Thermal MS49A23115A User manual

HIGH EFFICIENCY SERIES

MINI-SPLIT

INSTALLATION MANUAL

FOR THERMAL ZONE MODELS

AIR CONDITIONER HEAT PUMP

MS49A23115A MS49HP23115A

MS412A22115A MS412HP22115A

MS412A22230A MS412HP22230A

MS418A20230A MS418HP20230A

MS424A19230A MS424HP19230A

FOR SEA BREEZE MODELS

AIR CONDITIONER HEAT PUMP

9A423YGX 9H423YGX

12A422YGX 12H422YGX

12A422ZGX 12H422ZGX

18A420ZGX 18H420ZGX

24A419ZGX 24H419ZGX

950-0158 August 20, 2010

950-0158 - 1 - September 25, 2010

TABLE OF CONTENTS

Installation Steps 2

Notes to Installer 2

Parts Included with Indoor Unit 3

Installer Supplied Parts 3

Condensate Pump 3

Decorative Channel 4

Wall Brackets 4

Installation Considerations 4

General Information 4

Select Locations for Indoor Unit 5

Select Locations for Outdoor Unit 5

Line Set Length 5

Indoor Unit (Evaporator) installation 6

Outdoor Unit (Condenser) installation 8

Connecting Line Set 9

Electrical Connection – Notes 10

Connect the Cable to the Outdoor Unit – Notes 11

Typical Electrical Wiring Connections 12

Connect the Cable to the Indoor Unit – Diagram 13

Install the drain fitting and the drain hose (for heat pump unit only) 13

Evacuation of the Refrigeration Tubes and Indoor Unit 14

Leak Testing 14

Evacuation 14

Start Up Testing 15

Preparation 15

Operational Test 15

Technical Specifications for Cooling Only 16

Technical Specifications for Heat Pump 18

Troubleshooting 20

Flash Codes on Outdoor PC Board 21

Indoor Unit Error Codes 22

Ambient Sensor Resistance 22

Tube Sensor Resistance 23

Outdoor Exhaust Sensor Resistance 23

Outdoor Electrical Schematics (9K,12K – 115 VAC) 24

Indoor Electrical Schematics (9K,12K – 115 VAC) 25

Outdoor Electrical Schematics (12K – 230 VAC) 26

Indoor Electrical Schematics (12K – 230 VAC) 27

Outdoor Electrical Schematics (18K, 24K – 230 VAC) 28

Indoor Electrical Schematics (18K, 24K – 230 VAC) 29

Warranty and Technical Support 30

Do not dispose this product as unsorted municipal waste. Collection of such waste for

special treatment is necessary.

950-0158 - 2 - September 25, 2010

Installation Steps:

•Select the location for the indoor and outdoor unit. (page 5)

•Mount the indoor wall brackets. (page 6)

•Drill wall penetration holes. (page 6)

•Hang the indoor units. (page 7)

•Locate and mount the outdoor unit. (page 8)

•Connect and route line set. (page 9 – 10)

•Connect the wiring from the indoor unit to the outdoor unit. (Page 11 – 13)

•Evacuate line set. (page 14)

•Start Up Testing. (page 15)

NOTES TO INSTALLER

This manual is to aid the qualified HVAC contractor in the installation of this Mini Split system.

Report all shipping damage to the carrier IMMEDIATELY. Check units and box exterior for damage.

Please read and understand these instructions prior to installing the unit, failure to comply with these

instructions may result in improper installation, operation and maintenance, possibly resulting in fire, electrical

shock, property damage, personal injury or death.

CAUTION! Do not use old refrigerant lines with new installation:

For connecting pipes use new and clean piping materials with high pressure fittings made for R410A only.

This air conditioner adopts the new HFC refrigerant (R410A) which does not destroy the ozone layer. R410A

refrigerant operates at approximately 1.6 times the pressure of refrigerant R22. Accompanied with the

adoption of the new refrigerant, the refrigeration lubricating oil has also been changed. During installation be

sure that water, dust or foreign material does not enter into the new system. The system must not be left open

to the atmosphere for any reason for any period of time as the systems oil quickly absorbs moisture and will

contaminate and damage the system. To prevent mixing of refrigerant or refrigeration lubricating oil, the sizes

of connecting sections of charging port on main unit and installation tools are different from those used for the

conventional refrigerant units. Accordingly, special tools are required for the new refrigerant (R410A) units.

The best and recommended solution is do not use the existing line sets because there may be some

problems with pressure fittings and possible impurities in the existing piping.

When installing this unit, an electrical surge suppressor is recommended.

Installers please pass this manual and warranty registration to end user. If technical assistance is required

during installation or start up, please call 704-504-8590 (M-F 8:00 am to 4:30 pm ET) to speak to a Technical

Service Engineer. Before calling please have the Model and Serial numbers available.

Safety Instructions:

1. Carefully read all instructions prior to installation.

2. Check Rating Plate for correct system voltage before installing the unit. Installing and operating a

unit with the incorrect voltage may result in malfunction or other issues and will void the warranty.

3. Units must be connected to a correctly grounded electrical supply.

4. Do not use the units if they have been dropped or otherwise damaged or installed incorrectly.

The manufacturer of the unit will not be liable for any damages caused by failure to comply with the

installation and operating instructions in this manual.

The unit rating plate contains pertinent information for unit operation; please refer to it as required.

Inspect all parts for damage prior to installation and start up. Units must be installed by a qualified HVAC

contractor.

950-0158 - 3 - September 25, 2010

PARTS INCLUDED WITH UNIT

Indoor unit Outdoor Unit

Wall Bracket Drain Fitting (only for Heat Pump units)

Remote Control Installation Manual

Batteries for Remote Control (2 AAA)

Remote Control Holder

Drain Tubing 24 ft.

Operation Manual

INSTALLER SUPPLIED PARTS

The following additional Items are required for proper installation.

•Refrigerant line set: Insulated copper tubing:

o9K Indoor – 1/4” (liquid line) and 3/8” (suction line).

o12K Indoor – 1/4” (liquid line) and 1/2” (suction line).

o18K Indoor – 1/4” (liquid line) and 1/2” (suction line)

o24K Indoor – 1/4” (liquid line) and 5/8” (suction line).

•Flare nuts 2 ea. required per line, see above (line set) for size.

•Vinyl UV resistant tape.

•Supply Power:

MS49A23115CA, MS412A22115CA, MS418A20230CA, MS424A19230CA,

MS49HP23115CA, MS412HP22115CA, MS418HP20230CA, MS424HP19230CA,

9A423YOGX, 12A422YOGX, 18A420ZOGX, 24A419ZOGX,

9H423YOGX, 12H422YOGX, 18H420ZOGX, 24H419ZOGX

o25 amp circuit breaker, #12 AWG copper wire from outdoor unit to power disconnect

MS412A22230CA, MS412HP22230CA, 12A422ZOGX, 12H422ZOGX

o15 amp circuit breaker, #14 AWG copper wire from outdoor unit to power disconnect

•Interconnect wire cable:

o4C - 16 AWG per indoor unit.

•Refrigerant - R410A required for additional line set charge.

•Sealing putty.

•1/4” to 5/16” access fitting adaptor (PN: QC-S5)

•Mounting hardware - Wall anchors, condenser pad etc.

•Optional: Condensate pump, miniature, 115 VAC P/N DE05LUA520 (4100122).

Condensate pump, miniature, 230 VAC P/N DE05LUA720 (4100123).

Condensate pump, accessory kit P/N GC1KFX2010 (4100124).

Surge protector (highly recommended)

Note: Condensate pump P/N 77B2033 (4100123) can not be connected to the indoor unit. Power

connections must be made at outdoor unit supply power.

Main system breaker or disconnect sized per unit requirements should be mounted adjacent to outdoor unit.

950-0158 - 4 - September 25, 2010

Decorative Channel

Route the bundled piping and wiring to the outdoor unit and connect per the OUTDOOR UNIT installation

instructions. Our Plastic-Duct piping and wiring duct work provides a convenient and professional looking

system to route and protect the pipes and wires. Please see the illustrations below:

Wall Bracket

The outdoor unit may be mounted using a wall bracket (optional) (Our Catalog # BR-440L for up to 440 lbs),

or located in a freestanding position on the floor or pad (preferably slightly elevated).

INSTALLATION CONSIDERATIONS

General Information

Application

Check the application of the unit prior to installation. Certain applications require additional components or

installation parameters.

Computer or Data Server Rooms

These require approximately 12,000 BTU/H capacity per 250 ft² of room size (Based on 8’ ceiling height).

Offices and Commercial Spaces, Churches etc.

These require approximately 12,000 BTU/H capacity per 400 ft² of room size (Based on 8’ ceiling height).

Residential, Bedrooms, Family Rooms etc.

These require approximately 12,000 BTU/H capacity per 600 ft² of room size (Based on 8’ ceiling height).

Note: This system does not contain a back-up heat source and is NOT recommended as a primary

source of heat.

950-0158 - 5 - September 25, 2010

Selecting locations for the Indoor unit

1. Determine the best location for

mounting the Indoor unit. Ensure

the dimensions requirement

indicated be the arrows are

followed.

2. Paying close attention to the air

circulation in the room, these

units throw air approximately

15ft. Ensure that no obstacles

impede airflow.

3. Do not mount this unit close to a

heat source or a doorway.

Selecting location for Outdoor

unit

1. Determine the best location for

mounting the outdoor unit.

Ensure the dimensions

requirement indicated be the

arrows are followed.

2. Do not mount this unit close to

combustibles or heat sources.

3. Although this unit is fairly quiet

when in operation, do not mount

where noise issues could be a

problem.

Please view Figure 1

Line set length

Locate the Indoor and Outdoor units as close together as possible. Line set height cannot exceed

specifications.

Models Max Line Length Max Vertical Height Design Length Additional Charge

9K & 12K 65.6 ft 32.8 ft 24.9 ft

18K & 24K 98.4 ft 49.2 ft 26.2 ft

See specifications on

pages 17 and 19.

NOTE:

1. Refrigerant must be added when line set total length exceeds the max design length.

2. An oil trap is recommended if the indoor unit is over 19 feet in height from the outdoor unit.

Space to the ceiling

Space to the wall

Space to the floor

Air outlet side

Space to the wall

95"

20"

12"

Airoutletside

Air inlet side

Space to the wall

Space to the obstruction

Figure 1

950-0158 - 6 - September 25, 2010

INDOOR UNIT (EVAPORATOR) INSTALLATION

1. Clearances and Mounting requirements (Indoor Unit)

Enough space should be left around the unit to facilitate maintenance. Please view Figure. 2 for

recommended dimensions:

(Rear piping hole)

Left Right

Mark the middle Level

Min.

(Rear piping hole)

Min.

Wall

Min.

Minimum clearances as noted above. Mount indoor unit with a minimum 6” to ceiling. Indoor unit should have

approximately 16 feet of unobstructed area directly in front for proper air flow for the 9K and 12K indoor units.

The 18K and 24K should have approximately 25 feet of unobstructed area directly in front. Line set can exit at

the right or left rear or ends of the indoor unit.

Be sure that the indoor unit is mounted firmly to the wall, and that the wall structure will support the weight of

the unit.

Be sure that the air inlet and outlets are unobstructed.

Be sure that all clearances are as noted in the above Figure 2.

This unit is not designed to be connected to a plug-in outlet.

Do not install this unit:

Near a heat source

In direct sunlight

In areas where hazardous chemicals are present

Near combustible gases

2. Mounting the Wall Plate

After determining an acceptable location for the indoor unit, fasten the wall bracket securely to the wall using

the proper anchors (installer supplied). Be sure the wall bracket is level and firm to the wall using a minimum

of 4 screws or wall anchors. Failure to mount the wall bracket level can result in improper condensation

drainage.

3. Wall Penetration

Using the measurements in Figure 2, determine the exit point of the

line set. For best results, the right rear is preferred. Left rear exit of

the line set requires that the line set be connected to the indoor unit

prior to mounting it to the wall plate. If desired the line set may run

along the inside wall by removing the cutouts along the back edge

of the case. Line sets mounted along the inside wall may be

covered with Plasti-Duct line set covering (See page 4).

Cut a 2-5/8” hole slanted downward towards the outside.

Hole diameter is based on wall sleeve made from 2-1/2” PVC pipe.

Wall penetration should be slanted slightly downward to the outside

a minimum of 3/8" to provide proper condensation drainage.

Wall sleeve can now be inserted into the hole. Insert sleeve from

the inside to the outside. The sleeve should be approximately

3/16” longer than the wall thickness.

Inside Outside

Wrap with

tape

Figure 2

Figure 3

950-0158 - 7 - September 25, 2010

4. Identify Line Sets

Mark the line sets as necessary to prevent

crossed connections. Crossed line sets will

prevent proper operation.

5. Mounting the Indoor Unit

If right rear exit of line set is used the indoor

unit can now be mounted. Remove retaining

clips from back of unit to allow access to the

line set stubs. Gently form the line set stubs

straight outward. Use caution when forming the

line set; being careful not to kink the copper

lines.

See Figure 4.

6. Connecting Line Set

If installer determines the line set should be connected at this time, see page 9 for torque standards.

7. Hang the Indoor Units

Once lines are straight, carefully slide the ends

of line set out through the wall sleeve. Hook

the indoor unit onto the top clips of the wall

plate. Carefully lower the bottom portion of the

indoor unit towards the wall, snapping it into

the clips at the bottom of the unit. See Figure 5.

If using the left rear exit run lines from outside

to indoor unit. Form line set to mate to indoor

unit stubs and connect prior to mounting to

indoor unit. If necessary run lines along inside

wall and carefully remove the proper cut out from the indoor unit housing. Line sets may be covered with

Plasti-Duct for a more professional job (see page 4).

8. Inspect the Installation

Ensure that the hooks at the top and bottom of

the inside unit are firmly locked in place.

9. Verify the Indoor Unit is Properly Leveled.

Accurate leveling is critical to prevent water

damage during operation.

10. Check the Drain Hose

Observe that the condensate drain pipe does

not curve upward and is in the lower part of the

pipe bundle. See Figure 6.

11. Seal the Hole

Fill the gap between the wall sleeve and the line

set with sealing putty (installer provided) to

prevent outside air and moisture from entering

room (see Figure 7).

Inside Outside

Seal Putty

Drain hose

Curve upward

Figure 6

Figure 7

Figure 4

Pipelines of indoor unit

Drainpipe Rearpipe

Figure 5

Top clips

Bottom clips

950-0158 - 8 - September 25, 2010

OUTDOOR UNIT (CONDENSER) INSTALLATION

The location must allow easy servicing and provide good air circulation as shown in the illustration below:

OUTDOOR

(CONDENSER)

UNIT

Shaded area

must be clear

Mounting the Outdoor (condenser) Unit

Follow the clearance guidelines in the

diagram above. Clearance distances

are minimums. Minimum clearance

above unit is 12" to allow for servicing.

For Heat Pump units, install drain plug

as in Figure 9 (included). Drain hose

not included.

Do not mount this unit close to

combustibles or heat sources.

Although this unit is fairly quiet when

in operation, do not mount this unit

where noise issues could be a problem.

Mount unit on an equipment pad or solid surface, install drain plug and tube as necessary. If wall mounting is

necessary a wall mount bracket may be purchased (BR-440L) for this purpose. Follow mounting instructions

for bracket to ensure safe installation.

Anchor bolts of the proper size and type (Installer provided) must be used.

For best results mount this unit as close as possible to the evaporators. Check maximum line length

specifications before mounting.

MAXIMUM LINE LENGTH MUST NOT BE EXCEEDED!

Figure 8 (Top View)

Figure 9

950-0158 - 9 - September 25, 2010

Torquewrenc

Spanner

Flarenut

Joint Connectionpipe

CONNECTING LINE SET

Refrigerant Tubing

1. After the outside unit is secured to the mounting location (Pad, Wall Brackets, etc.), route the line set(s)

from the Indoor unit to the outdoor unit, and secure with clamps or Plastic-Duct as required.

Installation Notes:

The outdoor unit is supplied with a sufficient refrigerant charge of R410A for a maximum Design

Length, no extra refrigerant required. Beyond this length additional refrigerant is required and must

be weighted in. (see specifications)

Indoor unit contains a small quantity of nitrogen. DO NOT remove the caps until the tubing is ready to be

installed.

NOTE: An oil trap is recommended to be installed if the indoor unit is over 19 feet in height from the outdoor

unit. To prevent kinking, bend tubes using a tubing tool.

CAUTION! WHEN REMOVING THE VALVE CAPS, DO NOT STAND IN FRONT OF VALVES, AS THE

SYSTEM IS UNDER HIGH PRESSURE.

2. Line set can now be terminated (if necessary), to the proper length. Cut the tubing a little longer than

measured distance. Completely remove all burrs from the cross cut section of tubing. Do not allow debris

to fall into copper tube. It is extremely important to clean the copper tubing prior to connecting to system.

3. Install flare nuts and follow standard flaring procedures. Use proper flaring tools for a leakproof

connection. If a flared section is defective, cut it off and follow standard flaring procedures again.

4. After cutting to length, creating the flares and before connecting the line set, clear all foreign materials by

blowing nitrogen through copper tubing. Align the center of the tubing flare with its mating connector.

Screw on the flare nut by hand and tighten the nut with a spanner and torque wrench. See Figure 10.

Note: Exceeding the tightening torque will damage the flare surface.

Tightening Torque Table:

Tube Dia. Tightening Torque

1/4” 11 – 15 lbs. ft

3/8” 25 – 30 lbs. ft

1/2” 36 – 42 lbs. ft

5/8” 43 – 47 lbs. ft

5. Verify that the proper line set is being

connected to the intended port of the outdoor

unit. Connect the line sets to their appropriate

fittings on the outside unit, and torque the flare

fittings per the table above.

Figure 11

Figure 10

DO NOT CROSS WIRES OR CROSS

CONNECT SYSTEMS TO OUTDOOR

UNIT.

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