Johnson Controls York YDVC028 Installation guide

VRF Air-Conditioner

Installation Manual

FORM NO.:YDVC IOM-EN(1212)

VRF Air-Conditioner IOM

Contents

1. SAFETY CONSIDERATIONS ............................................................................................................ 1

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

3. SELECTING INSTALLATION SITE .................................................................................................... 2

4. INDOOR UNIT INSTALLTION ......................................................................................................... 2

5. REFRIGERANT PIPING WORK ....................................................................................................... 4

6. DRAIN PIPING WORK ................................................................................................................... 5

7. INSTALLING THE DUCT ................................................................................................................. 6

8. ELECTRIC WIRING WORK ............................................................................................................. 6

VRF Air-Conditioner IOM

1

1 SAFETY CONSIDERATIONS

Please read the “SAFETY CONSIDERATIONS” carefully

before installing the air-conditioner equipment and be

sure to install it correctly.

The below notes include two types, both of which are

related to safety and extremely important. Please read

it carefully.

WARNING Indicates a potentially

hazardous situation, which, if not avoided, could result

in death or serious injury.

CAUTION Indicates a situation that may

result in injury or equipment damage. According to

different conditions, it also may result in the accidents

of serious injury or other damage.

 Ask the specially trained personnel to carry out

the installation work. Do not try to install the

machine by yourself.

 Please perform the installation work in accordance

with the steps in this manual.

Improper installation may result in water leakage,

electric shock or fire.

 Make sure that a separate power supply circuit is

provided for this unit and that all electrical work is

carried out by specially trained personnel

according local laws, regulations and this

installation manual.

An insufficient power supply capacity or improper

electrical construction may lead to electric shock

or fire.

 Make sure that the specified wires that comply

with national standard are used and all wiring is

secure. No external forces act on the terminal

connections or wires.

Improper wiring connections or installation may

result in electric shock or fire.

 When connecting the wiring of power supply,

wired controller and remote controller, the wiring

should be laid orderly so that the electric parts

box lid can be securely fastened.

 If it appears refrigerant leakage during the

installation process, open the doors and windows

immediately to ventilate the room thoroughly.

 Toxic gas may be produced if the refrigerant comes

in contact with fire such as a fan heater, stove or

cooking device.

 Power off the unit before touching the electrical

parts.

 Do not touch the switch with wet fingers.

Touching the switch with wet fingers may cause

electric shock.

 Be sure the air-conditioner is well grounded.

Never connect the ground line with the gas pipe,

water pipe, lightning conductor or telephone lines.

Incomplete ground line may cause electric shock

or fire.

 Be sure to install a ground leakage breaker.

Failure to install a ground leakage breaker may

result in electric shock or fire.

 Please follow the instructions in this manual to

install drain pipe in order to ensure smooth

drainage and good piping insulation to avoid

accumulating of condensate water.

Improper drain pipe may result in water leakage

and property damage.

 Install the air-conditioner unit, power supply

wiring and connection wires at least 1m away

from electrical equipments, such as TVs, radios,

etc. to avoid electromagnetic waves interference

or noise.

 Remote controller transmitting distance may be

shortened than the expected one in the rooms

with electronic fluorescent lamps (inverter or

rapid start types).

Install the indoor unit as far away from fluorescent

lamps as possible.

 Do not install the air-conditioner in the following

locations:

(a) Where a mineral oil mist or an oil spray or

vapor is produced, for example in a kitchen.

Plastic parts may be deteriorated, corroded or

damaged.

(b) Where corrosive gas, such as sulfurous acid

gas is produced.

Corroded copper tubes or soldered parts may

result in refrigerant leakage.

(c) Where near machinery emitting

electromagnetic waves.

Electromagnetic waves may disturb the

operation of the control system and result in a

malfunction of the equipment.

(d) Where it may have flammable gas leakage,

carboform or floating flammable dust,

volatile flammable material such as gasoline

or thinner.

Using air-conditioner in those places may

result in fire.

 Do not touch heat exchanger fins

Improper touching the heat exchanger fins may

result in machine damage or personnel injury.

 Be very careful about the product transportation.

Do not use any packaging PP bands for a means of

transportation to avoid PP bands rupturing and

result in product damaging or personnel injury.

2 BEFORE INSTALLATION

 Do not unpack the unit before reaching the

installation site. Where unpacking is unavoidable,

countermeasure should be done after unpacking

WARNING

VRF Air-Conditioner IOM

2

to avoid damaging or scratching of the unit.

 When moving the unit during or after unpacking,

be sure to avoid putting any pressure or strength

on the refrigerant piping, drain pipe or the other

plastic parts, which may damage the unit.

 Before installing the unit, be sure to check the

type of refrigerant to be used is R22 or R410A

which should be same as outdoor unit.

 For the installation of the outdoor unit, please

refer to the installation manual attached to the

outdoor unit.

3 SELECTING INSTALLATION SITE

 If it has the possibility that the temperature and

humidity inside the ceiling might exceed 30°C and

RH80%, please reinforce the insulation on the

unit.

Use glass wool or polyethylene foam as insulation

and its thickness is more than 10mm.

3.1 INSTALLATION SITE REQUIREMENTS

 The ceiling is strong enough to bear the indoor

unit weight. If not, please reinforce the ceiling

before installation.

 Ensure optimum air distribution and nothing

blocks the air passage.

 Condensate water can be drained out smoothly.

 No risk of flammable gas leakage.

 Ensure sufficient clearance for maintenance and

service. (Refer to Fig. 1)

 Piping between indoor and outdoor units is within

the allowable limit.

Fig. 1 Clearance for Maintenance and Service

4 INDOOR UNIT INSTALLATION

4.1 Confirm the installation position

 Refer to Fig. 2 to see the unit’s diameter and confirm the installation location.

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CAUTION

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Fig. 2 Indoor Unit Dimension

Model

Dimension

(A)

Unit Dimension

(B)

Air Supply

(C)

Installation

Hole

(D)

Pipe Diameter (mm)

Liquid Pipe

Gas Pipe

YDVC028 730 570 532 513 6.35 9.52

YDVC045 980 820 782 763 6.35 12.7

YDVC056

1334

1170

1132

1113

6.35

12.7

YDVC071 1334 1170 1132 1113 9.52 15.88

 To leave an inspection opening for convenient

maintenance and inspection of the parts such

as electrical parts, refrigerant connection nuts,

temperature sensors, EXV coil, drain pump (if it

has), etc. Refer to Fig. 3 for the inspection

opening size.

Figure 3 Servica Space

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4

4.2 Check if the unit is horizontally level

 Make sure that the unit is installed level using a

spirit level or a plastic tube filled with water. (Refer

to Fig. 4)

(One thing to watch out for in particular is if the

unit is installed so that the slope is not in the

direction of the drain pipe, which might cause

condensate water leaking.)

Fig. 4 Check Unit Level

4.3 Install the suspension bolts

Shall ensure the unit being in horizontal level and

installed firmly. Install anchor bolt to fix unit

securely if necessary.

5 REFRIGERANT PIPING WORK

 Execute insulation completely on both sides of the

gas piping and the liquid piping. Otherwise,

condensate water may be formed and dropped

down.

 Please use the insulation materials that can

withstand temperature of at least 120°C. Reinforce

the insulation on the refrigerant piping according

to the installation environment. Otherwise,

condensate water may form on the surface of the

insulation.

Please follow the below items.

 Apply ester oil or ether oil to the flare section

(internal and external surface) when using a flare

connection.

 Only the flare nuts included with the unit can be

used. Using different flare nuts may cause

refrigerant leakage.

 To prevent dust, moisture or other contaminant

from infiltrating the piping, either pinch the end or

cover it with tape.

 Do not allow anything other than the designated

refrigerant to get mixed into the refrigerant circuit,

such as air, etc.

 When brazing the refrigerant piping, perform

nitrogen replacement first, or perform brazing

while feeding nitrogen into the refrigerant piping,

and finally connect the indoor unit using the flare

connections.

 When brazing a pipe while feeding nitrogen inside

the pipe, make sure to set the nitrogen pressure to

0.02MPa (0.2kgf/cm

2

) around.

 Do not use flux when brazing refrigerant piping.

Therefore, use the phosphor copper brazing filler

metal (BCuP) which does not require flux.

If chlorine or fluoric based flux is used, it will cause

pipe corrosion and contamination of refrigerant oil

5.1 Connect the piping

 Be sure to use both a spanner and torque wrench

together, as shown in Fig. 5, when connecting or

disconnecting pipes to/from the unit.

Fig. 5 Piping Connection

 Refer to Table 1 for the tightening torque.

Table 1

Pipe Diameter

mm (inch)

Tightening Torque

(N m)

6.35 (1/4") 14 17

9.53 (3/8") 32.5 40

12.7 (1/2") 49.5 60

15.88 (5/8") 62 75

19.05 (3/4") 80 95

22.23 (7/8") 100 115

 If no torque wrench is available, please follow the

below method to do the installation.

Using a wrench to tighten flare nuts causes the

tightening torque to suddenly grow much tighter

after a certain point. From that point, tighten the

nut further by the appropriate angle listed in Table

2.

Table 2

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VRF Air-Conditioner IOM

5

Pipe Diameter

mm (inch)

Further

tightening angle

Recommended arm

length of toll

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

19.05(3/4")

30 60

400mm

22.23(7/8")

30 60

400mm

Over tightening may damage the flare and cause

leakage.

5.2 AIR TIGHT TEST

 Air tight test should be done after the piping

connection completed.

 Operation method:

(a) Fill in dry nitrogen into the refrigerant piping

and let the pressure slowly rise to 4.3MPa.

(b) The specified pressure should be maintained

for 10 minutes, and then soapy water or other

foaming agent are applied to the connection

positions, such as brazing seams, screwed

joints ,etc. for leakage detection.

(c) If it has leakage, then tighten or braze the

leakage point.

(d) After it has been confirmed that the piping

does not leak, the dwelling test should be

performed. Fill in the dry nitrogen again and

let the pressure slowly rise to 4.3MPa.

(e) The pressure needs to be maintained for 6

hours and then record the pressure value

through the manometer. 24 hours later, record

the pressure again.

(f) No pressure drop after 24 hours means it has

no leakage. Otherwise, the leaking point must

be found and mended. Then repeat the above

(d) and (e) steps.

 Gas pressure is relevant to ambient temperature.

So temperature should be considered when judging

the pressure variation. The relationship of pressure

and temperature is shown below.

2

1

273

1

273

t

P P

t

 

+

∆ = × −

 

+

 

2correction

P P P= − ∆

P∆

— Pressure correction value (Pa)

correction

P

— the correced pressure value (Pa)

1

P

— 1

st

record pressure (Pa)

2

P

— 2

nd

record pressure (Pa)

1

t

— 1

st

record temperature (°C)

1

t

—2

nd

record temperature (°C)

 Do not connect indoor units with outdoor units

during the air test process. Otherwise, it may result

in nitrogen gas emtering into the outdoor unit.

5.3 Insulate the piping

 After checking it has no leakage, be sure to insulate

the connection parts of both liquid and and gas

pipe with sufficient thickness heat-resistant

polythylene materials.

 Be sure to insulate the field piping all the way to

the piping connection inside the unit. Any exposed

piping may casue condensate water or being

scalded if touched.

6 DRAIN PIPING WORK

 YDVC series indoor unit drain pipe is the free

drainage.

 Be sure the drain pipe works well and smothly

before making the duct connection. (It is not easy

to check the drain pipe when the duct has been

connected.)

6.1 Install the drain pipe

 Make sure the drain works properly.

 Diameter of the drain pipe should be larger than or

equal to the one of the connecting pipe. (drain pipe

connection diameter of indoor unit is Ф20)

 Make a water trap on the drain pipe outlet from

indoor unit. The water trap should meet below

requirements. (A, B 50mm)

 If central drain pipe has been used, keep the drain

pipe short and sloping downwards at a gradient of

at least 2/100 to prevent air pockets from forming.

(Refer to Fig. 6)

Fig. 6 Central Drain Pipe

 Select central drain pipe of proper size according to

the total capacity of the connected unit.

(a) The parts of drain pan outlet should be well

insulated to avoid condensate water

NO

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CAUTION

VRF Air-Conditioner IOM

6

accumulating.

 When connecting the drain pipe, effective method

should be carried out to guarantee no leakage on

each connection area.

 To avoid condensate water accumulating on the

drain pipe and dropping down, the drain pipe

should be insulated.

6.2 Check the drain pipe

 After piping work is finished, check if drainage

flows smoothly.

Free drainage

Gradually insert approximately 1000 ml clean

water into the drain pan to check drainage

status.

 The electric wiring works should be performed by

specially qualified electricians.

 If no electricians in site, please flow the above

steps to do drainage confirmation after the system

test running.

7 INSTALLING THE DUCT

 Materials for duct installation are supplied in the

field.

 Refer to Fig. 7 to connect the duct.

Fig. 7 Duct Connection

 Wrap both the inlet-side and outlet-side flange and

the duct connection area with aluminium tape for

something similar to prevent air escaping.

 Please attach an air filter inside the air passage on

the inlet-side. (Use an air filter which duct

collection efficiency (in a gravimetric technique) is

higher than 50%)

 Be sure to insulate the duct to prevent condensate

water from forming. (Material: glass wool or

polyethylene foam, above 25mm thickness)

 The air outlet height should be appropriate and

cannot be positioned at the place where it directly

blows the people for a long period.

 To reduce vibration and noise, it is better to use

flexible connection to connect the air inlet and

outlet duct with indoor unit.

8 ELECTRIC WIRING WORK

8.1 General introduction

 Refer to figure 11 for indoor unit electrical wiring.

 All field supplied parts and materials and electric

works must conform to local laws.

 Only copper wires can be used.

 Please refer to the wiring diagram attached with

the unit when performing the electric work.

 Please refer to the installation guide attached with

wire controller for electric and detailed instruction.

 All wiring works should be performed by specially

qualified electricians.

 Shall install the circuit breaker that can shut off the

whole system.

 Do not turn on the power supply unless all the

work has been done.

 Refer to the installation guide attached with

outdoor unit for specifications of circuit breaker

switch and wire, etc.

 The system incorporates multiple indoor units.

Please number the indoor units before installation.

When performing the communicating wires, must

ensure the numbers of indoor wires are same with

the numbers on the terminals of outdoor unit.

Malfunction will occur if the wire connection is

converse or mistake.

 Be sure the air-conditioner is well grounded. Never

connect the ground line with gas pipe, water pipe,

lightning conductor or telephone lines. Improper

grounded may cause electric shock.

Gas pipe: it may cause explosion or fire when

gas leaks.

Water pipe: No grounded when using

stereoplasm polyethylene.

Lighting conductor or telephone wire: the

earthing potential may rise abnormally when

thunderstrike.

 Must use the terminal having insulation in order to

avoid short circuit.

 Wires shall be fixed firmly, then secure to prevent

external pressure being exerted on the terminal

board.

 Wires shall be laid orderly. Lid shall be in place and

fixed securely.

Be sure the ground resistance is lower than 0.1Ω.

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VRF Air-Conditioner IOM

7

MCA: Maximum Current (A)

8.2 Power distribution

 Refer to Fig. 8 for power distribution of the system.

Fig. 8 Indoor and Outdoor Units Power Distribution Diagram

8.3 Indoor unit field wiring

 Refer to the “Wring Diagram” attached to the control box lid for details.

8.4 Setting indoor unit model

 Refer to the “Wring Diagram” attached to the control box for the indoor unit setting.

8.5 Communication network

Fig. 9 Connection Line Connection

VRF Air-Conditioner IOM

8

Note: indoor unit communication lines cannot be conversely connected, otherwise it will have

communication failure and the unit cannot startup.

8.6 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 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.

8.7 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. 10)

(b) When one wire controller connecting multi

indoor units: (refer to Fig. 11)

Fig. 10

One wire controller connects to one indoor unit

Fig. 11

One wire controller connects to multi indoor units

YDVC IOM-EN(1212)

Y

DVC

-

IOM(

1204

)

NONE

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