit discharges water. Ensure that the drain hose is placed in an appropriate area to avoid water damage and slippage.

DO NOT pull the drainpipe forcefully. This could disconnect it.

1. Cover the drain hose with heat insulation to prevent condensation and leakage.
2. Attach the mouth of the drain hose to the unit's outlet pipe. Sheath the mouth of the hose and clip it firmly with a pipe clasp (see Fig. 26). Diagram Description (Fig. 26 - Indoor Drainpipe Installation): Shows how to attach the drain hose to the unit's outlet pipe with insulation and a pipe clasp.
3. Pass the drain hose through the wall hole. Ensure the water drains to a safe location where it will not cause water damage or a slipping hazard.

Note: The drainpipe outlet should be at least 2in (5cm) above the ground. If the outlet touches the ground, the unit may become blocked and malfunction. If you discharge the water directly into a sewer, make sure the drain has a U or S pipe to catch odors that might otherwise come back into the house.

Diagram Description (Fig. 27 - Condensate piping without a pump): Shows condensate piping without a pump, illustrating slope and height.

Diagram Description (Fig. 28 - Condensate piping with a pump): Shows condensate piping with a pump, illustrating slope, height, and lift pipe requirements.

When connecting multiple drainpipes, install the pipes as shown in Fig. 29.

Diagram Description (Fig. 29 - Connecting Multiple Drain Pipes): Illustrates how to connect multiple drainpipes for units with and without pumps.

Condensate Drain and Condensate Lift Pump Installation (Horizontal Installation)

For sizes 9, 12 and 18, the condensate lift pump is provided in a separate box. Use the following steps to install the External Condensate Lift Pump for a horizontal installation of the indoor unit.

Note: Drain connections A, B and C are covered with caps.

1. For sizes 09K and 12K:

1. Remove the cap on the drainage outlet.
2. Cut both ends of the rubber tubing provided into a straight one.
3. Connect the drainage outlet and condensate lift pump using the rubber tubing and secure it with clamps on both ends (see Fig. 30). Diagram Description (Fig. 30 - Condensate lift pump installation sizes 09K-12K): Shows the condensate lift pump installation for 09K-12K units, illustrating tubing and clamps.
4. Plug the power cable of the external pump to CN13 / "PUMP" pin and plug the water level sensor cable to the CN5 / "WATER" to enable the pump (see Fig. 34).

2. For size 18K:

1. Remove the cap on drain connector B.
2. Connect drain connector B and the condensate lift pump using the L rubber hose and secure it with clamps on both ends.
3. Connect the drainpipe to connector D (see Fig. 31). Diagram Description (Fig. 31 - Condensate lift pump installation size 18K): Shows condensate lift pump installation for 18K units, connecting to connector D.
4. Plug the power cable of the external pump to CN13 / "PUMP" pin and plug the water level sensor cable to CN5 / "WATER" to enable the pump (see Fig. 34).

3. For sizes 24K, 36K, 48K and 58K:

These sizes have a built-in condensate lift pump. Drain connections (A, B and C) are covered with caps. Connect the drainpipe to connector D (see Fig. 32). Diagram Description (Fig. 32 - Connection of drain pipe to condensate lift pump sizes 24-58K): Shows drain pipe connection to connector D for units with built-in pumps.

Disabling the Condensate Lift Pump

The pump must be disabled while the unit is installed vertically (upflow) or the lift pump assembly is removed from its original position.

• Open the Control Box assembly cover, unplug the "CN13 PUMP" pin to disable the pump function, and short-connect the "CN5 WATER" plug to disable the water level sensor by either splicing the wires coming out of the CN5 WATER plug or by using a jumper plug. Replacement Component part number 17401204000333 (optional in some units otherwise sold separately) (see Figures 33 and 34).

Diagram Description (Fig. 33 - Disable condensate lift pump): Shows how to disable the condensate lift pump by unplugging CN13 and short-connecting CN5.

Diagram Description (Fig. 34 - Condensate Lift Pump Connectors): Shows the locations of CN13 (PUMP) and CN5 (WATER) connectors.

Remove the cap from connector C and connect the condensate drain pipe to drain connector C (see Fig. 36).

Note: For size 18K, the external condensate lift pump should be removed (see Fig. 35).

Diagram Description (Fig. 35 - Sizes 9K, 12K, 18K with External Condensate Lift Pump): Shows external condensate lift pump connections for 9K, 12K, 18K units.

Diagram Description (Fig. 36 - Sizes 24K to 48K with Built-in Condensate Lift Pump): Shows built-in condensate lift pump connections for 24K-48K units.

Drainage Test for Units Without a Condensate Lift Pump

1. Ensure the drainpipe is unobstructed.
2. Fill the drain pan with 0.5 gallons (2 liters) of water.

Diagram Description (Fig. 37 - Units without a pipe): Shows a unit without a pipe for the drainage test.

Condensate Lift Pump and Drainage Test

Follow these steps to perform the test:

1. Remove the test cover by rotating it counter-clockwise (see Fig. 38).
2. Using a piece of tubing or pipe to fill the condensate lift pump reservoir with 70 oz. of water (see Fig. 39).
3. Turn the unit ON in the COOLING mode and the condensate lift pump turns on. Watch the end of the drain pipe for any water.

Note: It may take some time for the water to travel, depending on the length of the drain pipe.

Diagram Description (Fig. 38 - Check the Bends and Joints for Leakage): Shows checking for leaks during the test.

Diagram Description (Fig. 39 - Tube Pipe Insert): Shows inserting a tube/pipe into the reservoir.

Condensate Lift Pump Maintenance

1. Remove the four screws from the drain pump (sizes 24K to 48K).
2. Unplug the pump power supply and the water level switch cable.
3. Detach the pump. Diagram Description (Fig. 40 - Detach the Pump): Shows detaching the pump.

Step 5 - Electrical Connections

Before proceeding with electrical connections, make certain that the supply voltage, frequency, phase, and ampacity are as specified on the unit rating plate. Review the unit wiring label for proper field high and low voltage wiring.

Ensure all electrical connections are in accordance with the NEC and any local codes or ordinances that may apply. Use copper wire only.

CAUTION: PROPERTY DAMAGE HAZARD. Failure to follow this caution may result in product or property damage. If a disconnect switch is to be mounted on the unit, select a location where the drill or fastener will not contact electrical or refrigerant components.

WARNING: ELECTRICAL SHOCK HAZARD. Failure to follow this warning could result in personal injury or death. Field wires on the line side of the disconnect found in the fan coil unit remain live, even when the pull-out is removed. Service and maintenance to incoming wiring cannot be performed until the main disconnect switch (remote to the unit) is turned off.

CAUTION: EQUIPMENT DAMAGE HAZARD. Failure to follow this caution may result in equipment damage or improper operation. Size the wires in accordance with NEC and local codes.

1. Run an interconnecting wiring from the outdoor unit to the indoor unit.
2. Connect the wiring from the outdoor unit per the connection diagram (see Fig. 43 on page 16 and see Fig. 44 on page 16).
3. Prepare the cable for connection. Use wire strippers to strip the rubber jacket from both ends of the signal cable to expose roughly 5.9in(15cm) of wire. Strip the insulation from both ends of the wires. Use a wire crimper to crimp the u-lugs to the end of the wires.
4. Remove the electric control box cover of the indoor unit.
5. Connect the u-lugs to the terminals. Match the wire colors/labels with the labels on the terminal block. Firmly screw the u-lug of each wire to its corresponding terminal. Refer to the serial number and wiring diagram located on the cover of the electric control box.

Diagram Description (Fig. 41 - Control Box): Shows the control box with wiring diagram and connective wiring diagram.

Ferrite Core (Magnetic Ring): If supplied and packed with the accessories, wrap the signal wires between the indoor unit and outdoor unit after installation and around the Ferrite core twice.

Diagram Description (Fig. 42 - Ferrite Core (Magnetic Ring)): Shows how to pass the belt through the hole of the ferrite core to secure it to the cable.

6. Clamp the cable with the cable clamp. Ensure the cable is not loose as to not pull on the u-lugs.
7. Replace the indoor unit field wiring cover.

Diagram Description (Fig. 43 - Connection Diagrams (sizes 09K to 24K)): Illustrates connection diagrams for 09K to 24K units, showing power supply and communication wiring.

Diagram Description (Fig. 44 - Connection Diagrams (sizes 36K and 58K)): Illustrates connection diagrams for 36K and 58K units, showing power supply and communication wiring.

Diagram Description (Fig. 45 - Control and Power Terminal on Indoor Unit (sizes 09K to 24K)): Shows terminals on the indoor unit for 09K to 24K sizes.

Diagram Description (Fig. 46 - Control and Power Terminals on Indoor Unit (sizes 36K to 58K)): Shows terminals on the indoor unit for 36K to 58K sizes.

Wiring

Size all wires per the NEC (National Electrical Code) or CEC (Canadian Electrical Code) and local codes. Use the electrical data from the outdoor unit (MCA - minimum circuit amps and MOCP - maximum over current protection), to correctly size the wires and the disconnect fuse or breakers respectively.

Sizes 09-24 Recommended Connection Method for Power and Communication Wiring

Power and Communication Wiring: The main power is supplied to the outdoor unit. The field supplied 14/3 power/communication wiring, from the outdoor unit to the indoor unit, consists of four (4) wires and provides the power for the indoor unit. Two wires are high voltage AC power, one is communication wiring and the other is a ground wire.

To minimize communication interference: If installed in a high Electromagnetic field (EMF) area and communication issues arise, a 14/2 stranded shielded wire can be used to replace L2 and (S) between the outdoor and indoor units - landing the shield onto the ground in the outdoor unit only.

Table 7 - Wiring Sizes 09-24

Sizes 36-58 Recommended Connection Method for Power and Communication Wiring

Power and Communication Wiring: The main power is supplied to the outdoor unit. The field supplied power wiring from the outdoor unit to the indoor unit consists of three (3) wires and provides the power for the indoor unit. Two wires are high voltage AC power and one is a ground wire. To minimize voltage drop, the factory recommended wire size is 14/2 stranded with a ground.

Communication Wiring: A separate shielded stranded copper conductor only, with a 600 volt rating and double insulated copper wire, must be used as the communication wire from the outdoor unit to the indoor unit. Please use a separate shielded 16GA stranded control wire.

Table 8 - Wiring Sizes 36-58

CAUTION: EQUIPMENT DAMAGE HAZARD. Be sure to comply with local codes while running wire from the indoor unit to the outdoor unit. Every wire must be connected firmly. Loose wiring may cause the terminal to overheat or result in a unit malfunction. A fire hazard may also exist. Ensure all wiring is tightly connected. No wire should touch the refrigerant tubing, compressor or any moving parts. Disconnecting means must be provided and located within sight and readily accessible from the system. Route the connecting cable with conduit through the hole in the conduit panel.

Note: The main power is supplied to the outdoor unit. When disconnecting the power of the outdoor unit, the indoor unit would lose power. A disconnect switch is not required on the Indoor unit side on the wiring between the Outdoor and Indoor unit. A 3 pole disconnect may be used for extra protection between the Indoor and Outdoor Unit.

Electrical Data

Table 9 - Electrical Data

This table provides electrical data including FLA, HP, W, and MAX FUSE CB AMP for indoor fans across unit sizes 09 through 58.

Connection Diagrams

Diagram Description (Fig. 43 - Connection Diagrams (sizes 09K to 24K)): Shows connection diagrams for 09K to 24K units, illustrating wiring between outdoor and indoor units, including power supply and communication.

Diagram Description (Fig. 44 - Connection Diagrams (sizes 36K and 58K)): Shows connection diagrams for 36K and 58K units, illustrating wiring between outdoor and indoor units, including power supply and communication.

Diagram Description (Fig. 45 - Control and Power Terminal on Indoor Unit (sizes 09K to 24K)): Illustrates the control and power terminals on the indoor unit for 09K to 24K sizes.

Diagram Description (Fig. 46 - Control and Power Terminals on Indoor Unit (sizes 36K to 58K)): Illustrates the control and power terminals on the indoor unit for 36K to 58K sizes.

Step 6 - Refrigerant Piping

IMPORTANT: Both refrigerant lines must be insulated separately.

• The minimum refrigerant line length between the indoor and outdoor units is 10 ft. (3 m).
• Table 10 lists the pipe sizes for the indoor unit. Refer to the outdoor unit's installation instructions for the additional allowed piping lengths and refrigerant information.
• Refer to the outdoor unit's installation manual for details regarding the allowable pipe length and height difference.

Table 10 - Piping Size

This table details the Gas Pipe and Liquid Pipe sizes (in inches and mm) for unit sizes 9K through 58K.

Piping Steps

1. Run interconnecting piping from the outdoor unit to the indoor unit.
2. Connect the refrigerant piping and drain line outside the indoor unit. Complete the pipe insulation at the flare connection then fasten the piping and wiring to the wall as required. Completely seal the hole in the wall.
3. Piping:
4. Cut the pipe, with a pipe cutter, at 90 degrees (see Fig. 47).
5. Remove the service connection (if provided with the unit).
6. Remove all the burrs from the cut cross section of the pipe, avoiding any burrs from inside the tubes.
7. Remove the flare nuts attached to the indoor and outdoor units.
8. Install the correct size flare nut onto the tubing and make the flare connection. Refer to Table 11 for the flare nut spacing.
9. Apply a small amount of refrigerant oil onto the flare connection on the tubing.
10. Align the center of the pipes and/or the service valve. Diagram Description (Fig. 49 - Align Pipe Center): Shows aligning pipe centers.
11. Connect both the liquid and gas piping to the indoor unit.
12. Tighten the flare nut with a torque wrench (see Table 12).

Table 11 - Flare Nut Spacing

This table provides the maximum and minimum spacing (in mm) for flare nuts based on the outer diameter of the pipe (1/4" to 5/8").

Diagram Description (Fig. 48 - Flare Nut Spacing): Illustrates flare nut spacing with a handle, bar, yoke, and cone.

Table 12 - Tightening Torque

This table specifies the recommended seating torque for brass flare nuts for various sizes (Ø1/4" to Ø3/4"), providing values in Ft.-Lbs. and N-M.

Diagram Description (Fig. 50 - Tighten the flare nut): Shows tightening a flare nut with a torque wrench.

Connect the drain line. Ensure there are absolutely no traps in the drain line anywhere in its length. Ensure the drain line pitches down and insulated up to the outside wall.

Note: For applications where gravity cannot be used for drainage, a condensate pump accessory is available. Consult the condensate pump installation instructions for more information.

CAUTION: UNIT DAMAGE HAZARD. Failure to follow this caution may result in equipment damage or improper operation. Never use the system compressor as a vacuum pump. Refrigerant tubes and the indoor coil should be evacuated using the recommended 500 Microns Deep Vacuum method. The alternate Triple Evacuation Method may be used if the procedure outlined below is followed. Review the unit's service manual for the 500 Microns Deep Vacuum or the Triple Evacuation Method.

Note: Always break a vacuum with dry nitrogen.

Final Tubing Check

IMPORTANT: Ensure that certain factory tubing on both the indoor and the outdoor unit has not shifted during shipment. Ensure tubes are not rubbing against each other or any sheet metal. Pay close attention to feeder tubes, making sure wire ties on feeder tubes are secure and tight.

Wireless Remote Controller Installation

Mounting Bracket (if installed on the wall)

1. Use the two screws supplied with the remote controller to attach the mounting bracket to the wall in a location selected by customer and within the remote controller's operating range.
2. Install the batteries in the remote controller.
3. Place the remote controller into the remote control mounting bracket.
4. For remote controller operation, refer to the unit's owner manual.

Note: If a wireless remote controller is used, relocate the IR receiver within the line of sight of the remote location using the 6 ft. cable included. The factory location of the IR receiver is inside the remote controller box (see Fig. 51).

Wired Remote Controller Installation

To connect the included wired remote controller (7 Day Programmable KSACN**) to the indoor unit, use the 4-pin adapter cable supplied with the controller and plug it into CN40 located on the control board.

To connect the wired remote controller (Timer Function KSACN0101AAA sold separately) to the indoor unit, use a 5-core shielded cable supplied with the wired controller to plug into the 5-pin connector from the IR receiver located in the control box (see figure 51).

For setup instructions, refer to the wired remote controller installation manual.

Start-Up

Test Operation

After completing the gas leak and electrical safety check, perform the test operation (see Fig. 52).

Diagram Description (Fig. 51 - Control Box): Shows the control box with the location of the wired remote controller connections (4-pin for CN40, 5-pin for IR receiver).

IR Receiver Display Panel

1. Press MANUAL on the IR Receiver Display Panel located in the control box to begin testing.

Note: A protection feature prevents the system from starting for approximately 3 to 4 minutes.

2. Push MODE, select COOLING, HEATING, and FAN mode to verify that all the functions work as designed.
3. To run the test using the MANUAL option on the indoor unit: Open the front panel of the indoor unit; Press MANUAL once to energize the unit. The set conditions of the manual operation are as follows: Preset the set point: 76°F (24°C); Fan speed: AUTO; Discharge the air direction: Pre-set position based on an operation in the COOL or HEAT mode.
4. Set the MANUAL option to OFF (by pushing it twice again) after completing the test.

Diagram Description (Fig. 52 - IR Receiver Display Panel): Shows the IR receiver display panel with indicators for Manual button, Operation indicator, Timer indicator, LED display, Infrared receiver, Alarm indicator, and PRE-DEF indicator.

Step 7 - Setting Static Pressure or Automatic Airflow

The indoor ducted units can be programmed for different static pressures settings or airflows and the factory default setting is SP1. Use the following steps to set the static pressure or Automatic Airflow using the Wired Remote Controller or the Wireless Remote Controller according to the installation conditions.

When Using the KSACN** Wired Controller:

• The external static pressure can be manually changed to the fan curves SP1, SP2, SP3, SP4.
• Use the Automatic Airflow "AF" Adjustment function to automatically identify the static pressure and regulate the airflow amount.

Follow these instructions to configure:

1. Ensure the test run is done with a dry coil. If the coil is not dry, run the unit for 2 hours in the FAN ONLY mode to dry the coil.
2. Check that both the power supply wiring and the duct installation have been completed. Check that dampers are properly positioned. Check that the air filter is properly attached to the air inlet side passage of the unit.
3. If there is more than one air inlet and/or outlet, adjust the dampers so that the airflow rate of each air inlet and outlet conforms to the designed airflow rate. Ensure the unit is in FAN ONLY mode. Press and set the Airflow Adjustment "AF" on the remote controller to adjust the airflow rate from H to L. Turn the indoor unit OFF with the Wired Controller.
4. Set the parameters for airflow adjustment. When the system is OFF, perform the following steps: Press and hold COPY for approximately 4 seconds. Press "+" or "-" to scroll through the menu and make a selection, either SP or AF.

Note: T1, T2, T2b, T3, T4 are sub-menus for thermistors. DO NOT select to set the external static pressure.

Diagram Description (Fig. 53 - Wired Controller Menu Selection): Shows the menu selection screen with options like SP and AF.

1. If setting the external static pressure manually, select SP and press CONFIRM. Select the SP number (SP1, SP2, SP3, SP4 - see "FAN PERFORMANCES AT VARYING STATIC PRESSURES" on page 20 and curves (Figs. 55 through 61)). Power down the unit to lock in the selection.
2. If choosing the AUTOMATIC AIRFLOW ADJUSTMENT function, select AF and press CONFIRM. The system starts the fan for the airflow automatic adjustment. The ON indicator flashes when the fan runs during the AUTOMATIC AIRFLOW ADJUSTMENT. After 3 to 6 minutes, the system stops operating once the AUTOMATIC AIRFLOW ADJUSTMENT is complete.

Diagram Description (Fig. 54 - Automatic Airflow ON signal): Shows the "ON" indicator flashing during automatic airflow adjustment.

Note: The external static pressure can also be selected using the wireless remote controller (RG57F3(B)/BGEFU1), included with the indoor unit, by pointing it toward the indoor unit's Infrared Receiver typically located inside the control box. Refer to the wireless remote controller service manual for further instructions.

CAUTION: Do not use the AUTOMATIC AIRFLOW ADJUSTMENT with the remote control if using booster fans, an outdoor air processing unit, or a HRV via duct. If the ductwork or static pressure have been changed, reset the AUTOMATIC AIRFLOW ADJUSTMENT following steps 3 and 4.

When Using the 24V Interface KSAIC**

The wireless remote controller, wired controllers KSACN** and Wi-Fi kits would be disabled. Since a wired controller is required to setup the static pressure of the indoor ducted units, the 24V interface must be temporarily bypassed using the steps below:

1. Turn off the power to the unit.
2. On the 24V interface, disconnect the plugs from the CN11 (to Outdoor) and CN12 (to Indoor) connections.
3. Sizes: For sizes 9K-24K only: Add a jumper between the indoor S terminal to the outdoor S terminal. For sizes 36K-58K only: Disconnect S1 and S2 from the 24V interface (CN8 and CN9) and splice together S1 from outdoor to S1 from indoor and S2 from outdoor to S2 from indoor.
4. Connect the Wired Controller (KSACN**) and follow the external static pressure setup.
5. Once the static pressure is adjusted, disconnect the wired controller.
6. Sizes: For sizes 9K-24K only: Remove the S jumper from the terminal block. For sizes 36K-58K only: Remove the splice and reconnect S1 and S2 back to the 24V interface accordingly.
7. Reconnect the plugs back to CN11 (to outdoor) and CN12 (to indoor) accordingly.
8. Restore power to the unit.

Note: When a system uses the 24V interface, the indoor unit's fan speed defaults to AUTO with the indoor unit's default logic.

CAUTION: DUCT SIZING. Duct work must be properly sized using the standard duct sizing program practices. Failure to do so could result in inadequate airflow to the target area. It is recommended to follow the standard practices listed on the ACCA Manual D for designing Duct Systems.

Fan Performances at Varying Static Pressures

The factory default setting is SP1. Airflows and fan curves applicable starting on production of Week 28 Year 2020 (Serial Number 2820V10001). For previous serial numbers refer to previous revision of this document.

Table 13 - Airflow at SP1 Setting

This table shows the High, Medium, and Low airflow (CFM) for unit sizes 9 through 58 at the SP1 setting.

Table 14 - 9K

This table details the airflow (CFM) for the 9K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 15 - 12K

This table details the airflow (CFM) for the 12K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 16 - 18K

This table details the airflow (CFM) for the 18K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 17 - 24K

This table details the airflow (CFM) for the 24K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 18 - 36K

This table details the airflow (CFM) for the 36K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 19 - 48K

This table details the airflow (CFM) for the 48K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Table 20 - 58K

This table details the airflow (CFM) for the 58K unit across various static pressures (IN.WC) and static pressure settings (SP4, SP3, SP2, SP1), categorized by High (H), Medium (M), and Low (L) airflow.

Diagrams (Figs. 55-61): These figures display fan performance curves showing airflow (CFM) versus static pressure for each unit size (9K to 58K) across different static pressure settings (SP1 to SP4) and airflow levels (H, M, L).

System Checks

1. Conceal the tubing where possible.
2. Ensure the drain tube slopes downward along its entire length.
3. Ensure all tubing and connections are properly insulated.
4. Fasten the tubes to the outside wall, when possible.
5. Seal the hole through which the cables and tubing pass.

Indoor Unit Checks

1. Do all the remote controller buttons function properly?
2. Do the display panel lights work properly?
3. Does the air deflection louver function properly?
4. Does the drain work?

Explain the following items to customer (with the aid of the owner's manual): How to turn the system ON and OFF; how to select COOLING, HEATING and other operating modes; how to set a desired temperature; how to set the timer to automatically start and stop the system's operation; how to control all other features of the remote controller and display panel; how to remove and clean the air filter; how to set the air deflection louver; unit care and maintenance.

Present the owner's manual and installation instructions to the customer.

Fan Motor Maintenance

Sizes 09K-48K:

1. Remove the panel.
2. Remove the blower housing.
3. Remove the motor. Diagram Description (Fig. 62 - Motor Maintenance sizes 09K-48K): Shows the motor, blower housing, and panel for maintenance.

Size 58K:

Two methods available:

1. Remove the front side plate from the top.
2. Remove the top cover. Diagram Description (Fig. 63 - Remove the top cover): Shows removing the top cover.
3. Loosen the four bolts and two screws that secure the front side plate. Diagram Description (Fig. 64 - Loosen the four bolts and two screws): Shows loosening bolts and screws.
4. Remove the motor cord, take off the front side plate and repair the motor. Diagram Description (Fig. 65 - Remove the motor cord): Shows removing the motor cord.
5. Remove the front side plate from the bottom.
6. Remove the bottom base. Diagram Description (Fig. 66 - Remove the bottom base): Shows removing the bottom base.
7. Loosen the four bolts and two screws that secure the front side plate. Be careful, the front side plate may fall down. Diagram Description (Fig. 67 - Loosen the four bolts): Shows loosening bolts.
8. Remove the motor cord, take off the front side plate and repair the motor. Diagram Description (Fig. 68 - Remove the motor cord): Shows removing the motor cord.

Troubleshooting

For ease of service, the systems are equipped with diagnostic code display LEDs on both the indoor and outdoor units. The outdoor diagnostic display consists of two LEDs (red and green) on the outdoor unit board and is limited to a few errors. The indoor diagnostic display is a combination of flashing LEDs on the display panel or the front of the unit. If possible, always check the diagnostic codes displayed on the indoor unit first before consulting a service technician.

The diagnostic codes, displayed in the indoor and outdoor units, are listed in Table 21.

Table 21 - Indoor Unit Diagnostic Guides

Note: O (light) X (off) (flash)

For additional diagnostic information, refer to the indoor unit service manual.

Advanced Service and Installation Functions

Refer to the Wireless Remote Controller service manual for access to advanced functions such as:

• Auto-Start
• Temperature Compensation
• Filter Reminder
• Indoor Fan Motor Speed Control (after set temperature is reached)
• Lowest or Highest Temperature Setting
• Static Pressure Setting

All changes should be performed ONLY by authorized professionals.