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1. Capacity Pipe Size Torque Btu h GAS LIQUID 7K 9K 3 8 4 2kg m 1 4 1 8kg m 12K 18K 1 2 5 5kg m 1 4 1 8kg m 24K 5 8 6 6kg m 3 8 4 2kg m When extending the drain hose at the indoor unit install the drain pipe Indoor unit drain hose Vinyl tape narrow Adhesive F Wrap the insulation material around the connecting portion Overlap the connection pipe insulation material and the indoor unit pipe insulation material Bind them together with vinyl tape so that there is no gap Plastic bands Insulation material rd Coe UU C Fe C Wrap the area which accommodates the rear piping housing section with vinyl tape Indoor Connection ie unit pipe pipe Vinyl tape i Wrap with vinyl tape wide Connecting cable Vinyl tape narrow Bundle the piping and drain hose together by wrapping them with vinyl tape over the range within which they fit into the rear piping housing section Wrap with vinyl tape Vinyl tape wide Drain hose For left rear piping A Route the indoor tubing with the drain hose to the required piping hole position B Insert the piping drain hose and the connecting cable into the piping hole Connecting cable Drain pipe Pipe Air Conditioner Service Manual C Insert the connecting cable into the indoor unit 1 Don t connect the cable to the indoor unit 2 Make
2. 2 Check that the gas and liquid side service valves are fully open A Prepare remote control 1 Remove the battery cover by pulling it according to the arrow direction 2 Insert new batteries making sure that the and of battery are installed correctly 3 Reattach the cover by pushing it back into position NOTE Use 1 5volt batteries Do not use rechargeable batteries Remove the batteries from the remote control if the system is not going to be used for a long time B Settlement of outdoor unit 1 Anchor the outdoor unit with a bolt and nut tightly and horizontally on a concrete or rigid mount 2 When installing on the wall roof or rooftop anchor the mounting base securely with a nail or wire assum ing the influence of wind and earthquake 3 In the case when the vibration of the unit is conveyed to the hose secure the unit with an anti vibration rub ber Bolt Tubing connection C Evaluation of the performance Operate unit for 15 20 minutes then check the system refrigerant charge 1 Measure the pressure of the gas side service valve 2 Measure the temperature of the intake and discharge of air 3 Ensure the difference between the intake temperature and the discharge is more than 8 C Cooling or reversely Heating Intake temperature Discharge air 4 For reference the gas side pressure of optimum condi tion is as below Cooling Outside a
3. Confirm the Lo knob of the manifold valve is open Then run the vacuum pump The operation time for evacuation varies with tubing Indoor unit length and capacity of the pump The following table z shows the time required for evacuation Required time for evacuation when 30 gal h vacuum pump is used If tubing length is less than 10m 33 ft if tubing length is longer than 10m 33 ft 10 min or more 15 min or more When the desired vacuum is reached close the Lo knob of the manifold valve and stop the vacuum pump D Finishing the job 1 With a service valve wrench turn the valve stem of lig uid side valve counter clockwise to fully open the valve 2 Turn the valve stem of gas side valve counter clock wise to fully open the valve 3 Loosen the charge hose connected to the gas side service port slightly to release the pressure then remove the hose 4 Replace the flare nut and its bonnet on the gas side service port and fasten the flare nut securely with an adjustable wrench This process is very important to prevent leakage from the system 5 Replace the service valve caps at both the gas and the liquid side and fasten them tight This completes air purging with a vacuum pump The air conditioner is now ready to test run Vacuum pump 15 Air Conditioner Service Manual 3 9 Test running 1 Check that all tubing and wiring have been properly connected
4. leakage circuit breaker in a wet or moist area 8 The following would be caused by voltage drop Vibration of a magnetic switch which will damage the contact point fuse breaking disturbance of the normal function of the overload 9 The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an air gap contact separation of at least 3mm in each active phase conductors Sec 5 Pi 12 Air Conditioner Service Manual 3 7 Checking the Drainage and forming the pipings 3 7 1 Checking the drainage A To remove the front panel from the indoor unit remove the front panel from the indoor unit cabinet 1 Set the air direction louvers up and down to the posi tion horizontally by hand 2 Remove 3 screws that retain the front panel Pull the lower left and right sides of the grille toward you and lift it off Grille Chassis Remove screws 3places B To check the drainage 1 Pour a glass of water on the evaporator 2 Ensure the water flows through the drain hose of the indoor unit without any leakage and goes out the drain exit Z C Drain piping e The drain hose should point downward for easy drain flow Downward slope Do not make drain piping Accumulated Do not raise drain water Air Y h i h i i i Water Water Water leakage leakage Waving leakage Tip of drain hose XX dipped in water Less than 50mm gap Di
5. material uu Wrap the area which accommodates the rear piping housing section with vinly tape Indoor unit piping Connection pipe Vinyl tape Wrap with vinyl tape Connecting cable Vinyl tape narrow Air Conditioner Service Manual Bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section Wrap with vinyl tape Drain hose H Reroute the pipings and the drain hose across the back of the chassis passage through piping hole I Set the pipings and the drain hose to the back of the chassis with the tubing holder Hook the edge of tubing holder to tap on chassis and push the bottom of tubing holder to be engaged at the bottom of chassis J Indoor unit installation 1 Remove the spacer 2 Ensure that the hooks are properly seated on the installation plate by moving it left and right Connecting cable Drain hose Press the lower left and right sides of the unit against the installation plate until the hooks engage into their Slots clicking sound 3 5 3 Connection of the pipes Outdoor A Align the center of the pipings and sufficiently tighten the flare nut by hand B Finally tighten the flare nut with torque wrench until the w
6. necting cable 74cm Liquid side piping Cable PE C Tape the tubing drain hose and the connecting cable Be sure that the drain hose is located at the lowest side of the bundle Locating at the upper side can cause drain pan to overflow inside the unit Connecting Gas side cable piping Liquid side ie hose piping NOTE If the drain hose is routed inside the room insulate the hose with an insulation material so that dripping from sweat ing condensation will not damage furniture or floors Foamed polyethylene or equivalent is recommended D Indoor unit installation Hook the indoor unit onto the upper portion of the installation plate Engage the two hooks of the rear top of the indoor unit with the upper edge of the installation plate Ensure that the hooks are properly seated on the installation plate by moving it left and right Connecting cable Drain hose Press the lower left and right sides of the unit against the installation plate until the hooks engage into their slots click ing sound E Connecting the pipings to the indoor unit and drain hose to drain pipe Align the center of the pipings and sufficiently tighten the flare nut by hand EE Ge D OS Flare nut Pipings Indoor unit tubing Air Conditioner Service Manual Tighten the flare nut with a wrench Spanner fixed Flare nut Torque wrench Connection pipe Indoor unit tubing
7. the terminals on the control board individually B Secure the cable onto the control board with the cord clamp C Refix the control cover to the original position with Connecting cable the screw D Use a recognized circuit breaker 20A 18K 25A 24K between the power source and the unit A disconnecting device to adequately dis connect all supply lines must be fitted Outdoor unit Terminal block Power cord power connecting cable Control cover eun After the confirmation of the above conditions prepare the wiring as follows 1 Never fail to have an individual power circuit specifically for the air conditioner As for the method of wiring be guided by the circuit diagram posted on the inside of control cover 2 The screw which fasten the wiring in the casing of electrical fittings are liable to come loose from vibrations to which the unit is subjected during the course of transportation Check them and make sure that they are all tightly fastened If they are loose it could cause burn out of the wires 3 Specification of power source 4 Confirm that electrical capacity is sufficient 5 See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the name plate 6 Confirm that the cable thickness is as specified in the power source specification Particularly note the relation between cable length and thickness 7 Always install an earth
8. 4 Drill a hole in the wall Drill the piping hole with a 270mm hole core drill Drill the piping hole at either the right or the left with the hole slightly slanted to the outdoor side WALL Indoor Outdoor 5 7mm Air Conditioner Service Manual 3 5 Flaring work and connection of piping 3 5 1 Flaring work Main cause for gas leakage is due to defect in flaring work Carry out correct flaring work in the following procedure A Cut the pipes and the cable 1 Use the piping kit accessory or the pipes pur chased locally 2 Measure the distance between the indoor and the outdoor unit 3 Cut the pipes a little longer than measured dis tance 4 Cut the cable 1 5m longer than the pipe length B Burrs removal 1 Completely remove all burrs from the cut cross section of pipe tube 2 Put the end of the copper tube pipe in a downward direction as you remove burrs in order to avoid dropping burrs into the tubing Pipe Reamer Point down C Putting nut on Remove flare nuts attached to indoor and outdoor unit then put them on pipe tube having completed burr removal not possible to put them on after flaring work Flare nut Copper tube D Flaring work Carry out flaring work using flaring tool as shown below Outside diameter A mm inch mm 96 35 1 4 1 0 1 3 99 52 3 8 0 81 0 912 7 1 2 0 5 0 8 915 88 5 8 0 5 0 8 Firmly hold copper
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10. Air Conditioner Service Manual Kimairex KSWT SERIES INSTALLATION INSTRUCTION Wall mounted Split Type Air Conditioner Service Manual INSTALLATION 1 Characteristics of refrigerant 1 1 Temperature pressure relationships in saturated condition Saturation curve Pressure kg cm2 G Temperature C 1 2 Strong weak points of freon 1 2 1 Strong points 1 Chemical stability 2 No toxicity 3 By little corrosive action on metals it is applicable to almost all metals 4 The ratio of Cp Cv is lower than ammonia and the discharge gas temperature is low so air cooling type is available 1 2 2 Weak points 1 A little amount of evaporation heat should circulate a great deal of liquid at the same refrigerating capacity 2 When using for iron steels scale occurs more rapidly than ammonia use due to hydrolysis 3 Generally it is fused in lubricant 4 Since it is not melted in water water is separated and water closing occurs in capillary tube 5 High price R 12 2 Tools required 2 1 Tools Screw driver Hand drill Assembly disassmbly Indoor installation plate fixing Core drill diameter 70mm Monkey spanner 300mm 2EA lt D 9 Indoor Outdoor pipe connection Clamp meter 2 2 Accessory Winter cover c Outdoor protection Connnection cable Indoor Outdoor wire connnection Refrigerant pipe for high low pressure Refrigerant circuit connection to Indoor Outdoor Ch
11. a small loop with the cable for easy connection later D Tape the tubing drain hose and the connecting cable Connecting cable Capacity Btu h Cooling Model Heat Pump Model 7K 9K 12K 18K Go eed e 24K eed CD amp E Indoor unit installation 1 Hang the indoor unit from the hooks at the top of the installation plate 2 Insert the spacer etc between the indoor unit and the installation plate and separate the bottom of the indoor unit from the wall Indoor unit Spacer Installation plate Onam F Connecting the pipings to the indoor unit and the drain hose to drain pipe Align the center of the pipings and sufficiently tighten the flare nut by hand MEE den zD Os Indoor unit tubing Flare nut Pipings Tighten the flare nut with a wrench Torque wrench Connection pipe Indoor unit tubing Capacity Pipe Size Torque Btu h GAS LIQUID 7K 9K 3 8 4 2kg m 1 4 1 8kg m 12K 18K 1 2 5 5kg m 1 4 1 8kg m 24K 5 8 6 6kg m 3 8 4 2kg m When extending the drain hose at the indoor unit install the drain pipe Indoor unit drain hose Adhesive Vin tape narrow G Wrap the insulation material around the connect ing portion Overlap the connection pipe heat insulation and the indoor unit pipe heat insulation material Bind them together with vinyl tape so that there is no gap Plastic bands Insulation
12. age to the wall t More than 5cm More than 5cm N CAUTION Install the indoor unit on the wall where the height from the floors more than 2 3 meters 3 1 2 Outdoor unit 1 If an awning is built over the unit to prevent direct sun light or rain exposure make sure that heat radiation from the condenser is not restricted 2 Ensure that the space around the back and sides is more than 10cm The front of the unit should have more than 70cm of space 3 Do not place animals and plants in the path of the warm air 4 Take the air conditioner weight into account and select a place where noise and vibration are minimum 5 Select a place so that the warm air and noise from the air conditioner do not disturb neighbors 1 More than 60cm More than 10cm More than 10cm More More than 70cm than 60cm 6 Rooftop Installations If the outdoor unit is installed on a roof structure be sure to level the unit Ensure the roof structure and anchoring method are adequate for the unit location Consult local codes regarding rooftop mounting 3 2 Piping length and elevation Pipe Size Standard Max Max Additional Length Elevation length Refrigerant Btu h GAS LIQUID m m dim gm 7K 9K 3e 14 3or5 5 10 20 12K 1 2 14 3 50r5 5 10 20 18K 1 2 1 4 45 5 15 30 Capacity 24K 5 8 3 8 5 5 15 30 Both gas and liquid interconnecting pipes
13. aging of wall through hole Air Conditioner Service Manual Ruler knife amp soup water Ruler distance measurement Knife Tape cutting Current voltage resistance measurement Indoor outdoor pipe connection Drive torch Anti vibration rubber c AZ c2 Wire amp pipe finishing Wire amp pipe finishing Remocon hanger Gas leak detector Hex wrench Large side 4mm 5mm Thermometer Temperature measurement at Indoor suction inlet discharge outlet Service valve operating Flare tool set Insulation resistance measurement Electric shock prevention Pipe cutting Burr removal Mega tester Adhesive Drain hose Finishing Fixture clamping screw Remocon fixture fixing Remark Some of the above parts are provided by the installer and not included in the standard air conditioner Air Conditioner Service Manual 3 Split type installation 3 1 Select the best location 3 1 1 Indoor unit 1 Do not have any heat or steam near the unit 2 Select a place where there are no obstacles in front of the unit 3 Make sure that condensation drainage can be conve niently routed away 4 Do not install near a doorway 5 Ensure that the space around the left and right of the unit is more than 5cm The unit should be installed as high on the wall as possible allowing a minimum of 5cm from ceiling 6 Use a stud finder to locate studs to prevent unneces sary dam
14. d in a vertical standing position Do a leak test of all joints of the tubing both indoor and outdoor and both gas and liquid side service valves Bubbles indicate a leak Be sure to wipe off the soap with a clean cloth After the system is found to be free of leaks relieve the nitrogen pressure by loosening the charge hose con nector at the nitrogen cylinder When the system pres sure is reduced to normal disconnect the hose from the cylinder Indoor unit P 1 cane OE Charge hose Nitrogen gas cylinder in vertical standing position 14 Air Conditioner Service Manual Soap water method 1 Remove the caps from the 2 way and 3 way valves 2 Remove the service port cap from the 3 way valve 3 To open the 2 way valve turn the valve stem counter clockwise approximately 90 wait for about 2 3 sec and close it 4 Apply a soap water or a liquid neutral detergent on the indoor unit connection or outdoor unit connections by a soft brush to check for leakage of the connecting points of the piping 5 If bubbles come out the pipes have leakage Outdoor unit Cover control Gas side Bigger diameta Liquid side 3 way valve Smaller diameta close Hexagonal wrench C Evacuation Connect the charge hose end described in the preced ing steps to the vacuum pump to evacuate the tubing and indoor unit Service port cap
15. g efficiency drops 4 Moisture in the refrigerant circuit may freeze and block capillary tubing 5 Water may lead to corrosion of parts in the refrigera tion system Therefore the indoor unit and tubing between the indoor and outdoor unit must be leak tested and evacuated to remove any noncondensables and moisture from the system 3 8 2 Air purging with vacuum pump A Preparation Check that each tube both liquid and gas side tubes between the indoor and outdoor units have been prop erly connected and all wiring for the test run has been completed Remove the service valve caps from both the gas and the liquid side on the outdoor unit Note that both the liquid and the gas side service valves on the outdoor unit are kept closed at this stage B Leak test Connect the manifold valve with pressure gauges and dry nitrogen gas cylinder to this service port with charge hoses Be sure to use a manifold valve for air purging If it is not available use a stop valve for this purpose The Hi knob of the manifold valve must always be kept close Pressurize the system to no more than 150 P S I G with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150 P S I G Next test for leaks with liquid soap To avoid nitrogen entering the refrigerant system in a liquid state the top of the cylinder must be higher than its bottom when you pressurize the system Usually the cylinder is use
16. l The connecting cable connected to the indoor and out door unit should be complied with the following specifi BROWN BLUE GREENYELLOW RED YELLOW cations i Eb Type HO7RN F approved by HAR or SAA Terminal on the indoor unit N 3 BROWN BLUE GRENYELLON RED YELLOW NORMAL Terminal on the outdoor unit PAOSS SECTIONAL AREA 0 75mm 24K cooling model Terminal on the indoor unit J A WHITE BLUE BROWN Power supply 77 GREENYELLOW WHITE BLUE BROWN 9245 neat pump modal Terminal on the outdoor unit A Terminal on the indoor unit EA ko t WHITE RED YELLOW BROWN BLUE GREEN YELLOW Power supply Wu WHITE RED YELLOW BROWN BLUE GREENYELLOW yoy t t t t Terminal on the outdoor unit CD O 18K Model O 24K Model If a power plug is not to be used provide a circuit breaker If a power plug is not to be used provide a circuit breaker between power source and the unit as shown below between power source and the unit as shown below Main power source Main power source Air Conditioner Circuit Breaker een anes Ll Use a circuit breaker or time delay fuse Circuit Breaker Ll Use a 25A circuit breaker or time delay fuse 11 Air Conditioner Service Manual 3 6 2 Connect the cable to the outdoor unit A Remove the control cover from the unit by loosen ing the screw Connect the wires to
17. mbient TEMP The pressure of the gas side service valve 35 C 95F 4 6kg cm G 56 8 85 2 P S 1 NOTE If the actual pressure are higher than shown the system is most likely over charged and charge should be removed If the actual pressure are lower than shown the system is most likely undercharged and charge should be added The air conditioner is now ready for use r PUMP DOWN This is performed when the unit is to be relocated or the refrigerant circuit is serviced Pump Down means collecting all refrigerant in the out door unit without loss in refrigerant gas CAUTION Be sure to perform Pump Down procedure with the unit cooling mode Pump Down Procedure 1 Connect a low pressure gauge manifold hose to the charge port on the gas side service valve 2 Open the gas side service valve halfway and purge the air from the manifold hose using the refrigerant gas 3 Close the liquid side service valve all the way in 4 Turn on the unit s operating switch and start the cooling operation 5 When the low pressure gauge reading becomes 1 to 0 5kg cm2 G 14 2 to 7 1 P S I G fully close the gas side valve stem and then quickly turn off the unit At that time Pump Down has been completed and all refrigerant gas will have been collected in the outdoor unit 16 Kimairex The Klimaire logo is a registered Trademark of Klimaire Products inc Copyright 2010 Klimaire Products Inc 2190 NW
18. must be insulated as a pair but it is not necessary to indi vidually insulate them Outdoor unit Indoor unit Outdoor unit Oil trap x 1 Indoor unit In case more than 5m Capacity is based on standard length and maximum allowance length is on the basis of reliability Oil trap should be installed every 5 7 meters Air Conditioner Service Manual 3 3 How to fix installation plate The wall you select should be strong and solid enough to prevent vibration 3 3 1 Mount the installation plate on the wall with four type A screws If mounting the unit on a concrete wall use anchor bolts Mount the installation plate horizontally by aligning the center line using a level Type A screw Marking off line I Thread Weight 3 3 2 Measure the wall and mark the centerline It is also important to use caution concerning the location of the installation plate routing of the wiring to power outlets is through the walls typically Drilling the hole through the wall for piping connections must be done safely Left rear piping Right rear piping D A B C na x Y g70mm Hole Center Installation plate For right rear piping and left rear piping draw a line in the direction of the arrow marked D The meeting point of the two lines is the center of the hole The position of the center of the hole Left holecore position Right holecore position 3
19. pipe in a die in the dimension shown in the table above E Check 1 Compare the flared work with figure below 2 If flare is noted to be defective cut off the flared sec tion and do flaring work again Smooth all round Inside is shiny without scratches Pd y Improper flaring Inclined_ Surface Cracked Uneven damaged thickness Even length all round Air Conditioner Service Manual 3 5 2 Connection of piping Indoor 1 Preparing the indoor unit s piping and drain hose for installation through the wall 2 Remove the plastic tubing retainer see illustration below and pull the tubing and drain hose away from chassis 3 Replace the plastic tubing holder in the original posi tion Z CAUTION When install make sure that the remaining parts must be removed clearly so as not to damage the piping and drain hose especially power cord and connecting cable For right rear piping A Route the indoor tubing and the drain hose in the direction of rear right Sl Drain hose EN B Insert the connecting cable into the indoor unit from the outdoor unit through the piping hole 1 Do not connect the cable to the indoor unit 2 Make a small loop with the cable for easy connection later 3 Connecting cable Capacity Btu h Cooling Model Heat Pump Model 7K 9K 12K 18K ee CD SD 24K ED GD Length of con Gas side piping
20. rench clicks When tightening the flare nut with torque wrench ensure the direction for tightening follows the arrow on the wrench Capacity Pipe Size Torque Btu h GAS LIQUID 7K 9K 3 8 4 2kg m 1 4 1 8kg m 12K 18K 1 2 5 5kg m 1 4 1 8kg m 24K 5 8 6 6kg m 3 8 4 2kg m Outdoor unit Gas side piping Bigger diameter Liquid side piping Smaller diameter 10 Air Conditioner Service Manual 3 6 Connecting the cable between indoor a unit and outdoor unit CAUTION 3 6 1 Connect the cable to the Indoor unit The power cord connected to the indoor unit should be complied with the following specifications Connect the cable to the indoor unit by connecting Type HO5VV F Indoor HO7RN F Outdoor approved the wires to the terminals on the control board indi by HAR or SAA vidually according to the outdoor unit connection Ensure that the color of the wires of the outdoor unit NORMAL and the terminal No are the same as those of the CROSS SECTIONAL indoor unit AREA 2 5mm 18K 1 5mm2 7K 14K 1 0mm 7K 18K cooling model A The power connecting cable connected to the indoor Leg ener and outdoor unit should be complied with the following specifications BROWN BLUE GREENYELLOW Type HO7RN F approved by HAR or SAA BROWN BLUE GREENYELLOW NORMAL i CROSS SECTIONAL Terminal on the outdoor unit AREA 2 5mm 18K 1 5mm 7K 14K 1 0mm 7K 18K heat pump mode
21. tch 3 7 2 Form the piping A Form the piping by wrapping the connecting portion of the indoor unit with insulation material and secure it with two kinds of vinyl tapes If you want to connect an additional drain hose the end of the drain outlet should be routed above the ground Secure the drain hose appropriately B In cases where the outdoor unit is installed below the indoor unit perform the following 1 Tape the piping drain hose and connecting cable from down to up 2 Secure the tapped piping along the exterior wall using saddle or equivalent Seal small openings around pipings with a gum type sealer Trap is required to prevent water from entering into electrical parts C In cases where the Outdoor unit is installed above the Indoor unit perform the following 1 Tape the piping and connecting cable from down to up 2 Secure the taped piping along the exterior wall Form a trap to prevent water entering the room 3 Fix the piping onto the wall by saddle or equivalent Seal small openings around pipings with a gum type sealer a SS Sud SS Trap is required to prevent water from entering into electrical parts Air Conditioner Service Manual 3 8 Air purging 3 8 1 Air purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below 1 Pressure in the system rises 2 Operating current rises 3 Cooling or heatin

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