Carrier 42qg24-h Manual

							 
 
28
 
CONNECTING REFRIGERANT PIPING (Cont.)  
15.5    DESCRIPTION OF REFRIGERANT CONNECTIONS OF OUTDOOR UNIT.  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
15.6    DESCRIPTION OF REFRIGERANT CONNECTIONS  
     OF HI WALL INDOOR UNITS  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
   
15.7    DESCRIPTION OF REFRIGERANT CONNECTIONS 
     OF REFERIGERANT PIPING LINES 
 
 
 
  
15.8    CUTTING AND FLARING TOOLS 
 
Make sure that have the required tools available before preparing refrigerant piping lines 
(1)  Suction flare valve. 
(2)  Suction service valve. 
(3)   Suction port to open & close. 
(4)   Cap for suction service valve. 
(5)  Cap for suction port. 
(6)  Liquid flare valve. 
(7)  Liquid service valve. 
(8)  Liquid port to open & close. 
(9)  Cap for liquid service valve. 
(10) Cap for liquid port. 
Half Union 
Suction 
Half Union  
Liquid  
REFRIGERANT 
CONNECTIONS
Pipe Cutter  
Flare Tool
7 & 9
4
5
23
1
8
6
10 
						

							 
 
29
Corrugated CuttingWrap Cutting 
 
CONNECTING REFRIGERANT PIPING LINES (Cont.) 
 
15-9 STEPS FOR PREPARING REFRIGERANT PIPING LINES BEFORE CONNECTIONS 
( IN CASE OF NOT USING THE OPTIONAL FACTORY REFRIGERANT PIPING LINES WITH THE FLARE NUTS ) 
 
 
 STEP (1): Cutting refrigerant piping  lines 
• Remove protective caps from copper pipe ends. 
• Position tube end downwards, cut the pipe to the 
required length with a pipe cutter. 
 
NOTE:  
• It is recommended to cut approx. 30→50 cm 
longer than the estimated pipe length.  
• Take care to ensure that the cut edge remains at a 
90° angle with the side of pipe, and refer to the 
illustrations for examples of edges cut correctly 
and incorrectly.
  
     
 Removing the burrs 
• 
Remove burrs at the end of the connection pipe 
with a pipe reamer or a file.
 
This process is important and should be done 
carefully to make a good flare and to prevent any 
gas leaking out. 
 
NOTE:  
When reaming, hold the pipe end downward and 
be sure that no copper scraps fall into the pipe. 
 
 
 
 STEP (2): Removing the flare nuts from the   
       indoor unit. 
 
Remove the suction and liquid flare nuts from the 
indoor unit connections. 
 
NOTES:  
• Do not remove the flare nuts from the indoor unit 
until refrigerant piping lines are ready for 
connections. 
• It is that easier to remove flare nuts from the 
indoor unit before being installed on the wall hang 
bracket.
  
 
 
 STEP (3): Removing the flare nuts from the   
       outdoor unit  Remove the suction   
       and liquid flare nuts from the      
       outdoor unit connections. 
 
NOTES:  
• Do not remove the flare nuts from the outdoor unit 
until refrigerant piping lines are ready for 
connection. 
• It is easier to remove flare nuts from the outdoor 
unit before being installed on the wall support.
  
 
Debarring
After
Before 
1: Connection pipes 
2: Reamer 
1
2
Pipe Cutter
Correct CuttingInclined Cutting  
						

							 
 
30
 
CONNECTING REFRIGERANT PIPING LINES (Cont.)  
STEPS FOR PREPARING REFRIGERANT PIPING LINES BEFORE CONNECTIONS (Cont.) 
 
 STEP (4): Mounting flare nuts on the              
       refrigerant piping lines
   
• Mount the suction flare nut on the other side of 
suction piping line. 
• Mount the liquid flare nut on the other side of 
liquid piping line.
  
 
 
 STEP (5): Flaring the Piping  
• Use flare tool to flare ends of both suction and 
liquid piping lines slide a flare nut on to the tube 
and modify the flare. 
  
NOTES:  
    1) Good flare should have the following 
characteristics : 
• Inside surface is glossy and smooth. 
• Edge is smooth and must not have any burrs  
or imperfections. 
• Tapered sides are of uniform length. 
 
 
 
 
 
 
 
 
2)  Be sure to apply a sealing cap or waterproof tape 
to prevent dust or water from getting into the 
refrigeration piping lines before they are used. 
 
 
 
Avoid incorrect flaring, which results in 
damaged or cracked or inclined with 
uneven thickness surface. 
 
 
STEP (6): Mounting flare nuts on the other 
side of refrigerant piping lines 
 
• Mount the suction flare nut (Large nut) on the 
other side of suction refrigerant piping line. 
 
• Mount the liquid flare nut (Small nut) on the other 
side of liquid refrigerant piping line.
 
  
 
RecommendFlare tool
Refrigerant 
Piping 
Flare Nut  Flare Tool 
Liquid Line 
Suction Line 
Refrigerant Piping Lines After 
Connecting Flare Nuts From Both Sides
Liquid  
Piping Line
Suction  
Piping Line 
						

							 
 
31
 
CONNECTING REFRIGERANT PIPING (Cont.) 
 
 15-10   STEPS FOR CONNECTING REFRIGERANT PIPING LINES TO INDOOR UNIT 
 
Connecting suction and liquid piping 
lines respectively with suction and 
liquid half unions of indoor unit. 
 
A.  Lubricate suction and liquid piping line end 
and the threads of the suction and liquid half 
unions of indoor unit with anti – freeze oil. 
This is effective for reducing gas leaks.   
  
B.  For proper connection, align the centers of 
suction union pipe and flare pipe straight with 
each other, then finger tighten several turns 
the flare nut tightly at first to obtain a smooth 
match. 
 
 
 
 
C.  Then hold the union side with a double-ended 
wrench and tighten the flare nut by applying 
the tightening torque indicated in the 
following table (1). Be careful not to damage 
the flare nut threads. 
 
NOTE:  
One.  Insufficient tightening torque will 
cause Freon leaks. 
Two. Over tightening the fitting will 
damage the tube flaring and cause 
Freon leaks.
 
  
 
15-11 STEPS FOR CONNECTING REFRIGERANT PIPING LINES TO OUTDOOR UNIT 
• Connecting the other ends of suction and 
liquid piping lines respectively with suction 
and liquid flare couplings of the outdoor 
unit. 
• Repeat steps (A), (B), (C) when connecting 
refrigerant piping lines to the couplings of 
the outdoor unit. 
 
 
 
(1) 
Fingers tighten 
several turns the 
flare nuts of piping 
at the outdoor unit 
valves. Table (1)Half Union
Flare Spanner 
or 
Torque Wrench
Indoor 
 
Side 
Tightening Torque 
Kg - Cm Flare Nut 
N.M Kg - cm 
3/8” 31-35 310-350 
5/8” 50-55 500-550 
Piping Lines
(2) 
Tighten the flare 
nuts with 
adjustable wrench 
or torque wrench. 
Pot only from oil  
refrigerating her  and her
Flare nut 
						

							 
 
32
 
CONNECTING REFRIGERANT PIPING LINES (Cont.)  
15-12   AIR AND MOISTURE PURGE 
In some countries the law does not permit purging by blowing refrigerant through the lines.  
If this is the case, please refer to page (31) using the vacuum pump. 
 
 
(A) AIR PURGE USING REFRIGERANT  
    IN THE UNIT OUTDOOR UNIT 
Air and moisture in the refrigerant  
system have undesirable effects. 
They must be purged completely. 
The outdoor unit includes an extra  
50 grams of refrigerant for air purge.
 
 
 
 
 
 
• Air purging procedure 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
(1) 
(2) 
Remove the valve caps of 
suction  & liquid valve. Loosen the valve stem of liquid 
valve by 90 degrees (1/4 turn) for 5 
seconds with a hex key wrench  
Push the valve core of the 
suction valve. 
Stop pushing the valve core as 
soon as the refrigerant hissing 
stops.  Open the liquid valve for about 3 
seconds, then close quickly to check 
for gas leaks. 
After checking for gas leaks, open the 
liquid and suction valve all the way.  Reinstall the caps and of the 
liquid valve, suction valve 
and service port nut. 
(5) 
(4)(3) COMPLETE 
(1)
Remove service port nut 
of suction valve. 
OPEN
OPEN & CLOSE CLOSE
PUSHOPEN OPEN
(1)  Suction flare valve. 
(2)  Suction service valve. 
(3)   Suction port to open & close. 
(4)   Cap for suction service valve. 
(5)  Cap for suction port. 
(6)  Liquid flare valve. 
(7)  Liquid service valve. 
(8)  Liquid port to open & close. 
(9)  Cap for liquid service valve.  
(10) Cap for liquid port. 
7 & 9
4
5
23
1
8
6
10 
						

							 
 
33
 
CONNECTING REFRIGERANT PIPING LINES (Cont.)  
 AIR AND MOISTURE PURGE (Cont.) 
 
(B) AIR PURGE USING THE VACUUM PUMP  
1. Connect the gauge manifold and the vacuum pump. 
 
2. Open the low-pressure valve and close the high-
pressure valve of gauge manifold completely. 
 
3. Operate the vacuum pump during at least 20 minutes 
until the pressure reaches – 101Kpa   (-760mm Hg). 
 
4. Close the low-pressure valve of the gauge manifold 
and stop the vacuum pump operation.  
  (If the indicator of gauge manifold is returned within 
1-2 minute after stopping the vacuum pump, check 
the piping connection leakage).
 
 
5. Close both the liquid and suction valve caps completely. 
 
6. Remove the gauge manifold and the vacuum pump. 
  (During the disconnection, please be cautious not to loose 
any refrigerant and oil).
 
 
7.  Reinstall the valve caps and service port nuts. 
 
(C) NOTES:  
Tighten the valve caps and the service port nut to the 
specified torque as shown in the table: 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
CONNECTION DIAGRAM OF VACUUM PUMP 
 
PART TIGHTENING TORQUE  
(Kgf – Cm) 
SERVICE PORT NUT  150 → 200  
VALVE CAP     170 → 220 
Valve Stem 
Valve Cap  Valve Cap Hex key WrenchLow  
pressure valve 
High  
pressure valve 
Gauge manifold
Vacuum Pump Valve Core 
Service Port NutIndoor Unit 
Suction 
 
Line 
Liquid
 
Line  Vacuum 
Pump 
Outdoor Unit
Split System 53QG Series  
						

							 
 
34
Unit on 
Cooling 
Wait about 
3 minutes 
3  3  1  
2  
 
CONNECTING REFRIGERANT PIPING LINES (Cont.) 
 
15-13  REFRIGERANT LEAK CHECK  
 
After connecting the refrigerant piping lines, with both 
outdoor and indoor units check the joints for leakage with 
electronic leak detector or soapy water.
 
 
 
15-14 INSULATING REFRIGERANT PIPING LINES 
To conserve energy and prevent wet floors due to 
condensation, the suction and liquid piping lines must be well 
insulated with a proper insulation material. 
 
The thickness of the insulation should be a minimum of 9 mm.  
The insulation you select must have good insulation 
characteristic, be easy to use, resist age and not easily absorb 
moisture. 
 
Finally wrap the flare couplings and pipes with insulation and 
tighten this with tape without exerting too much pressure on 
the insulation. 
 
CAUTION: 
• After a pipe has been insulated, never try to bend it into a 
narrow curve, as this way will cause the pipe to break or 
crack. 
• Repair and cover any possible cracks in the insulation 
• Avoid dripping due to insufficient insulation of piping.   
 
15-15 PUMP DOWN 
Pump down means collecting all the refrigerant in the system 
back into the outdoor unit. Pump down must be actuated 
before disconnection of pipes, to avoid loss of refrigerant gas. 
Pump down is used when the unit is moved to another 
installation location or when the system is repaired. 
 
PUMP DOWN PROCEDURE : 
1.  Close the liquid valve with the Allen wrench. 
2.  Turn the system ON in cooling mode with fan 
operating at high speed. 
  Then the refrigerant will be collected into the outdoor unit. 
(Compressor will immediately start, provided 3 
minutes have elapsed since the last stop). 
 
3- After 3 minutes of operation, close the suction valve 
with the Allen wrench. 
    Turn the system off and switch mains supply OFF. 
    Disconnect refrigerant piping lines. 
 After disconnection, protect valves and piping ends 
from dust.
 
 
 
Pipe
Insulation   
Pipe   Fastening tape   
						

							 
 
35
 
16. CONNECTING CONDENSATE DRAIN LINE  
 
16-1  INSTRUCTIONS FOR CONNECTING CONDENSATE DRAIN LINE  
The condensate drain line (not supplied) for indoor unit must be made of PVC piping with an inside 
diameter of 5/8” (16 mm) and have suitable length for the chosen installation site. 
 
Instructions for connecting drain hose Possible outlet locations of condensate  
drain line from the indoor unit 
 
a.  The drain hose must be 
gradually inclined downwards 
 to the outside to ensure flow  
of condensate water to outside. 
 
 
b.   The condensate drain line 
must not be connected to 
the sewerage system. 
 
 
 
 
c.  The drain hose must not be 
looped upwards to avoid 
over-flowing of condensate 
water. 
 
 
 
 
The condensate drain line is connected to the loose 
end of the drain hose coming out of the indoor unit in 
one of the following four outlet locations: 
 
d. The drain hose must have no  kinks or bends hampering   smooth drainage of water due  to air stagnation. 
 
 
 
 
 
 
 
 
 
 
     Avoid horizontal kinks or bends                       Avoid vertical kinks or bends 
      Avoid horizontal drain line with                Avoid any rise in drain line 
           Less than 2 % slope 
      
e. Drainage Test 
  Check the drainage of the unit by pouring some water into the unit drain pan and ensure it drains out 
through the drain hose and there is no leakage from other parts. 
 
 
Sr.  Outlet Location Notes  
1  Unit Right  Remove right side knock-out 
2  Unit Bottom  Remove bottom knock-out 
3  Unit Back  Do not remove side or 
bottom knock-out 
4  Unit Left  Remove left side knock-out 
 
4 3
2 1 
						

							 
 
36
 
17. CONNECTING ELECTRICAL WIRING 
 
17-1 ELECTRICAL WIRING BETWEEN ELECTRICAL POWER SUPPLY  
AND CIRCUIT BREAKER OF AIR CONDITIONER 
 
All electrical connections between electrical power supply and circuit breaker of air conditioner 
are the responsibility of the customer and must be done by a qualified electrical technician 
according to national electrical wiring regulations to avoid fire due to short-circuiting. 
  
(A) Operating Voltage 
  The operating voltage of electrical power supply should be within the limits of voltage mentioned 
on unit nameplate data. 
(B)  Electrical kWh Counter KWH 
  The capacity of electrical kWh counter should be lager than the operating currents required for air 
conditioner(s) and any other electrical domestic appliances in use simultaneously from the same 
supply. 
(C)  Electrical Distribution Box 
  The installation of electrical distribution box after the electrical KWH counter is necessary  
to properly distribute the electrical loads. 
  The electrical distribution box should be equipped with circuit breakers according to the electrical 
loads. 
  For each installed air conditioner, a separate circuit breaker with its own overload should be 
installed on the electrical distribution box. 
(D)  Operation On / Off Circuit Breaker 
  The installation of two pole automatic circuit breaker is necessary to operate the air conditioner. 

						

							 
 
37
 
CONNECTING ELECTRICAL WIRING (Cont.) 
 
17-2 ELECTRICAL WIRING BETWEEN INDOOR UNIT, OUTDOOR UNIT  
AND CIRCUIT BREAKER OF AIR CONDITIONER 
 
All electrical connections between the outdoor unit, indoor unit and circuit breaker are the 
responsibility of the qualified installer and must be done according to national electrical  
wiring regulations to avoid fire due to short circuiting.
 
 
-  Both of the outdoor and indoor units leave the factory with complete internal electrical wiring. 
  Do not change any internal electrical wiring of both units. 
-  A qualified electrical technician should carry out the electrical connections. 
-  It is very important before making the electrical connections between the indoor, outdoor units, 
and the power supply, to pay attention to the following safety instructions:
     
 
(A) Operating  Voltage 
  The operating voltage of electrical power supply should be within the limits of voltage mentioned on unit 
nameplate data. 
 
  Shown on the indoor and outdoor units of the air conditioner.   
(B)  Field Electrical Connection Cables 
  *   Do not use electrical connection cords except the approved one for use with air conditioners. 
  *   Each cable should be a complete unit, without extensions. 
 
(C) Electrical  Connections 
a.  Check that the electrical connections between the terminal blocks of indoor and outdoor units are in 
accordance with the wiring diagrams and caution field electrical wiring contained in the manual. 
 
      Miswiring may cause malfunction of the system and an electric shock. 
b.  Do not connect wires when power is ON. 
 
c.  Make ground connection prior to any other electrical connections in accordance with the electrical 
local codes. 
 
d.  Make electrical connections between outdoor and indoor units prior to proceeding to mains supply 
connection. 
 
e.  Before proceeding with the unit connection to the mains supply locates live L and neutral N, then 
make connections as shown in the wiring diagram. 
 
  Be sure that the live and neutral wire connected respectively to the Live (L) and the Neutral (N) 
terminals of terminal block of outdoor units. 
 
f.  Ensure that mains supply connection is made through a switch that disconnects all poles, with 
contact gap of at least 3 mm. 
 
g. Avoid slack connections of the electrical cords when connected to the terminal blocks of indoor  
and outdoor units. and also to circuit breaker These slack connections lead to voltage drop and unit 
malfunctions. Every wire must be connected firmly.
 
 
WARNING 
!