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Refrigerant pipe connection
1
Flaring work
Main cause for refrigerant leakage is due to defects in
the flaring work. Carry out correct flaring work using the
following procedure:
90 C
Oblique
Roughness
Burr
A: Cut the pipes and the cable.
1
Use the piping kit accessory (if applicable) or pipes
purchased locally.
2
Measure the distance between the indoor and the
outdoor unit.
3
Cut the pipes a little longer than the measured distance.
4
Cut the cable 1.5m longer than the pipe length.
B: Burr removal
1
Completely remove all burrs from the cut cross section
of pipe/tube.
2
Face the end of the copper pipe/tube in a downward
direction as you remove burrs in order to avoid burrs
dropping into the tubing.
Pipe
Reamer
Face down
caution
C: Putting flare nut on
Remove flare nuts attached to indoor and outdoor unit,
then put them on pipe/tube having completed burr removal
Note: It is not possible to put them on after flaring work.
Flare nut
Copper tube
D: Flaring work
•
Carry out flaring work using flaring tool as shown below.
•
Firmly hold copper pipe in a die according to the
dimension shown in the table below.
8 installation instructions Kelvinator Air Conditioning
A(mm)
Outer diam. (mm)
Max.
Min.
φ 6.35
1.3
0.7
φ 9.53
1.6
1.0
φ 12.7
1.8
1.0
φ 16.0
2.4
2.2
Handle
Bar
Bar
Yoke
Cone
Copper pipe
Clamp handle
Red arrow mark
Tightening Connection
•
Align the center of the pipes.
•
Sufficiently tighten the flare nut with fingers, and
then tighten it with a spanner and torque wrench
as shown below.
Indoor unit tubing
Flare nut
Pipings
Tightening torque
Additional Tightening
Outer diam.
(Kg.m)
Torque (Kg.m)
φ 6.35
1.6
2.0
φ 9.53
3.0
3.5
φ 12.7
5.0
5.5
φ 16.0
7.5
8.0
caution
•
Excessive torque can break nut depending on
installation conditions.
E: Check
•
Compare the flared work with the adjacent diagram.
•
If flare is found to be defective, cut off the flared section
and do flaring work again.
Smooth all round
Improper flaring
Even length
all round
Indoor unit piping
Taper nut
Piping
Spanner
Torque
wrench
Suction
Discharge
Maximum
Maximum
Model
(mm)
(mm)
lenght
Height
6.4 (1/4")
9.5 (3/8")
KSV26CRC
15
10
6.4 (1/4")
9.5 (3/8")
KSV26HRC
15
10
6.4 (1/4")
9.5 (3/8")
KSV35CRC
20
10
KSV35HRC
6.4 (1/4")
9.5 (3/8")
20
10
KSV53HRC
6.4 (1/4")
16.0 (5/8")
25
10
KSV62HRC
6.4 (1/4")
16.0 (5/8")
20
10
KSV70CRC
6.4 (1/4")
16.0 (5/8")
25
10
6.4 (1/4")
16.0 (5/8")
KSV70HRC
25
10
6.4 (1/4")
16.0 (5/8")
KSV80HRC
25
10
Note:
Connect the connection pipe to indoor unit at first and then
to outdoor unit. Handle piping bending with care. Do not
damage the connection pipe. Ensure that the joint nut is
tightened firmly, otherwise, it may cause leakage.
Installation of outdoor unit
Electric wiring
1
Remove the handle on the right side plate of
outdoor unit.
2
Take off wire cord anchorage. Connect and fix power
connection cord to the terminal board. Wiring should fit
that of indoor unit.
3
Fix the power connection cord with wire clamps and then
connect the corresponding connector.
4
Confirm if the wire has been fixed properly.
5
Reinstall the handle.
For 2.6kW and 3.5kW units:
Handle
2
3
N(1)
yellow-
green
blue
black
brown
indoor unit connection
For 5.3kW, 6.2kW, 7.0kW and 8kW units:
Handle
2
3
N(1)
yellow-
green
blue
black
brown
indoor unit connection
Air Purging and Leakage Test
1
Connect charging hose of manifold valve to charge end
of low pressure valve (both high/low pressure valves
must be tightly shut).
2
Connect joint of charging hose to vacuum pump.
3
Fully open the handle of Lo manifold valve.
4
Open the vacuum pump for vacuumization. At the
beginning, slightly loosen joint nut of low pressure valve
to check if there is air coming inside. (If noise of vacuum
pump has been changed, the reading of multimeter is 0)
Then tighten the nut.
5
Keep vacuuming for more than 15mins and make sure the
reading of multi-meter is -1.0 10
5
pa (-76cmHg).
6
Fully open high/low pressure valves.
7
Remove charging hose from charging end of low
pressure valve.
8
Tighten lid of low pressure valve. (As shown in below)
Manifold
Multimeter
Valve
-76cmHg
Lo Handle
Hi handle
Charging hose
Low pressure valve
Charging hose
Vacu um pump
Outdoor Condensate Drainage (only for Heat pump unit)
During heating operation, the condensate and defrosting
water should be drained out reliably through the drain hose.
Install the outdoor drain connector in a
25mm hole on the
base plate and attach the drain hose to the connector so
that the waste water formed in the outdoor unit can be
drained out. The hole diameter 25mm must be plugged.
Whether to plug other holes will be determined by the
installer according to actual conditions.
Drain-water hole
Bottom frame
Drain plug
Drain connecter
Hose (available commercially,
inner diameter 16mm)
Kelvinator Air Conditioning installation instructions 9
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