Installation Instructions
619RC / 538PR
CASSETTE DUCTLESS SPLIT SYSTEM
SIZES 09 TO 18
Installation Instructions
TABLE OF CONTENTS
PAGE
PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 3
SYSTEM REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CLEARANCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INSTALLATION TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
INDOOR UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 9
OUTDOOR UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . 15
INSTALL ALL POWER AND INTERCONNECTING WIRING
TO OUTDOOR UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ELECTRICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOTE CONTROL INSTALLATION . . . . . . . . . . . . . . . . . 17
SYSTEM VACUUM AND CHARGE . . . . . . . . . . . . . . . . . . . 17
START--UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
NOTE: Read the entire instruction manual before starting the
installation.
PARTS LIST
Fig. 1 --- Parts List
A150633
Note:
--- 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 to the indoor unit. This will ensure that rain drips from the connection pipe before entering the wall.
--- Piping and the interconnecting wiring are field supplied.
--- Fig.1 is only a sketch. Different models may be slightly different.
2
SAFETY CONSIDERATIONS
WARNING
!
Installing, starting up, and servicing air--conditioning equipment
can be hazardous due to system pressures, electrical components,
and equipment location (roofs, elevated structures, etc.).
Only trained, qualified installers and service mechanics should
install, start--up, and service this equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning coils. All other operations should be performed by
trained service personnel.
When working on the equipment, observe precautions in the
literature and on tags, stickers, and labels attached to the
equipment.
Follow all safety codes. Wear safety glasses and work gloves. Keep
quenching cloth and fire extinguisher nearby when brazing. Use
care in handling, rigging, and setting bulky equipment.
Read these instructions thoroughly and follow all warnings or
cautions included in literature and attached to the unit. Consult
local building codes and National Electrical Code (NEC) for
special requirements. Recognize safety information. This is the
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing, modifying, or servicing system, main
electrical disconnect switch must be in the OFF
position. There may be more than 1 disconnect switch.
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.
safety--alert symbol !! . When you see this symbol on the unit and
in instructions or manuals, be alert to the potential for personal
injury. Understand these signal words: DANGER, WARNING,
and CAUTION. These words are used with the safety--alert
symbol. DANGER identifies the most serious hazards which will
result in severe personal injury or death. WARNING signifies
hazards which could result in personal injury or death. CAUTION
is used to identify unsafe practices which may result in minor
personal injury or product and property damage. NOTE is used to
highlight suggestions which will result in enhanced installation,
reliability, or operation.
!
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 system shutdown. This causes
refrigerant slugging and could possibly damage the
compressor at start--up.
3
SYSTEM REQUIREMENTS
Allow sufficient space for airflow and servicing unit. See Fig. 5 for minimum required distances between unit and walls or ceilings.
Piping
IMPORTANT: Both refrigerant lines must be insulated separately.
S Minimum refrigerant line length between the indoor and outdoor units is 10 ft. (3 m).
S Table 1 lists the maximum lengths.
Table 1—Piping Lengths
SYSTEM SIZE
Min. Piping Length
Standard Piping Length
Max. outdoor--- indoor height difference
(OU higher than IU)
Max. outdoor--- indoor height difference
(IU higher than OU)
Piping
Max. Piping length with no additional refrigerant
charge
Max. Piping Length
Additional refrigerant charge
(between standard --- Max piping length)
Gas Pipe (size--- connection type)
Liquid Pipe (size--- connection type)
Refrigerant Type
Refrigerant
Charge Amount
ft(m)
ft(m)
9K
10 (3)
25 (7.6)
12K
10 (3)
25 (7.6)
18K
10 (3)
25 (7.6)
ft(m)
32 (10)
32 (10)
65 (20)
ft(m)
32(10)
32(10)
65(20)
ft(m)
25 (7.6)
25 (7.6)
25 (7.6)
ft(m)
82 (25)
82 (25)
98 (30)
Oz/ft(g/m)
0.27 (25)
0.27 (25)
0.43 (40)
in(mm)
in(mm)
3/8 (9.52)
1/4 (6.35)
R410A
2.76 (1.25)
1/2 (12.7)
1/4 (6.35)
R410A
2.76 (1.25)
1/2 (12.7)
1/4 (6.35)
R410A
4.19 (1.90)
Lbs(kg)
S Above charge is for piping runs up to 25 ft. (7.6 m).
S For piping runs greater than 25 ft. (7.6 m), add refrigerant up to the allowable length as specified in Table 1.
The outdoor unit has an electronic expansion valve to manage the refrigerant flow of the fan coil connected.
All wires must be sized per NEC (National Electrical Code) or
CEC (Canadian Electrical Code) and local codes. Use the
Electrical Data table MCA (minimum circuit amps) and MOCP
(maximum over current protection) to correctly size the wires and
the disconnect fuse or breakers respectively.
Per the caution note, only stranded copper conductors with a 600
volt rating and double insulated copper wire must be used. The
use of BX cable is not recommended.
IMPORTANT: The use of BX cable is not recommended.
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 indoor unit consists of four (4) wires and provides the power
for the indoor unit. Two wires are high voltage AC power. One
wire is communication wiring and the other is a ground wire.
Recommended Connection Method for Power and
Communication Wiring (To minimize communication wiring
interference)
Power Wiring:
The main power is supplied to the outdoor unit. The field
supplied connecting cable 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.
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.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
S Wires should be sized based on NEC and local codes.
S Use copper conductors only with a 600 volt rating and
double insulated copper wire.
4
DIMENSIONS -- INDOOR
Fig. 2 --- Indoor Unit
Table 2—Dimensions Indoor
9K
UNIT SIZE
BODY
Height
Width
Depth
in(mm)
in(mm)
in(mm)
10.24 (260)
22.44 (570)
22.44 (570)
Height
Width
Depth
Weight--- Gross
Weight--- Net
in(mm)
in(mm)
in(mm)
lbs(kg)
lbs(kg)
11.42 (290)
25.79 (655)
25.79 (655)
41.88 (19)
35.27 (16)
12K
PANEL
BODY
Dimensions
1.97 (50)
10.24 (260)
25.47 (647)
22.44 (570)
25.47 (647)
22.44 (570)
Packing
4.84 (123)
11.42 (290)
28.15 (715)
25.79 (655)
28.15 (715)
25.79 (655)
9.92 (4.5)
41.88 (19)
5.51 (2.5)
35.27 (16)
5
18K
PANEL
BODY
PANEL
1.97 (50)
25.47 (647)
25.47 (647)
10.24 (260)
22.44 (570)
22.44 (570)
1.97 (50)
25.47 (647)
25.47 (647)
4.84 (123)
28.15 (715)
28.15 (715)
9.92 (4.5)
5.51 (2.5)
11.42 (290)
25.79 (655)
25.79 (655)
46.3 (21)
39.68 (18)
4.84 (123)
28.15 (715)
28.15 (715)
9.92 (4.5)
5.51 (2.5)
DIMENSIONS - OUTDOOR
Fig. 3 --- Outdoor Unit
Table 3—Dimensions Outdoor
MODEL
W in (mm)
D in (mm)
H in (mm)
L1 in (mm)
L2 in (mm)
OPERATING WEIGHT
lb (kg)
9K/12K
32.0 (810)
12.2 (310)
22.0 (558)
20.9 (530)
11.4 (290)
82.5 (37.4)
18K
32.3 (845)
12.6 (320)
27.6 (700)
22.1 (560)
13.2 (335)
102.5 (46.5)
6
CLEARANCES -- INDOOR
Fig. 4 --- Cassette Unit Clearance
7
CLEARANCES - OUTDOOR
A
Air-inlet
E
D
B
C
Air-outlet
A07894
Fig. 5 --- Outdoor Unit Clearance
Table 4—Outdoor Unit Clearance Dimensions
MINIMUM VALUE
in. (mm)
24 (610)
24 (610)
24 (610)
4 (101)
4 (101)
UNIT
A
B
C
D
E
8
25.47in/647
22.44in/570
Indoor Unit
Installation locations include:
S A location where there are no obstacles near the inlet and outlet
areas.
S A location which can bear the weight of the indoor unit is
critical.
S Do not install indoor units near a direct source of heat such as
direct sunlight or a heating appliance.
S A location which provides appropriate clearances as outlined in
Fig. 4.
Outdoor Unit
S A location which is convenient to installation and not exposed to
strong wind.
S A location which can bear the weight of outdoor unit and where
the outdoor unit can be mounted in a level position.
S A location which provides appropriate clearances as outlined in
Fig. 5.
S Do not install the indoor or outdoor units in a location with
special environmental conditions. For those applications, contact
your Ductless Split representative.
IMPORTANT: Drilling holes in the ceiling must be performed by
professional personnel.
20.59in/523
INSTALLATION TIPS
21.45in/545
22.44in/570
25.47in/647
Fig. 7 --- Drilling Holes
INDOOR UNIT INSTALLATION
1. Obstructions should be removed from the indoor unit’s intake
or outlet vents so air can flow throughout the room.
2. Ensure the installation is in accordance with the schematic
diagram’s required clearances.
3. Select a location that can withstand four times the weight of
the indoor unit and would not increase the operating noise.
4. Ensure the unit is level.
5. Select a location where condensated coagulated water can
drain easily away from the outdoor unit.
6. Ensure there is enough space for care and maintenance.
Ensure the height between the indoor unit and ground is 
3ft. (1mt) or  16ft. (5mt).
in/
Fig. 8 --- Drilling Holes
7. Check if the install site can withstand a weight 4 times of
the unit’s. If not, reinforce the site prior to installation. Refer
to the install cardboard to determine where the location
should be reinforced.
IMPORTANT: To guarantee a good performance, the unit must be
installed by professional personnel in accordance with this manual.
25 3/5 in (650 mm)
22 4/9 in (570 mm)
Fig. 9 --- Drilling Holes
NOTE: Installation is possible with a ceiling dimension of 23.62
in. (600m) (marked with *). However to achieve a ceiling--panel
overlapping dimension of 0.59 in (15mm), the spacing between the
ceiling and the unit should be 0.79 in. (20mm) or less. If the
spacing between the ceiling and the unit is over 0.79 in. (20mm),
attach the sealing material in the part or recover the ceiling.
33 in(840 mm)
35 in(890 mm)
30 5/7 in (780 mm)
37 2/5 in (950 mm)
22 4/9 i n ( 570 mm)
23 7/9 i n ( 604 mm)
25 3/5 i n ( 650 mm)
15 3/4 in (400 mm)
26 7/9 in (680 mm)
33 in(8 40 mm)
35 in(8 90 mm)
37 2/5 in (950 mm)
Install dimension of mode
Fig. 6 --- Dimension of ceiling opening and location of the
hoisting screw (M10)
9
INDOOR UNIT MAIN BODY INSTALLATION
(1.)
(2.)
(3.)
(4.)
4. Secure
only).
1. Prepare the ceiling opening needed for installation where
applicable (for existing ceilings).
a. Create the ceiling opening required for installation. From the
side of the opening to the casing outlet, implement the
refrigerant and drain piping and wiring for the remote
controller (unnecessary for wireless type). Refer to each
piping or wiring section.
b. After creating an opening in the ceiling, it may be
necessary to reinforce the ceiling beams to keep the
ceiling level and to prevent it from vibrating. Consult
the builder for details.
2. Install the installation hooks. Use either a M8 or M10 size
bolt.
a. Use expansible hooks, sunken anchors or other field
supplied parts to reinforce the ceiling to bear the unit’s
weight.
b. Adjust the clearance from the ceiling before proceeding
further. For an installation example, see Fig. 10.
Nut (field supply)
Washer (field supply)
Hanger bracket
Double nuts (field supply, tighten)
the paper pattern for installation (for new ceilings
S
The paper pattern for installation corresponds with the
measurements of the ceiling opening. Consult the builder
for details.
S
The center of the ceiling opening is indicated on the
paper pattern for installation.
S
After removing the packaging material from the paper
pattern for installation, attach the paper pattern to the unit
with the attached screws (see Fig. 12).
1
2
3
4
Fig. 10 --- Installation Clearances
(1.) Ceiling slab
(2.) Expansible hook (optional)
(3.) Installation hook (optional)
(4.) False ceiling
NOTE: For an installation other than a standard installation,
contact your dealer for details.
When installing optional accessories, review the list of optional
accessories in the installation manual. Depending on field
conditions, it may be easier to install optional accessories before
the indoor unit is installed (except for the decoration panel).
However, for an existing ceiling, install the fresh air inlet
component kit and branch duct before installing the unit.
3. Install the indoor unit temporarily.
a. Attach the hanger bracket to the suspension bolt. Be sure
to fix it securely by using a nut and washer from the upper
and lower sides of the hanger bracket.
b. Secure the hanger bracket (see Fig. 11).
Fig. 12 --- Attach Screws
(1.) Paper pattern for installation (on some models)
(2.) Center of the ceiling opening
(3.) Screws (supplied with the decoration panel)
5. Adjust the unit to the right position for installation. Refer to
the chapter “Preparations Before Installation”.
6. Check if the unit is horizontally leveled.
a. Do not install the unit tilted. The indoor unit is
equipped with a built--in drain pump and a float switch.
NOTE: If the unit is tilted against the direction of the condensate
flow (the drain piping side is raised), the float switch may
malfunction and cause water to drip.
b. Check if the unit is level at all four corners with a water
level or a water--filled vinyl tube (see Fig. 13).
-
1
Fig. 13 --- Ensure unit is level
(1.) Water level
(2.) Vinyl tube
3
2
4
Fig. 11 --- Secure the Hanger Bracket
10
DRAIN PIPING WORK
DRAINAGE HOSE
Drain Piping Installation
Install the drain piping as shown in Fig. 14 and take steps to
eliminate condensation. Improperly rigged piping could lead to
leaks and eventually wet furniture and belongings.
IMPORTANT: Observe all local sanitary codes when installing
condensate drains.
1. Install the drain hose.
Fig. 14 --- Drain Piping Installation
S
The drain hose diameter should be equal or larger than the
connection pipe’s. The diameter of the polythene pipe:
Outer diameter 1 in. (25 mm) Surface thickness  0.06 in.
(1.5 mm).
S
The drain hose should be short and the drooping gradient
should be less than 1/100 to prevent the formation of an
air bubble. If the drain hose does not has enough of a
drooping gradient, a drain raising pipe should be added.
S
To prevent a bend in the drain hose, the distance between
the hoisting stand should be 3 to 5 ft. (1 to 1.5 m) (see
Fig. 17).
™
Fig. 15 --- Hanging Bar
(1.) Hanging bar
(2.) 1/100 gradient
Install the Drain Pipes
S
Keep piping as short as possible and slope it downwards
at a gradient of at least 1/100 so that air does not remain
trapped inside the pipe.
S
Keep the pipe size equal to or greater than that of the
connecting pipe (PVC pipe, nominal diameter 0.79 in.
(20mm)), outside diameter 0.98 in. (25mm).
S
S
Push the drain hose as far as possible over the drain
socket, and tighten the metal clamp securely.
S
Entwine the big sponge on the drain hose clamp to
insulate heat.
S
Heat insulation should be applied to the indoor drain
hose.
Fig. 17 --- Drain Hose
Use the drain hose and clamp attached. Insert the drain
hose into the drain vent, and then tighten the clamp.
Sponge(attachment)
Clamp(attachment)
Clamp
Sponge (gray)
Fig. 16 --- Push the Drain Hose
7. Remove the paper pattern for installation (for new ceilings
only).
(1.) Drain socket (attached to the unit)
(2.) Metal clamp
(3.) Drain hose
(4.) Insulation (field supply)
a. Insulate the drain hose inside the building.
b. If the drain hose cannot be sufficiently set on a slope, fit
the hose with the drain raising piping (field supplied).
c. Ensure the heat insulation work is executed on the
following two spots to prevent any possible water
leakage due to dew condensation:
(1.) Indoor drain pipe
(2.) Drain socket.
Drain hose
Below 1/6 in (4 mm)
Fig. 18 --- Drain Hose
NOTE: Drain Setup pipe
11
S
The install height of the drain raising pipe should be less
than 21 in. (530 mm).
S
The drain raising pipe should form a right angle with the
unit, and the distance to the unit should not exceed 11.81
in. (300 mm).
21in/530
8.7in/220
29.5in/750
0~75
0~2.95in
1. Install the drain hose according to the following process if
several drain hoses join together.
Fig. 21 --- Slant Gradient
2. Check the smoothness of the drain after the installation.
3. Check the drain state by draining 36 3/5 in. 3 (600 cc) of
water slowly from the outlet vent or test hole.
4. Check the drain in the state of refrigerating after installing
the electric circuit.
Unit: in/mm
Fig. 19 --- Drain Setup Pipe
INSTRUCTION
The slant gradient of the attached drain hose should be within 3 in.
(75 mm) so that the drain hole does not have to endure unnecessary
outside force.
Unit: in/mm
Fig. 22 --- Drain
Fig. 20 --- Slant Gradient
1
2
3
1
2
3
4
5
6
7
4
5
6
7
Fig. 23 --- Cassette
12
Control box lid
Wiring diagram label
Power supply terminal block
Clamp for wiring
Wiring between units
Plastic cover
Clamp (field supply)
INSTALLATION OF THE DECORATION PANEL
3. After installing the decoration panel, ensure there is no space
between the unit body and the decoration panel. Otherwise air
may leak through the gap and cause dewdrops (see Fig. 27).
Detach the intake grill
1. Slide the two grille hooks toward the middle of the
decoration panel.
1
Fig. 27 --- Eliminate Space
4. Mount the intake grille. Ensure the buckles at the back of
the grille are properly seated in the panel’s groove.
2
1
2
Intake grille
Grille hook
Fig. 24 --- Intake Grille
2. Open the intake grille and remove.
Fig. 28 --- Mount the Intake Grille
5. Connect the decoration panel’s two wires to the unit’s
mainboard.
Fig. 25 --- Open Intake Grille
Install the decoration panel
1. Align the indication marks “ ” on the decoration panel to
the indication marks “ ” on the unit.
2. Attach the decoration panel to the unit with the supplied
screws (see Fig. 26).
5-core wire
10-core wire
Fig. 29 --- Connect two wires
1
2
1
2
Decoration panel
Screws (M5)(supplied with the panel)
Fig. 26 --- Attach the Decoration Panel
13
Grille Louver Motor Power.
5 Pin Port
Grille Display
10 Pin Port
Wired Remote Controller
(Available as Accessory)
5 Pin Molex plug to be
connected to Wired
Controller’s cable
Grille Display.
10 pin Molex plug to be
connected to Control Board.
Grille Louver Motor Power.
5 Pin Molex plug to be
connected to Control Board
Fig. 30 --- Panel Cassette
6. Fasten the control box lid with two screws.
7. Close the intake grille, and close the two grille hooks.
Fig. 32 --- Close the Intake Grille
Fig. 31 --- Fasten the Control Box Lid
14
OUTDOOR UNIT INSTALLATION
Table 5— Tightening Torque
1. Use a rigid base to support the unit in a level position.
2. Locate the outdoor unit and connect the piping and wiring.
!
CAUTION
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment damage
or improper operation.
In regions with snowfall and cold temperatures, avoid
installing the outdoor unit in areas where it can be covered by
snow. If the outdoor unit is installed in areas where heavy
snow is expected, a field supplied ice or snow stand and/or
field supplied--installed wind baffle should be installed to
protect the unit from snow accumulation and/or blocked air
intake. Blocking the air intake may result in reduced airflow,
significantly reduced performance and damage to the
equipment.
Ft-- lb
N-- m
Ø1/4” (6.35)
10 to 13
13.6 to 17.6
Ø3/8” (9.52)
23 to 31
32.5 to 42.0
Ø1/2” (12.7)
37 to 46
50.1 to 62.3
Ø5/8” (15.88)
60 to 60
67.7 to 81.3
CAUTION
!
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
Excessive torque can break flare nut depending on
installation conditions.
INSTALL ALL POWER AND INTERCONNECTING
WIRING TO OUTDOOR UNITS
1. Mount the outdoor power disconnect.
2. Run the power wiring from the main box to disconnect per
NEC and local codes.
3. Remove the field wiring cover from the unit by loosening
the screws.
4. Remove the caps on the conduit panel.
5. Connect the conduit to the conduit panel (see Fig. 35).
6. Properly connect both the power supply and the control
lines to the terminal block per the connection diagram for
the appropriate unit capacity and voltage.
7. Ground the unit in accordance with NEC and local
electrical codes.
8. Use lock nuts to secure the conduit.
9. Reinstall the field wiring cover.
Strong
wind
Fig. 33 --- High Wind Installation
Tightening Torque
Pipe Diameter
Inch (mm)
A07350
MAKE REFRIGERANT PIPING CONNECTIONS
(OUTDOOR UNIT)
IMPORTANT: Use refrigeration grade tubing ONLY. No other
type of tubing may be used. Use of other types of tubing will
void the manufacturer’s warranty.
CAUTION
!
Do not open service valves or remove protective caps from tubing
ends until all the connections are made. Bend the tubing with
bending tools to avoid kinks and flat spots.
Keep the tubing free of dirt, sand, moisture, and other
contaminants to avoid damaging the refrigerant system.
EQUIPMENT DAMAGE HAZARD
Failure to follow this caution may result in equipment
damage or improper operation.
S Comply with local codes while running wire from indoor
unit to outdoor unit.
S Every wire must be connected firmly. Loose wiring may
cause the terminal to overheat or result in unit
malfunction. A fire hazard may also exist. Be sure all
wiring is tightly connected.
S No wire should be allowed to touch the refrigerant
tubing, compressor or any moving parts.
S Disconnecting means must be provided and shall be
located within sight and readily accessible from the air
conditioner.
S Connecting cable with conduit shall be routed through
hole in the conduit panel.
Avoid sags in the suction line to prevent the formation of oil traps.
Insulate each tube with minimum 3/8--in. (10 mm) wall thermal pipe
insulation. Inserting the tubing into the insulation before making the
connections will save time and improve installation quality.
1. Remove the service valve cover if provided with the unit.
2. Cut the tubing with a tubing cutter. Remove the service
connection if provided with unit.
3. Install the correct size flare nut onto the tubing and make
the flare connection.
4. Apply a small amount of refrigerant oil to the flare
connection on the tubing.
5. Properly align the tubing with the service valve.
6. Tighten the flare nut and finish the installation using two
wrenches as shown in Fig. 34.
Outdoor
unit
Terminal Block
Ove
r 1.5
7" (
40m
m)
G
Conduit panel
Conduit
Fig. 34 --- Tighten Flare Nut
A07354
Fig. 35 --- Field Wiring
15
A07455
ELECTRICAL DATA
Table 6—Electrical Data
UNIT OPER. VOLTAGE
SIZE
MAX / MIN*
COMPRESSOR
V/PH/HZ
RLA
9K
12K
253 / 187
208--- 230/1/60
18K
OUTDOOR FAN
V/PH/HZ
FLA
HP
INDOOR FAN
W
5.3
0.42 0.053
40
5.7
208--- 230/1/60 0.42 0.053
40
7.3
0.85 0.067
50
V/PH/HZ
FLA
208--- 230/1/60 0.146
HP
W
0.061
46
MCA
MAX FUSE
CB AMP
15
15
15
15
13
20
*Permissible limits of the voltage range at which the unit will operate satisfactorily.
LEGEND
FLA --- Full Load Amps
MCA --- Minimum Circuit Amps
RLA --- Rated Load Amps
CONNECTION DIAGRAMS
Fig. 36 --- Connection Diagrams
A150634
Notes:
1. Do not use thermostat wire for any connection between indoor and outdoor units.
2. All connections between indoor and outdoor units must be as shown. The connections are sensitive to polarity and will result in a fault code.
Fig. 37 --- Control and Power Wiring on Indoor Unit
A150635
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.
16
REMOTE CONTROL INSTALLATION
Manifold Gage
Mounting Bracket (if installed on the wall)
1. Use the two screws supplied with the control to attach the
mounting bracket to the wall in a location selected by the
customer and within operating range.
2. Install the remote control batteries.
3. Place the remote control into the remote control mounting
bracket.
4. For remote control operation, refer to the unit owner’s
manual.
CAUTION
!
500 microns
Low side valve
Charge hose
Vacuum pump
A07361
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 indoor coil should be evacuated using the
recommended deep vacuum method of 500 microns. The alternate
triple evacuation method may be used if the procedure outlined
below is followed. Always break a vacuum with dry nitrogen.
Fig. 39 --- Manifold
Deep Vacuum Method
The deep vacuum method requires a vacuum pump capable of
pulling a vacuum of 500 microns and a vacuum gage capable of
accurately measuring this vacuum depth. The deep vacuum
method is the most positive way of assuring a system is free of air
and liquid water (see Fig. 40).
5000
4500
4000
3500
3000
2500
2000
1500
1000
500
Using Vacuum Pump
1. Completely tighten flare nuts A, B, C, D and connect the
manifold gage charge hose to a charge port of the low side
service valve (see Fig. 38).
2. Connect the charge hose to the vacuum pump.
3. Fully open the low side of the manifold gage (see Fig. 39).
4. Start the vacuum pump.
5. Evacuate using either the deep vacuum or triple evacuation
method.
6. After evacuation is complete, fully close the low side of the
manifold gage and stop the vacuum pump operation.
7. The factory charge contained in the outdoor unit is good for
up to 25 ft. (8 m) of the line length. For refrigerant lines
longer than 25 ft. (8 m), add refrigerant, up to the allowable
length, as specified in the System Requirements section.
8. Disconnect the charge hose from the charge connection of
the low side service valve.
9. Fully open service valves B and A.
10. Securely tighten the service valves caps.
Refrigerant
Low Side
B
High Side
Indoor Unit
C
D
Service Valve
Fig. 38 --- Service Valve
A07360
LEAK IN
SYSTEM
MICRONS
SYSTEM VACUUM AND CHARGE
A
Charge hose
Low side valve
UNIT DAMAGE HAZARD
Outdoor Unit
High side valve
VACUUM TIGHT
TOO WET
TIGHT
DRY SYSTEM
0
1
2
3 4
5
MINUTES
6
7
A95424
Fig. 40 --- Deep Vacuum Graph
Triple Evacuation Method
The triple evacuation method should only be used when the
vacuum pump is only capable of pumping down to 28 in. of
mercury vacuum and the system does not contain any liquid water.
Refer to Fig. 41 and proceed as follows:
1. Pump the system down to 28 in. of mercury and allow the
pump to continue operating for an additional 15 minutes.
2. Close the service valves and shut off the vacuum pump.
3. Connect a nitrogen cylinder and regulator to the system and
open until the system’s pressure is 2 psig.
4. Close the service valve and allow the system to stand for 1
hr. During this time, dry nitrogen will be able to diffuse
throughout the system absorbing moisture.
5. Repeat this procedure as indicated in Fig. 41. The system
will then be free of any contaminants and water vapor.
17
SYSTEM CHECKS
EVACUATE
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.
BREAK VACUUM WITH DRY NITROGEN
WAIT
EVACUATE
BREAK VACUUM WITH DRY NITROGEN
INDOOR UNIT
WAIT
1.
2.
3.
4.
EVACUATE
CHECK FOR TIGHT, DRY SYSTEM
(IF IT HOLDS DEEP VACUUM)
RELEASE CHARGE INTO SYSTEM
Fig. 41 --- Triple Evacuation Method
Do all the remote control buttons function properly?
Do the display panel lights work properly?
Does the air deflection louver function properly?
Does the drain work?
OUTDOOR UNIT
A95425
Final Tubing Check
IMPORTANT: Ensure certain factory tubing on both the indoor
and outdoor unit has not shifted during shipment. Ensure the tubes
are not rubbing against each other or any sheet metal. Pay close
attention to feeder tubes, making sure wire ties on the feeder tubes
are secure and tight.
START--UP
Test Operation
Perform a test operation after completing a gas leak and electrical
safety check.
1. Press the “ON/OFF” button on the remote control to begin
testing.
NOTE: A protection feature prevents air conditioner from being
activated for approximately 3 to 4 minutes.
2. Press MODE and select COOLING, HEATING, FAN mode
to check if all functions work correctly.
3. To run the test using the manual button in the indoor unit:
(3.) Open the indoor unit’s front panel;
(4.) Press the manual switch once to energize the unit.
The set conditions of manual operation are as
follows:
· Preset set point: 76_F (24_C)
· Fan speed: AUTO
· Discharge air direction: Pre--set position based on
operation in “Cool” or “Heat” mode.
4. Be sure to set the manual switch to “OFF” (by pressing it
twice again) after finishing the test operation.
1. Are there unusual noises or vibrations during operation?
Explain Following Items To Customer
(with the aid of the Owner’s Manual):
1. How to turn air conditioner on and off; selecting
COOLING, HEATING and other operating modes; setting
a desired temperature; setting the timer to automatically
start and stop air conditioner operation; and all other
features of the remote control and display panel.
2. How to remove and clean the air filter.
3. How to set air deflection louver.
4. Explain care and maintenance.
5. Present the owner’s manual and installation instructions to
customer.
18
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.
The diagnostic codes displayed in the indoor and outdoor units are
listed in the tables below.
INDOOR UNIT DIAGNOSTIC GUIDES
Table 7—Indoor Unit Diagnostic Guides
Operation Lamp
☆1 time
☆ 2 times
☆4 times
☆5 times
☆6 times
☆7 times
☆8 times
☆1 time
☆2 times
☆3 times
☆4 times
☆5 times
☆6 times
☆7 times
☆8 times
☆9 times
☆10 times
☆1 time
☆2 times
☆3 times
☆4 times
☆5 times
☆6 times
☆7 times
☆8 times
Timer Lamp
X
X
X
X
X
X
X
O
O
O
O
O
O
O
O
O
O
☆
☆
☆
☆
☆
☆
☆
☆
Display
E0
E1
E3
E4
E5
EC
EE
F0
F1
F2
F3
F4
F5
F6
F7
F8
F9
P0
P1
P2
P3
P4
P5
P6
P7
LED Status
Indoor unit EEPROM error
Communication malfunction between indoor and outdoor units
Indoor fan speed has been out of control
Indoor room temperature sensor T1 open circuit or short circuit
Evaporator coil temperature sensor T2 open circuit or short circuit
Refrigerant leakage detection
Water--- level alarm malfunction
Current overload protection
Open circuit or short circuit of outdoor ambient temperature sensor T4
Open circuit or short circuit of condenser coil temperature sensor T3
Open circuit or short circuit of Compressor discharge temperature sensor T5
Outdoor unit EEPROM error
Outdoor fan speed has been out of control
T2B sensor error
Lifting --- panel communication error
Lifting --- panel malfunction
Lifting --- panel is not closed
IPM malfunction
Over voltage or over low voltage protection
High temperature protection of compressor top
Outdoor low temperature protection
Inverter compressor drive error
Mode conflict
Compressor low--- pressure protection
Outdoor IGBT temperature sensor error
O (light) X (off) ☆ (flash)
For additional diagnostic information, refer to the Service Manual.
OUTDOOR UNIT DIAGNOSTIC GUIDES
Table 8—Outdoor Unit Diagnostic Guides
LED2
(Green)
O
X
O
☆
O
X
☆
☆
LED1
(Red)
X
O
☆
X
O
☆
O
☆
Indoor Unit display
E5
P0
P1
P4
P4
P4
Failure Mode
Standby, normal
Operation, normal
Compressor drive board EEPROM error
IPM malfunction or IGBT over---strong current protection
Over voltage or too low voltage protection
Inverter compressor drive error
Inverter compressor drive error
Communication malfunction between main control board and driver board
☆ = Flashing, X = Off
For additional diagnostic information, refer to the Service Manual
19
E2015 Bryant Heating & Cooling Systems 7310 W. Morris St. Indianapolis, IN 46231
Edition Date:10/15
Catalog No. II---619RC ---538PR ---02
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
20
Replaces: 619RC--- 01SI
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