Johnson Controls York YDEC028 Installation guide

VRF Air-Conditioner

Installation Manual

FORM NO.:YDEC IOM-EN(1212)

VRF Air-Conditioner IOM

Contents

1. SAFETY CAUTIONS ....................................................................................................................... 1

2. BEFORE INSTALLATION ................................................................................................................ 1

3. SELECTION OF INSTALLATION POSITION ...................................................................................... 2

4. INSTALLATION OF INDOOR UNIT .................................................................................................. 2

5. INSTALLATION OF REFRIGERANT PIPING ...................................................................................... 4

6. INSTALLATION OF DRAINAGE PIPING ........................................................................................... 5

7. ELECTRIC CONNECTION ............................................................................................................... 6

VRF Air-Conditioner IOM

1

1. Safety Cautions

Please carefully read this "Safety Cautions" before

installing air conditioner so as to ensure correct

installation.

The following cautions are divided into two categories,

related to safety and of great importance, please

carefully read.

Warning…Inattention will lead to death or

serious injury.

Caution…Inattention will lead to injury or

machine damage, and may also cause serious injury

according to different conditions.

 Installation operation must be conducted by

professional personnel. Do not conduct without

approval.

 Please install the air conditioner in a solid place

sufficient to bear the weight.

Instable base may lead to air conditioner falling

and cause damage.

 Please use separate circuit for power supply. The

operation of all the electric parts must be in

accordance with the local laws and specifications

as well as this instruction.

 The operation shall be conducted by the

electrician with professional qualification.

Insufficient capacity or improper electric

operation may cause electric shock or fire hazard.

 Use the specification designated wires; all the

wires shall be connected well to make connecting

terminal and wire free from external force

drawing.

Poor connection and improper installation may

cause fire hazard.

 Straighten out and lay flat when connecting power

line, remote controller and wire controller line so

as to make electric parts and wire slot box cover

fastened down.

 If any refrigerant gas leakage in installation,

immediately open door and window for

ventilation.

The refrigerant gas will generate toxic gas when

meeting combustion sources such as air heater,

furnace and stove.

 Please power off first before touching electronic

parts.

 Do not touch the switch with wet hand.

Touching switch with wet hand may cause electric

shock.

 Air conditioner must be earthed.

Earthing wire shall not be connected to gas pipe,

tap water pipe, lightening rod and telephone line.

Poor earthing may lead to electric shock accident.

 Leakage earthing leakage breaker must be

installed.

If leakage earthing breaker is not installed, there

will be electric shock hazard or fire hazard.

 Please arrange drainage piping according to this

instruction to guarantee smooth drainage, and

insulate the piping in case of condensed water

accumulation.

Improper piping may lead to water leakage and

soak household items.

 Air conditioner, power line and connecting line

shall be far away from more than 1m at least from

such electrical equipment as television set and

radio to prevent from interference of

electromagnetic wave and noise.

 In the room equipped with fluorescent lamp

(inverter or quick start type), the signal

transmission distance of the remote controller may

not reach the preset value.

The indoor machine shall be away from

fluorescent lamp as far as possible.

 Installation should not be conducted in the

following places:

(a) Place where mineral oil smoke or mist or steam

is diffused, for example, kitchen.

Plastic parts may be deteriorated and damaged.

(b) Place where there is corrosive gas such as sulfur

dioxide.

Copper pipe or welding part may be corroded to

cause refrigerant leakage.

(c) Place which is close to the machine generating

electromagnetic wave.

Electromagnetic wave may influence the control

system to make the air conditioner incapable of

normally operating.

(d) Place where there is combustible gas leakage,

carbon fiber or combustible dust floating, or

volatile combustible placing such as gasoline or

diluent.

The use of air conditioner in such places may

cause fire hazard.

 Please do not touch the fin of the heat exchanger.

Improper touch may cause machine damage and

personal injury.

 Please pay special attention to product handling.

Do not handle by lifting PP strap in case of PP

strap rupture to damage unit and harm person.

2. Before Installation

 Air conditioner shall not be unsealed before

moved to the installation site. If it is necessary to

unseal, measures shall be taken after unsealing to

avoid damaging or scratching air conditioner.

 When moving the air conditioner during or after

unsealing, do not apply force to refrigerant piping,

drainage pipe or other plastic parts in order to

avoid damaging air conditioner.

 Before air conditioner installation, please confirm

whether the refrigerant used for the unit is R22 or

Warning

VRF Air-Conditioner IOM

2

R410a and whether it is consistent with that of

outdoor unit.

 For the installation of outdoor unit, please refer to

the installation and operation instructions attached

for outdoor unit.

3. Selection of Installation Position

Installation position conditions:

 Ceiling strength shall be sufficient to bear the

weight of indoor unit; if not, reinforce first.

 Guarantee good ventilation and make gas flow

free from obstructions shielding.

 Condensed water is capable of being discharged

smoothly.

 There is no combustible gas leakage hazard.

 Ensure adequate installation space.

 Piping length of indoor unit and outdoor unit is

within an allowable range.

4. Installation of Indoor Unit

4.1 Open wall hole

 Select installation position and determine pipe

passing direction and pipe outlet position.

 Select drill bit according to machine model and

use electric hammer or diamond to open wall

hole.

 Wall hole size in general: recommended wall hole

diameter Φ90mm for below 056 type and

Φ150mm for above 071 type.

 Keep clear of the walls with wire or foreign

matters inside and outside and the superhard walls

as much as possible in holing; the hole inside shall

be 0.5cm~1cm higher than outside considering

drainage; wall hole passing through outlet pipe of

indoor unit side shall be slightly lower than the

indoor unit downside; for holing with diamond,

plastic cloth shall be sticked to wall or other

method may be adopted to prevent water flow to

wall; for holing with electric hammer, dust

prevention measures shall be taken.

4.2 Install the unit

 Install Φ10 hoisting bolts (4).

 After the unit hoisting, conduct piping and wiring

work in ceiling, and determine the outlet direction

of piping after installation site selection.

Especially on the occasion with existing ceiling,

please pull refrigerant piping, drainage pipe,

indoor and outdoor connecting line and remote

controller line to a connection position before

hanging machine.

 Installation method for hoisting bolt.

Match with the existing structure and arrange

thread pitch according to the following shown

machine dimension.

Wooden occasion: arrange hoisting bolt by

mounting square bar on beam

Steel frame occasion: arrange and directly use

supporting angle steel

Existing concrete blank occasion:

Newly prepared concrete blank occasion:

Square bar

Hoisting bolt

Hanging bolt

Supporting angle steel

Ceiling

Beam

cm

VRF Air-Conditioner IOM

3

 Seat installation method.

Please use embedded bolt, expansion bolt, etc.;

the bolt material shall be high-quality carbon steel

(subjected to surface copper plating or other

rust-proof treatment) or stainless steel.

4.3 Install indoor unit

 Use pulley, etc. to hoist indoor unit to hoisting

bolt; use gradienter, etc. to install indoor unit

horizontally; otherwise, it may cause water

leakage.

 For embedded type installation, the procedure is

similar to hoisting mode, but hole must be opened

on the ceiling before installation, with the

specification as follows: 1170×610 for 028-112

type and 1600×610 for 140-160 type; take down

the right and left cover plates of indoor unit and

then embed one half of main body into the ceiling,

and only expose rear cover plate and head cover.

 For seat installation, use gradienter to install

Hoisting bolt

Hoisting support

Hoisting parts

Nut

Gasket

Side plate

Wall

Wedge bolt

Drainage outlet

Connector at gas side of cooling medium piping

Connector at liquid side of cooling medium piping

(Blade shape

Insertion)

(Slide insertion)

S

teel bar

Embedding screw bolt

(Pipe hang

ing and embedding

screw bolt)

VRF Air-Conditioner IOM

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indoor unit horizontally and maintain the main

body vertical to the floor. Dismantle pump, small

defrosting tray and water level switch before

installation, strip off the insulated shield of water

level switch connecting line and then screw

together to make short circuit, directly connect

drainage pipe in accessories to the main defrosting

tray outlet (select left or right water outlet of

defrosting tray according to actual installation

condition).

Model A

B

C

D

E

F

G

H

YDEC028-112

1245

680

150

760

450

1119

200

240

YDEC140-160

1670

680

150

1070

450

1542

200

240

5. Installation of Refrigerant Piping

 The piping at gas side and liquid side of

refrigerant shall be subjected to thermal insulation,

if not, the piping surface will have dew.

 Please use thermal insulation material which is

capable of withstanding above 120 high

temperature. Please strengthen thermal insulation

for refrigerant piping according to the installation

environment, otherwise, the surface of the thermal

insulation material may dew and frost.

Please comply with the following items:

 Coat fatty oil or ether oil at horn mouth (inside

and outside) when connecting horn mouth nut.

 Only use the horn mouth nut attached by the unit.

Other horn mouth nut may lead to refrigerant

leakage.

 Please clamp flat or seal the pipe end in order to

prevent dust, moisture or other foreign matter

entering into pipe.

 Except designated refrigerant, anything, for

example, air, shall not mix into refrigerating

circuit.

 Before welding refrigerant piping, please conduct

nitrogen replacement or fill nitrogen into piping in

welding, and finally connect with indoor unit by

horn mouth.

 When filling nitrogen into piping in welding,

guarantee to control the pressure with reducing

valve as 0.02MPa (0.2kgf/cm

2

) (like the feel of

breeze blowing cheek).

 Do not use welding flux when welding refrigerant

piping connector. Please use copper base brazing

filler metal without welding flux.

The use of welding flux containing chlorine or

fluorine may corrode the purity of piping or

refrigerating system.

5.1 Piping connection

 When connecting and dismantling piping to/from

air conditioner, simultaneously use an ordinary

spanner and a torque spanner.

 For relevant tightening torque, please refer to the

following table.

Pipe diameter

Tightening torque

(N.m)

6.35(1/4") 14.2~17.2

9.53(3/8") 32.7~39.9

12.7(1/2") 49.5~60.3

15.88(5/8") 61.8~75.4

 If it is necessary to install unit without torque

spanner, comply with the following method:

When using spanner to tighten the horn mouth nut,

the tightening torque on some point may suddenly

increase. Further tighten the horn mouth nut from

this position to the angle shown in the following

table.

Pipe diameter

Angle

tightened

further

Length of

recommended

tool arm

6.35(1/4") 60°~90°

~150mm

9.53(3/8") 60°~90°

~200mm

12.7(1/2") 45°~75°

~250mm

15.88(5/8") 45°~75°

~300mm

Caution

Hook

Dismantle pump assembly

Connect defrosting tray with

drainage pipe

Bolt

Gasket

Torque spanner

Ordinary spanner

Piping connector

Horn mouth nut

VRF Air-Conditioner IOM

5

 Excessive tightening may damage horn mouth and

lead to refrigerant leakage.

5.2 Air tightness leakage detection

 Conduct air tightness leakage detection

confirmation at the end of piping work.

 Leakage detection method:

(a) Fill dry compressed nitrogen into indoor unit and

piping system, and slowly boost the pressure to

4.3MPa;

(b) After maintaining pressure for 10min, coat soapy

water or other foaming agent at the connection

position such as weld and thread joint, and

observe whether there is leakage;

(c) If any leakage, tighten or repair weld leaking

position after pressure relief.

(d) Fill into dry compressed nitrogen again and

slowly boost the pressure to 4.3MPa;

(e) Start to record the reading of pressure gauge after

maintaining pressure for 6h, and then record the

reading of pressure gauge again after 24h;

(f) If no pressure drop, then the air tightness is

qualified. If any pressure drop, find out the

leakage point and repair, and then repeat the

above d and e procedures until qualified.

 Pressure reading is related to temperature

variation, so the temperature variation factor shall

be considered when judging whether there is

pressure drop. The relation of pressure correction

value and temperature variation is:













−

+

∗=∆ 1

273

1

2

1

t

PP

PPP

∆

−

=

2correction

P--Pressure correction value (bar)

P

correction

---Corrected pressure value (bar)

P

1

---The first pressure reading (bar)

P

2

---The second pressure reading (bar)

t

1

---Temperature at the first pressure reading ( )

t

2

---Temperature at the second pressure reading

( )

 In air tightness test, do not connect indoor unit

and outdoor unit, otherwise, nitrogen may leak to

outdoor unit.

5.3 Thermal insulation

 If no leakage after inspection, respectively wrap

liquid pipe, gas pipe and each connecting position

with thick-enough heat-resistant polyethylene, and

conduct good thermal insulation.

 Field piping must be connected to the piping

connecting part all the time. If poor thermal

insulation for piping, there will be dew outside

and scald if any touch.

6. Installation of Drainage Piping

6.1 Drainage piping installation

 In delivery, the drainage outlet is PVC pipe; in

connecting water pipe, please use auxiliary

sealing material and sleeve.

 Conduct thermal insulation for drainage pipe of

indoor unit, otherwise, condensation may be

caused. The connecting part of indoor unit must

also be subjected to thermal insulation treatment.

 Before installation, please confirm whether the

connection condition of pump defrosting tray and

the surface thermal insulation are intact.

 For drainage pipe connection, use hard PVC

binding agent and confirm there is no leakage.

 The junction of drainage pipe and drainage outlet

of indoor unit must be free from bearing any force,

including water pipe gravity.

 The downward inclination of drainage pipe shall

be above (1/100) and the middle shall be free

from bending.

 The transverse pull-out of drainage pipe shall be

within 20m. If the drainage pipe is longer, please

arrange a support to prevent bending.

 Drainage system joints must be sealed against

water leakage.

 The height from drainage pipe end to ground or

drainage channel bottom shall be larger than

50mm, and the drainage pipe end shall not be put

into water. When directly discharging condensed

water into foul ditch, bend drainage pipe upward

to a U-shaped water seal in order to avoid odor

entering into room through drainage pipe.

 For concentrated construction of drainage pipe of

multiple indoor units during suspended ceiling

installation (with pump), arrange U-shaped bend

at the branch water pipe connecting each indoor

unit to prevent water return from main drainage

pipe.

 For seat installation, dismantle pump assembly,

and directly connect the drainage pipe of

accessories to drainage outlet of defrosting tray.

Caution

Thermal insulation material

Incline downward

above 1/100

VRF Air-Conditioner IOM

6

 Concentrated construction of drainage pipe of

multiple indoor units in seat installation (pump

must be dismantled) shall be in accordance with

the following figure.

6.2 Drainage test

 Guarantee smooth drainage pipe connection and

check whether each joint is sealed.

 Confirm by injecting water into air outlet. Inject

water into air outlet with jar or hose; pay attention

to slowly injecting until the drainage nozzle of

water pond has water flow.

 At the end of preparation work, power on terminal

board and immediately start discharge pump in

refrigerating mode.

 Check the drainage condition of discharge pump

after operating for a few minutes.

 In seat installation, the method of drainage test is

to directly inject water slowly from air outlet until

the water outlet of drainage pipe end has water

discharge and observe whether the middle has

seepage along the pipeline.

7. Electric Connection

7.1 General

 Power off before implementing any electric

operation.

 All the purchased parts and materials as well as

electric operation must comply with the local laws

and regulations.

 All the connection operation must be implemented

by professional electrician.

 Line breaker or leakage breaker must be arranged

at power supply.

 Earthing resistance must below 4Ω.

 Air conditioner must be earthed reliably. Earthing

wire shall not be connected to gas pipe, tap water

pipe, lightening rod or telephone line.

 Do not power on before the end of all the electric

operation.

 The terminal of the same power supply shall not

be connected with two wires with different

diameters.

 Please use the power line with specified

specification, firmly connect and ensure terminal

free from external force drawing.

 Terminal screw should not be too tight or too

loose. Too tight will damage the terminal and too

loose may lead to poor contact and cause excess

heating to trigger hazard.

7.2 Unit power distribution

 Please refer to the following figure for power

distribution of indoor unit and outdoor unit.

 A set of independent cooling medium system shall

use an independent switch control; multiple

systems shall not use a switch control and partial

indoor unit in a system and indoor unit of other

system shall also not share a switch control.

About 10cm as much as possible

Incline downward

above 1/100

Drainage pipe

Inject water into air

outlet

Arrange drainage

pipe to U shape

against return

Wrap drainage pipe and its

connection posi

tion with

insulating pipe against

condensation

S-shaped

Bending

I

ndoor unit

Outdoor

unit

VRF Air-Conditioner IOM

7

7.3 Connection of indoor unit power line

 The power supply connection for indoor unit is detailed in electric schematic diagram on electric control box.

 Wiring specification is RVV2X2.5+1.5.

7.4 Type setting

Type setting is detailed in the electric schematic diagram on the electric control box.

7.5 Communication wire connection

Note: Inlet and outlet lines (TB2 inlet and TB3 outlet) of indoor unit shall not be reversed,

otherwise

, there will be fault and

the unit can't be started.

 Recommended model of communication wire is RVSP2X 0.75.

 "TB2 inlet" connects the communication wire from outdoor unit communication terminals (A and B) or from the

former indoor unit (TB3).

 Communication wire of "TB3 outlet" connects to the communication port of the next indoor unit (TB2 inlet).

 Inlet and outlet lines (TB2 inlet and TB3 outlet) of indoor unit shall not be reversed, otherwise, there will be fault

and the unit can't be started.

 Connect according to the diagram, do not allow A and B polarity connection error, otherwise, communication

failure or controller damage may be caused.

 In order to avoid signal interference, the communication wire must use shielding wire, and the shielding layer

shall be earthed.

 The communication wire exceeding the specific length may cause air conditioner out of service due to

communication problem: communication wire length ≤500m and total length ≤1000m.

7.6 Install the controller

 Install the wire controller on the pre-reserved site on the wall.

 Carcassing for communication wiring should be ready before installation the controller. The recommended

Outdoor unit

VRF Air-Conditioner IOM

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communication line is RVSP2 0.75. Be sure to pull the wires through the PVC conduit.

Note: the communication wire and PVC conduit are the field supplied parts.

7.7 Connect the wire controller and indoor unit

 Group control can be realized through the wire controller. One wire controller can connect to max 4 indoor

units.

 The indoor units in one group should be connected in one and same power supply to guarantee normal

initialization of wire controller when power on.

 Connection sketch of indoor unit and wire controller:

(a) When one wire controller connecting only one indoor unit: (refer to Fig. 13)

(b) When one wire controller connecting multi indoor units: (refer to Fig. 14)

Fig. 13

One wire controller connects to one indoor unit

Fig. 14

One wire controller connects to multi indoor units

9

YDEC IOM

-EN(1212)

NONE

YDEC IOM (0812)

Johnson Controls York YDEC028 Installation guide

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Johnson Controls York YDEC028 Installation guide

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