Emerald ACV200U, ACV200U-1 User Guide and Installation Manual

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Contents

This document outlines the following sections:

1. Safety Summary
2. Structure (Outdoor unit & refrigerant cycle, necessary tools)
3. Transportation and Handling
4. Outdoor Unit Installation
5. Refrigerant Piping Work
6. Electrical Wiring
7. Test Run
8. Safety and Control Device Setting
9. After Sales Service

Important Notice

Emerald Energy is committed to continuous improvement in product design and performance, reserving the right to vary specifications without prior notice. The company cannot anticipate every possible hazard. This air conditioner is designed for standard air conditioning use only and should not be used for drying clothes, refrigerating food, or other cooling/heating processes. Installers and specialists must ensure safety against leakage in compliance with local regulations. No part of this manual may be reproduced without written permission.

Signal words are used to denote hazard levels:

• DANGER: Immediate hazards that WILL result in severe personal injury or death.
• WARNING: Hazards or unsafe practices that COULD result in severe personal injury or death.
• CAUTION: Hazards or unsafe practices that COULD result in minor personal injury or product/property damage.
• NOTE: Useful information for operation and/or maintenance.

The manual assumes operation and servicing by English speakers. If not, distributors should provide safety signs in the native language. Contact your distributor or dealer for questions. This manual covers general descriptions applicable to multiple models.

Temperature Specifications

DB: Dry Bulb, WB: Wet Bulb. Operation outside these ranges may be intermittent or fail to start.

Installation and maintenance must be performed by qualified professionals. This system is designed for cooling or heating operation only; simultaneous operation may cause instability. This manual is a permanent part of the equipment.

Safety Summary

DANGER

• Use only refrigerant R410A. Do not charge oxygen, acetylene, or other flammable/poisonous gases into the refrigerant cycle for leakage or air-tightness tests, as they can cause explosions. Nitrogen is recommended for tests.
• Do not pour water into the indoor or outdoor units, as they contain electrical components that can cause electric shock.
• Do not touch or adjust safety devices inside the units; this may cause serious accidents.
• Always turn OFF the main power supply before opening service covers or access panels.
• If refrigerant leakage occurs, turn OFF the main switch, extinguish naked flames, and contact a service contractor. Refrigerant leakage can cause breathing difficulties.
• Installers and specialists must ensure safety against refrigerant leakage according to local regulations.
• Use an ELB (Electric Leakage Breaker) to prevent electric shock or fire.
• Do not install the outdoor unit in areas with high oil mist, flammable gases, salty air, or harmful gases like sulphur.

WARNING

• Do not use sprays (insecticide, lacquer, hair spray) within approximately 1 meter of the system.
• If a circuit breaker or fuse trips frequently, stop the system and contact your service contractor.
• Follow the installation manual for all installation, refrigerant piping, drain piping, and electrical wiring work to prevent water leakage, electric shock, or fire.
• Ensure the ground wire is securely connected. Improper grounding can lead to electric shock. Do not connect the ground wire to gas pipes, water pipes, lightning conductors, or telephone ground wires.
• Connect a fuse of the specified capacity.
• Do not place foreign material on or inside the unit.
• Ensure the outdoor unit is clear of snow or ice before operation.
• Before brazing, ensure no flammable materials are nearby. Wear leather gloves when handling refrigerant to prevent cold injuries.
• Protect wires and electrical parts from rodents. If unprotected, they may chew on parts, leading to fire.
• Secure cables firmly; external forces on terminals can cause fire.
• If the supply cord is damaged, it must be replaced by the manufacturer, service agent, or qualified personnel.
• This appliance is not intended for use by children or persons with reduced capabilities. Children should not play with the appliance, nor perform cleaning or maintenance.
• The appliances are not intended for operation via external timers or separate remote-control systems.
• Supervise children to ensure they do not play with the appliance.
• Keep the appliance and cord out of reach of children under 8 years.
• The appliance has an earth connection for functional purposes only.
• Installation must comply with national wiring regulations.

CAUTION

• Do not install the indoor unit, outdoor unit, remote control switch, or cable within approximately 3 meters of strong electromagnetic wave radiators (e.g., medical equipment).
• Do not step on or place materials on the product.
• Provide a strong, correct foundation for the outdoor unit, ensuring it is level, stable, and securely anchored to prevent tilting, noise, or falling due to strong winds or earthquakes.
• Models in this manual comply with International Standards and must be connected only to other units that comply with corresponding partial unit requirements and use the same refrigerant.

NOTE:

• Ventilate the room every 3-4 hours.
• Heating capacity decreases with lower outdoor ambient temperatures.
• Operate the air conditioner within specified temperature ranges: Installation altitude below 1000m; supply power frequency within ±1%Hz of rated frequency; transport/storage temperature between -25°C and 55°C.
• The A-weighted emission sound pressure level at workstations does not exceed 70 dB(A).

Checking Product Received

• Inspect for shipping damage upon receipt.
• Verify model number, electrical characteristics (power supply, voltage, frequency), and accessories.
• Standard utilization is explained in these instructions; deviations are not recommended. Contact your local agent for assistance.
• Emerald Energy's liability does not cover defects arising from alterations performed by a distributor without written consent.

Structure

Outdoor unit & refrigerant cycle

CAUTION: Do not install the indoor unit, outdoor unit, remote control switch, and cable within approximately 3 meters of strong electromagnetic wave radiators such as medical equipment.

Outdoor Unit Components

The outdoor unit consists of the following parts:

• 1: Compressor
• 2: Heat Exchanger
• 3: Strainer
• 4: Splitter
• 5: 4-Way Reversing Valve
• 6: Electrical Expansion Valve
• 7: Stop Valve (Liquid)
• 8: Stop Valve (Gas)
• 9: Electrical Box
• 10: Pressure Switch for Controlling
• 11: High Pressure Switch
• 12: Check Joint for High/Low Pressure (Cool/Heat)
• 13: Solenoid Valve
• 14: Propeller Fan
• 15: Damping Rubber Pad
• 16: Air Inlet
• 17: Air Outlet

Refrigerant Cycle Diagram

The system loop diagram illustrates the refrigerant flow. It shows the compressor, heat exchanger, various valves (stop valves, reversing valve, solenoid valve, expansion valve), filter, gas-liquid separator, distributor, and oil separator. The diagram indicates the flow direction for cooling and heating operations, as well as field refrigerant piping and flared connections.

Necessary Tools and Instrument List for Installation

NOTE: Use tools and measuring instruments exclusively for refrigerant R410A in case of direct contact with the refrigerant.

DANGER: Refrigerant R410A operates at pressures 1.4 times higher than conventional refrigerants. Impurities like moisture, oxide film, and grease can affect R410A. Ensure the refrigerant cycle is free of moisture, dust, different refrigerants, or oils. Using unspecified materials may lead to explosion, injury, leakage, electric shock, or fire.

Interchangeability and Tools

A table details the interchangeability with R22 and R407C for various measuring instruments and tools, indicating which are strictly required or prohibited for R410A. It also specifies the use and reasons for non-interchangeability, such as flaring tool compatibility, bending, and expanding tube requirements.

Piping thickness and material specifications for R410A are provided, based on JIS standard (JIS B8607). Flare nut dimensions are also specified.

Transportation and Handling

Transportation

Transport the product as close to the installation location as possible before unpacking.

CAUTION: Do not place any material on the product. Use two lifting wires for crane lifting, ensuring balance and safety.

Lifting Method

When lifting the unit, ensure balance, safety, and smooth lifting. Do not remove packing materials. Hang the unit with two ropes through the lifting holes in the wooden base.

Handling of Outdoor Unit

WARNING: Do not place foreign materials into the outdoor unit before installation and test run. Failure to do so may result in fire or equipment failure.

When Using Handles

For manual lifting using handles, do not remove the wooden base. Pay attention to the center of gravity to prevent overturning. Use two or more personnel for lifting.

CAUTION: Lift the unit in its factory packaging with 2 wire ropes. Ensure smooth lifting without tilting. Do not attach lifting equipment to plastic bands or corrugated paper frames. Protect the unit's exterior with cloth or paper.

Outdoor Unit Installation

Factory-Supplied Accessories

Verify the following accessories are packed with the outdoor unit:

• Installation Manual (1)
• Electrical Accessory Pouch (1)
• Accessory Pipe Pouch (-)

NOTE: If any accessories are missing, contact your contractor.

Initial Check

• Install the outdoor unit in a well-ventilated, dry location.
• Position the unit to avoid affecting neighbors or surrounding vegetation with sound or discharge air. Note that sound levels may be higher at the rear and sides than at the front.
• Ensure the foundation is flat, level, and sufficiently strong.
• Avoid locations with high oil mist, salty air, or harmful gases like sulphur.
• Do not install where electromagnetic waves directly radiate to the electrical box. Maintain at least 3 meters distance from electromagnetic wave radiators.
• In snow-covered areas, mount field-supplied hoods at the discharge and inlet sides.
• Install in a shaded area, avoiding direct sunlight or high-temperature heat sources.
• Avoid locations where dust or contaminants could block the outdoor heat exchanger.
• Install in a location with restricted public access.
• Do not install where seasonal winds or building downdrafts directly impact the outdoor heat exchanger or fan.

Installation in open spaces: If unavoidable, place the unit near a wall to shield it from wind. Ensure adequate service space is secured (minimum 600mm).

NOTE: Strong winds blowing directly against the air discharge can cause the fan to rotate in reverse, potentially causing damage.

CAUTION: Aluminum fins have sharp edges; handle with care to avoid injury.

NOTE: Install the outdoor unit on a roof or in an area inaccessible to people other than service engineers.

Installation Work

1. Securing the Outdoor Unit with Anchor Bolts

Install anchor bolts (M10) into concrete. Secure the outdoor unit to the anchor bolts using the provided special washer.

2. Fixing the Unit by Anchor Bolts

Ensure the unit is firmly secured to prevent tilting, noise, or falling due to strong winds or earthquakes. Additional fixing arrangements, such as vibration-proof rubber, may be necessary.

3. Foundation and Fixing

The unit must be firmly secured to prevent tilting, noise, or falling due to strong winds or earthquakes. Diagrams show anchor bolt installation and additional fixing arrangements.

4. Drainage on Roofs/Verandas

Be aware that drain water may freeze on cold mornings. Avoid draining in areas frequently used by people to prevent slipping hazards.

5. Drain Piping

If drain piping is necessary, use the optional drain-kit (DC-01Q).

Position of Anchor Bolts

Diagrams illustrate the recommended positions for anchor bolts, noting that securing the marked dimension facilitates bottom-side piping work without foundation interference.

Installation and Maintenance Space

Adequate space must be reserved around the outdoor unit for operation and maintenance. Diagrams illustrate required clearances based on the location of obstacles (air inlet, top, air outlet, sides) for both single and multiple installations.

Case 1: Obstacle on Air Inlet Side (Upper Opening)

Diagrams show minimum clearances for front, sides, and open around/seal around configurations.

Case 2: Obstacle on Top (Upper Opening)

Diagrams show minimum clearances for front, sides, and open around/seal around configurations.

Case 3: Obstacle on Air Outlet Side (Upper Opening)

Diagrams show minimum clearances for front, sides, and open around/seal around configurations.

Case 4: Obstacle on Both Sides (Upper Opening)

Diagrams show minimum clearances for front, sides, and open around/seal around configurations.

NOTE: If L (horizontal distance from wall) is greater than H (unit height + foundation height), install the unit so that H is greater than or equal to L. Ensure the foundation is firm and prevent short-circuiting of airflow.

Frame and Base Installation

The entire base of the outdoor unit must be installed on a foundation. If using a vibration-proof mat, position it similarly. For field-supplied frames, use metal plates to adjust frame width for stable installation. Diagrams show incorrect (unstable) and correct (stable) base installations, including recommended metal plate dimensions.

Refrigerant Piping Work

DANGER: Use only refrigerant R410A. Do not charge flammable or poisonous gases for leakage or air-tightness tests, as this can cause explosions. Compressed air, nitrogen, or refrigerant are recommended for tests.

Piping Materials

1. Prepare locally-supplied copper pipes.
2. Select piping size from the table.
3. Use clean copper pipes, free from dust and moisture. Purge pipes with nitrogen or dry air before connecting.

Cautions for Refrigerant Pipe Ends:

• When installing pipes through walls, secure a cap at the pipe end.
• Do not place pipes directly on the ground.
• Ensure pipe ends are capped with a cap or vinyl tape, potentially secured with a rubber band, to prevent rain entry.

CAUTION: Cap pipe ends when inserting through holes. Do not place pipes on the ground without caps.

Flaring Dimension

Diagrams and a table detail the correct flaring dimensions (angles and diameters) for R410A pipes. Note that 1/2H material may require an accessory pipe with a flare.

Piping Thickness and Material

A table lists R410A piping sizes, thicknesses, and materials based on JIS standard (JIS B8607).

Flare Nut Dimensions

A table specifies flare nut dimensions corresponding to pipe diameters, based on JIS standard (JIS B8607).

Refrigerant Piping Work

Follow the directions for refrigerant piping work as per the table, which specifies pipe diameters for gas and liquid lines based on outdoor unit capacity and system combination.

System Combination

A table shows system combinations, recommended maximum indoor unit quantity, and combination range. It notes that connection ratios should not exceed 100% for systems where all indoor units operate simultaneously to avoid overload.

Piping Connection

Pipes can be connected from four directions. Knock-out holes in the front pipe cover or bottom base should be used. Diagrams illustrate front, rear, and bottom side piping work, and right side piping connections. Insulation is recommended for cables and pipes.

• Front and Right Side Pipe: Select knock-out holes based on wiring type (power or communication).
• Bottom Side Piping Work: Perform piping and wiring after removing the bottom piping cover.
• Rear Piping Work: Punch out holes along guide lines after removing the rear piping cover.

NOTE: Prevent cables from direct contact with piping. Use rubber bushes and insulation to protect gaps and prevent water ingress.

Refrigerant Pipe System Limitations

A table outlines system items, maximum pipe lengths (L1, L2, L3), and high distance limitations between outdoor and indoor units, and between branch pipes and indoor units.

Pipe Specifications

A table details stop valve specifications and recommended pipe sizes for gas and liquid lines between the outdoor unit and the first branch, and between branches.

Air-Tightness Test

1. Ensure stop valves are fully closed.
2. Connect indoor and outdoor units with field-supplied piping, suspending it to prevent contact with building parts.
3. Apply a thin layer of oil to flare nut seat surfaces and tighten with two spanners.

CAUTION: Do not apply excessive force to spindle valves (max 5.0 N.m). Do not loosen the stop ring. Fully open the spindle during test run.

• Stop Valve Operation: Diagrams show how to open/close spindle valves, with torque specifications.
• Procedure: Connect manifold gauge with nitrogen cylinder to check joints. Apply nitrogen gas pressure (4.15MPa) without opening stop valves. Check for leaks using a gas leak detector or foaming agent. Release nitrogen gas after the test.

Vacuum Pumping and Charging Refrigerant

1. Connect manifold gauge to check joints. Vacuum pump until pressure reaches -0.1MPa or lower for 1-2 hours.
2. After vacuum pumping, stop the pump and check if pressure remains stable for one hour.
3. Fully open gas and liquid valves.
4. Add refrigerant according to piping diameter and length.
5. Check for gas leaks using a detector or foaming agent (avoid household detergents).

Recommended Foaming Agents: SNOOP, Gupoflex.

NOTE: A sound upon removing the spindle cap is not a gas leak. Use only R410A compatible tools. If vacuum degree is not achieved, check for leaks.

Refrigerant Piping System Diagram

A diagram illustrates the overall refrigerant piping system, showing the outdoor unit connected to indoor units via branch pipes. It highlights the need for insulation on liquid lines, stop valves, and includes connections for manifold gauges, vacuum pumps, nitrogen tanks, and refrigerant cylinders. It also warns about the dangers of refrigerant leaks, such as oxygen deficiency and harmful gas generation.

CAUTION: Fully open the spindle during test run. An excess or shortage of refrigerant is a common cause of trouble. Charge the correct quantity as specified on the label. Check carefully for refrigerant leaks.

WARNING: Use only R410A refrigerant. Other substances can cause explosions. R410A is a greenhouse gas with a high GWP (2088); do not vent it into the atmosphere. CO2 equivalent calculation is provided.

NOTE: Fill in the unit label with the amount of refrigerant charged and CO2 equivalent. The equipment contains fluorinated greenhouse gases.

Additional Refrigerant Charge

Additional refrigerant charge may be necessary based on piping length. The manual provides a method for calculating this charge (W kg) and recording it. It includes an example calculation and a table for pipe charge based on diameter and length, and additional charge for indoor units.

Caution of the Pressure by Check Joint

Use check joints (A for gas stop valve, C for liquid piping) for pressure measurement. Pressure readings differ between cooling and heating operations. Diagrams illustrate the locations of check joints.

CAUTION: Maximum Permissible Concentration of R410A is 0.42 kg/m³. Calculate concentration and follow local codes. If leaks occur, take action to reduce concentration.

Collecting Refrigerant

Steps are provided for collecting refrigerant when relocating units: attach manifold gauge, turn on power, set DSW1-1 pin to ON for cooling, close liquid stop valve, collect refrigerant. When the low-pressure side indicates 0.02MPa, close the gas stop valve and set DSW1-1 pin to OFF. Turn off power.

CAUTION: Measure low pressure; if it drops below -0.01 MPa, the compressor may be faulty.

Electrical Wiring

WARNING: Turn OFF the main power switch for at least 10 minutes before any electrical work. Ensure fans have stopped. Protect wires from rodents. Ensure wiring does not touch refrigerant pipes, plate edges, or electrical parts.

CAUTION: Secure power source wiring with a cord clamp.

General Check

1. Ensure field-selected electrical components comply with NEC and electrical data.
2. Verify power supply voltage is within ±10% of nominal and earth phase is present.
3. Ensure sufficient power supply capacity to prevent compressor failure.
4. Confirm the earth wire is connected.
5. Check electrical resistance is over 1 megohm between ground and electrical parts.

Electrical Wiring Connection

1. Connect the Transmission Wire between outdoor and indoor units to terminals 1 and 2 on TB2. Incorrect connection can damage the PCB.
2. Do not wire in front of the service panel fixing screw.

Demand Response

The product is Demand Response ready (DRM1, DRM2, DRM3) and can receive signals from electricity providers to support grid stability by switching off, reducing output, or operating at a reduced level during high demand periods.

Electrical Wiring (Continued)

WARNING: Install an ELB (Electric Leakage Breaker). Follow specified screw tightening torques. Use appropriate wire sizes and types as per standards (IEC/AS/NZS 60245-1, AS/NZS 3000). If the power cord is damaged, contact professionals. Ensure the ground wire is longer than current-carrying conductors.

NOTE: Total wiring length for indoor/outdoor units is up to 100m. Remote control wiring can extend up to 500m. Power source wiring follows standard methods. Recommended fuse sizes and cable sizes are provided in a table.

Connection of Outdoor Unit

Diagrams show the terminal block for power source and control circuits (TB2, TB3, TB4) and the wiring connection of the outdoor unit. Wires should be fixed and tied properly to avoid contact with components. Use conduit correctly, ensuring separation between power and transmission wiring, and proper sealing.

CAUTION: Do not run conduit inside the outdoor unit. Ensure proper separation of power and transmission wiring. Seal conduit ends and provide drain holes. Secure power source wire with a cord clamp. Use an ELB. Do not operate until all checks are cleared. Install a multi-pole main switch with adequate contact spacing.

Test Run

WARNING: Do not operate the system until all check points are cleared. Confirm refrigerant pipe system and communication wire links. Check electrical resistance (>1 megohm). Ensure stop valves are fully opened. Ensure the main power switch has been ON for over 12 hours to warm the compressor oil heater.

During operation: Do not touch hot parts (discharge gas side >90°C). Do not push magnetic switches. Do not touch electrical components within 10 minutes after turning OFF the main switch. Operate each indoor unit individually.

Checking Wire Connection by Test Run

1. Turn ON the power supply for all indoor units.
2. Wait for auto-addressing (approx. 3-5 minutes). Select language from the menu.
3. Press and hold the menu and return buttons simultaneously for at least 3 seconds to display the test run menu.

Test Run Menu Display

Screenshots show the T.RUN MENU with options like T.RUN, Optional Setting, Input/Output Setting, and Indoor Adds Change. Users can confirm running status, indoor initialization, and preheating.

NOTE: If '0' is indicated, auto-address function may be performing. Cancel and reset.

Test Run Settings

Users can select and adjust settings like Mode (Cool/Heat), FAN speed (Middle), and Running Time (30-600 minutes).

Test Run Operation

Press the run/stop button to start the test run. The system may automatically set an OFF timer. Temperature detections by thermistors are valid during the test run.

Finishing Test Run

Press the run/stop button again or wait for the set test run time to elapse. Adjust running time as needed.

Abnormalities During Test Run

If the RUN indicator flashes, it indicates abnormalities such as activated protection devices. Alarm codes, unit model codes, and connected indoor unit numbers will be displayed. If the RUN indicator flashes on specific models (e.g., HYXE-JO1H), it may indicate transmission issues. Consult a service engineer if abnormalities persist.

Test Run and Maintenance Record

A table is provided for recording test run results, including checks for fan rotation direction, compressor sounds, operation duration, room temperature, outdoor ambient temperature, refrigerant temperature and pressure, voltage, compressor input, refrigerant charge adequacy, operation control devices, safety devices, refrigerant leakage, unit cleanliness, panel fixation, filter condition, heat exchanger cleanliness, stop valve status, and drain flow.

Alarm Code

A comprehensive table lists alarm codes, categories (Indoor unit, Outdoor unit, Transmission, Supply phase, Voltage, Cycle, Sensor, System, Protection Device, Inverter, Fan motor, Compressor), content of abnormality, and leading causes.

Safety and Control Device Setting

Compressor Protection

The High Pressure Switch cuts out compressor operation when discharge pressure exceeds the set limit.

Fan Motor Protection

When the thermistor temperature reaches a set point, motor output is decreased. The limitation is cancelled when the temperature lowers.

Specifications Table

A table provides specifications for the outdoor unit models ACV200U/ACV200U-1, including pressure switch settings (cut-out/cut-in MPa), main circuit fuse rating (A), CCP timer set time (min), and control circuit fuse rating (A).

After Sales Service

If the air conditioner does not operate normally, turn off the unit and cut off the power supply immediately. Contact the service center or technical department.

Contact information:

• Website: emerald.com.au/contact
• Emerald Energy Pty Ltd
• ABN 86 632 172 368
• Address: L2, 12a Rodborough Road Frenchs Forest NSW 2086

The information in this brochure is accurate as of the time of publication.