INSTALLATION MANUAL
Contents
1. Tapping screw 5 3 Outdoor unit wiring 1 Remove the outdoor unit connector cover 2 Bendthe endofthe cable as shown in the figure 3 Connect the end of the connection cable fully into the terminal block 4 Fasten the sheath with a cable clamp 5 Install the connector cover U COCO iii Ni 4 4 gt N Cable clamp Sheath 30 mm Indoor unit terminal block Outdoor unit terminal block Connection cable wiring Run the connection cable to the rear of the outdoor unit within the range of the arrows shown in the figure The connector cover becomes difficult to install Connection cable Is How to fixed connection cable and power supply cable at the cable clamp After passing the connection cable and power supply cable through the insulation tube fasten it with the cable clamp Insulation tube Use VW 1 1 0 mm thick PVC tube as the insulation tube En 3 9377863119_IM indb 3 1 Use crimp type terminals with insulating sleeves as shown in the figure below to con nect to the terminal block 2 Securely crimp the crimp type terminals to the wires using an appropriate tool so that the wires do not come loose 3 Use the specified wires connect them securely and fasten them so that there is no stress placed2. AOYG18LFC OUTDOOR UNIT INSTALLATION MANUAL INSTALLATION MANUAL For authorized service personnel only PART NO 9377863119 1 20 2011 6 07 25 PM 9377863119_IM indb 1 EC AIR CONDITIONER OUTDOOR UNIT INSTALLATION MANUAL 9377863119 Contents 1 SAFETY PRECAUTIONS K kaka kaka kaka kaka aka kaka ka KAKA k k kk 1 2 ABOUTTHEUNIT i 1 3 SELECTING THE MOUNTING POSITION allkl kaka 2 4 INSTALLATION DIAGRAM ii 2 5 INSTALLATION aaa ia 3 6 PUMPDOWN iii 4 1 SAFETY PRECAUTIONS 1 1 For authorized service personnel only This mark indicates procedures which if improperly per A WARNING ii formed might lead to the death or serious injury of the user For the room air conditioner to operate satisfactory install it as outlined in this installa tion manual Connect the indoor unit and outdoor unit with the air conditioner piping and cords avail able standards parts This installation manual describes the correct connections using the standard accessories and the parts specified in this installation manual Have installation work done by authorized service personnel only Do not use an extension cord Do not turn on the power until all installation work is complete This mark indicates procedures which if improperly performed might possibly result in personal harm to the user or damage to property N C
3. 2 Air filter removal and cleaning and how to use the airflow direction louvers 3 Give the operating and installation manuals to the customer 6 PUMP DOWN 6 1 Pump down PUMP DOWN OPERATION FORCED COOLING OPERATION To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal recover refrigerant by doing the cooling operation or forced cooling operation according to the following procedure When the cooling operation cannot start in winter and so on start the forced cooling operation 1 Do the air purging of the charge hose by connecting the charging hose of gauge mani fold to the charging port of 3 way valve and opening the low pressure valve slightly 2 Close the valve stem of 2 way valve completely 3 Start the cooling operation or following forced cooling operation Keep on pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds The operation in dicator lamp and timer indicator lamp will begin to flash simultaneously during test run The forced cooling operation cannot start if the MANUAL AUTO button is not kept on pressing for more than 10 seconds 4 Close the valve stem of 3 way valve when the reading on the compound pressure gage becomes 0 05 0 Mpa 0 5 0 kg cm 5 Stop the operation Press the START STOP button of the remote control unit to stop the operation Press the MANUAL AUTO button when stopping the operation from indoor unit side It
4. it will be exposed to direct sunlight If necessary Install a blind that does not interfere with the air flow 2 Do not install the unit where a strong wind blows or where it is very dusty 3 Do not install the unit where people pass 4 Take you neighbors into consideration so that they are not disturbed by air blowing into their windows or by noise 5 Provide the space shown in figure so that the airflow is not blocked Also for efficient operation leave open three of the four directions front rear and both sides 6 Install the unit where keep away more than 3 m from the antenna of TV set and Radio 7 Outdoor unit should be set to a place where both drainage and itself will not be affected when heating En 2 9377863119 IM indb 2 1 20 2011 6 09 05 PM 5 INSTALLATION 5 4 HOW TO CONNECT THE WIRE TO THE TERMINALS 5 1 Outdoor unit installation e Set the unit on a strong stand such as thing made of concrete blocks to minimize shock and vibration e Do not set the unit directly on the ground because it will cause trouble Install the unit where it will not be tilted by more than 5 When installing the outdoor unit where it may exposed to strong wind fasten it securely 5 2 Connector cover remove Connector cover removal e Remove the tapping screws Installing the connector cover 1 After inserting the four hooks then push upward 2 Tighten the tapping screws
5. when the outdoor unit is installed be sure to open the front and left side 2 7 Accessories The following installation accessories are supplied Use them as required Installation manual Outdoor 24 cm unit bottom RA na 5 One set of following parts are necessary installation of this product Drain hose QI Connection pipe assembl Connection cable A CAUTION Wall pipe Decorative tape Vinyl tape Wall cap Saddle In the area with heavy snowfall if the intake and outlet of outdoor unit is blocked with Drain hose snow it might become difficult to get warm and it is likely to cause of the breakdown Tapping screws Please construct a canopy and a pedestal or place the unit on a high stand local Sealant configured 3 SELECTING THE MOUNTING POSITION Decide the mounting position with the customer as follows When the outdoor temperature is 0 C or less do not use the accessory drain pipe and drain cap If the drain pipe and drain cap are used the drain water in the pipe may freeze in extreme cold weather Reverse cycle model only Do not set to a place where there is oily smoke oil is used in the factory the unit can contact sea breeze sulfide gases will be generated in the hot spring area corrosive gases will be generated animal may urine on the unit and ammonia will be generated and a dusty place 3 1 Outdoor unit 1 If possible do not install the unit where
6. AUTION When installing pipes shorter than 3 m sound of the outdoor unit will be transferred to the indoor unit which will cause large operating sound or some abnormal sound This installation manual describes how to install the outdoor unit only To install the indoor unit refer to the installation manual included with the indoor unit Be careful not to scratch the air conditioner when handling it After installation explain correct operation to the customer using the operating manual Let the customer keep this installation manual because it is used when the air condi tioner is serviced or moved The maximum length of the piping is 25 m The maximum height difference of the pip ing is 20 m if the units are further apart than these correct operation cannot be guar anteed 2 ABOUT THE UNIT 2 1 Precautions for using R410A refrigerant The basic installation work procedures are the same as conventional refrigerant R22 models However pay careful attention to the following points Since the working pressure is 1 6 times higher than that of conventional refrigerant R22 models some of the piping and installation and service tools are special See the table below Especially when replacing a conventional refrigerant R22 model with a new refrigerant R410A model always replace the conventional piping and flare nuts with the R410A piping and flare nuts Models that use refrigerant R410A have a different charging port thre
7. ad diameter to pre vent erroneous charging with conventional refrigerant R22 and for safety Therefore check beforehand The charging port thread diameter for R410A is 1 2 inch En 1 9377863119_IM indb 1 Be more careful that foreign matter oil water etc does not enter the piping than with refrigerant R22 models Also when storing the piping securely seal the opening by pinching taping etc When charging the refrigerant take into account the slight change in the composition of the gas and liquid phases And always charge from the liquid phase where refrigerant composition is stable 2 2 Special tools for R410A Pressure is high and cannot be measured with a conven tional R22 gauge To prevent erroneous mixing of other refrigerants the diameter of each port has been changed It is recommended the gauge with seals 0 1 to 5 3 MPa 1 to 53 bar for high pressure 0 1 to 3 8 MPa 1 to 38 bar for low pressure To increase pressure resistance the hose material and base Charge hose size were changed A conventional vacuum pump can be used by installing a Vacuum pump vacuum pump adapter Gas leakage detector Special gas leakage detector for HFC refrigerant R410A Copper pipes Gauge manifold It is necessary to use seamless copper pipes and it is desirable that the amount of residual oil is less than 40 mg 10 m Do not use copper pipes having a collapsed deformed or discolored portion especia
8. ard they cannot reach the unit Install the disconnect device with a contact gap of at least 3 mm in all poles nearby the units Both indoor unit and outdoor unit 4 INSTALLATION DIAGRAM e Install the circuit breaker nearby the units 2 5 Operating range Connection Cord Outdoor Cooling Dry Mode Heating Mode Conform to Type245 IEC57 Temperature About 10 to 46 C About 15 to 24 C INDOOR UNIT 10 cm or over OUTDOOR UNIT 60 cm or over 2 6 Additional charge Refrigerant suitable for a piping length of 15 m is charged in the outdoor unit at the factory When the piping is longer than 15 m additional charging is necessary AAA over il Between 15 m and 25 m when using a connection pipe other than that in the table charge additional refrigerant with 20 g 1 m as the criteria SS u TN VON For the additional amount see the table below 10 cm or over RSS a0 Pipe length o SES Additional refrigerant 100 g 200 g 20 gim 30 cm or over N CAUTION When adding refrigerant add the refrigerant from the charging port at the completion of work The maximum length of the piping is 25 m If the units are further apart than this correct operation can not be guaranteed 5 cm or over SHS Do not directly install it on the ground otherwise it will cause failure To obtain better operation ef ficiency
9. indoor unit piping 3 After matching the center of the flare surface and tightening the nut hand tight tighten the nut to the specified tightening torque with a torque wrench Table 1 FLARING 1 Cut the connection pipe to the necessary L length with a pipe cutter 2 Hold the pipe downward so that cuttings will not enter the pipe and remove the burrs 3 Insert the flare nut onto the pipe and flare the pipe with a flaring tool Insert the flare nut always use the flare nut attached to the indoor and outdoor units respectively onto the pipe and perform the flare processing with a flare tool Use the special R410A flare tool or the conventional for R22 flare tool When using the conventional flare tool always use an allowance adjustment gauge and secure the A dimension shown in table 2 Check if L is flared uniformly and is not cracked or scratched BENDING PIPES 1 When bending the pipe be careful not to crush it 2 To prevent breaking of the pipe avoid sharp bends Bend the pipe with a radius of curvature of 70 mm or over 3 If the copper pipe is bend the pipe or pulled to often it will become stiff Do not bend the pipes more than three times at one place Torque wrench To prevent gas leakage coat the flare surface with refrigerator oil 1 20 2011 6 09 36 PM i MN Table 1 Flare nut tightening torque Diameter mm x Torque N m 6 35 mm dia 17x 16 18 12 7 mm dia 26
10. is not necessary to press on keeping for more than 10 seconds During the pump down operation make sure that the compressor is turned off before you remove the refrigerant piping Do not remove the connection pipe while the compressor is in operation with 2 way or 3 way valve open This may cause abnormal pressure in the refrigeration cycle that leads to breakage and even injury En 4 1 20 2011 6 10 41 PM 9377863119 IM indb 5 1 20 2011 6 22 23 PM
11. lly on the interior surface Otherwise the expansion value or capillary tube may become blocked with contaminants As an air conditioner using R410A incurs pressure higher than when using R22 it is neces sary to choose adequate materials Thicknesses of copper pipes used with R410A are as shown in Table1 Never use copper pipes thinner than 0 8 mm even when it is available on the market Thicknesses of Annealed Copper Pipes Maximum height between indoor and out door 25 m 82 ft 20 m 66 ft N WARNING Do not use the existing for R22 piping and flare nuts If the existing materials are used the pressure inside the refrigerant cycle will rise and cause failure injury etc Use the special R410A materials Nominal Outer Maximum a j Thickness diameter diameter length When installing and relocating the air conditioner do not mix gases other than the specified refrigerant R410A to enter the refrigerant cycle If air or other gas enters the refrigerant cycle the pressure inside the cycle will rise to an abnormally high value and cause failure injury etc The rated voltage 230 V AC 50 Hz N WARNING The rated voltage of this product is 230 V AC 50 Hz Before turning on the power check if the voltage is within the 220 V 10 to 240 V 10 range Always use a special branch circuit and install a special receptacle to supply power to the room air conditioner Use a circuit breaker and
12. on the terminals 4 Use an appropriate screwdriver to tighten the terminal screws Do not use a screw driver that is too small otherwise the screw heads may be damaged and prevent the screws from being properly tightened 5 Do not tighten the terminal screws too much otherwise the screws may break 6 See the table below for the terminal screw tightening torques Tightening torque 1 2 to 1 8 N m 12 to 18 kgf cm 2 0 to 3 0 N m 20 to 30 kgf cm M4 screw M5 screw Strip Crimp type terminal 10 mm Screw with special washer Crimp type terminal Vai K Terminal board lt Terminal block Screw with special washer Wire Crimp type terminal Wire N CAUTION Match the terminal block numbers and connection cable colors with those of the indoor unit Erroneous wiring may cause burning of the electric parts Connect the connection cables firmly to the terminal block Imperfect installation may cause a fire Always fasten the outside covering of the connection cable with the cable clamp If the insulator is chafed electric leakage may occur Securely earth the power cable plug Do not use the earth screw for an external connector Only use for interconnection between two units 5 5 Connecting the piping CONNECTION 1 Install the outdoor unit wall cap supplied with the optional installation set or pro cured at the site to the wall pipe 2 Connect the outdoor unit and
13. receptacle matched to the capacity of the air conditioner Do not extend the power cable Perform wiring work in accordance with standards so that the air conditioner can be operated safely and positively Install a leakage circuit breaker in accordance with the related laws and regulations and electric company standards The circuit breaker is installed in the permanent wiring Always use a circuit that can trip all the poles of the wiring and has an isolation distance of at least 3 mm between the contacts of each pole Z A CAUTION The power source capacity must be the sum of the air conditioner current and the cur rent of other electrical appliances When the current contracted capacity is insufficient change the contracted capacity When the voltage is low and the air conditioner is difficult to start contact the power company the voltage raised 1 20 2011 6 09 01 PM 2 4 Electric requirement N WARNING Install at a place that can withstand the weight of the outdoor units and install positively so that the units will not topple or fall e Electric wire size and fuse capacity MAX ly cabl 2 Do not install where there is the danger of combustible gas leakage Do not install near heat sources Use conformed cable with Type245 IEC57 If children under 10 years old may approach the unit take preventive measures so that e Install all electrical works in accordance to the national stand
14. t Charging port cap Vacuum pump ae Tightening torque Blank cap 2 way valve 20 0 to 25 0 N m 200 to 250 kgf cm ON Blank cap 3 way valve 28 0 to 32 0 N m 280 to 320 kgf cm e e Charging port cap 12 5 to 16 0 N e m 125 to 160 kgf cm 5 7 TEST RUN e Perform test operation and check items below e For the test operation method refer to the operating manual e The outdoor unit may not operate depending on the room temperature In this case press the test run button on the remote controller while the air conditioner is running Point the transmitter section of the remote controller toward the air conditioner and press the test run button with the tip of a ball point pen etc e To end test operation press the remote controller START STOP button 9377863119 _IM indb 4 When the air conditioner is run by pressing the test run button the OPERATION indica tor lamp and TIMER indicator lamp will simultaneously flash slowly OUTDOOR UNIT 1 Is there any abnormal noise and vibration during Transmitter section operation 2 Will noise wind or drain water from the unit disturb the neighbors 3 Is there any gas leakage Test run button 5 8 CUSTOMER GUIDANCE Explain the followings to the customer in accordance with the operating manual 1 Starting and stopping method operation switching temperature adjustment timer airflow switching and other remote controller operations
15. valve and check if air enters then retighten the flare nut When the flare nut is loosened the operating sound of the vacuum pump changes and the reading of the compound pressure gauge goes from minus to zero 7 Pump down the system for at least 15 minutes then check if the compound pressure gauge reads 0 1 MPa 76 cmHg 1 bar 8 At the end of pump down close the low pressure side gauge of the gauge manifold fully and stop the vacuum pump 9 Slowly loosen the valve stem of the 3 way valve When the compound pressure gauge reading reaches 0 1 0 2 MPa retighten the valve stem and disconnect the charge hose from the 3 way valve charging port If the stem of the 3 way valve is opened fully before the charge hose is disconnect ed it may be difficult to disconnect the charge hose 10 Fully open the valve stems of the 2 way valve and 3 way valve using a hexagon wrench After the valve stem begins to turn turn it with a torque of less than 2 9 N m 30 kgf cm until it stops turning 11 Firmly tighten the 2 way valve and 3 way valve blank cap and the charging port cap Nr _ Gauge manifold Compound pressure gauge Pressure gauge 0 1 MPa 3 way valve 2 Way valve 76 cmHg SA i gar Flare nut 1 bar CA oN High N SS Low pressure pressure SS side valve side valve SS closed SS SS SS 2 Valve stem SES PE Charge S gt Bank cap hose gt Charge hose gt Charging por
16. x 49 61 Table 2 Pipe outside diameter Flare tool for 26 35 mm ir 212 7 mm 172 Fasten a flare nut with a torque wrench as instructed in this manual If fastened too tight the flare nut may be broken after a long period of time and cause a leakage of refrigerant Pipe outside diameter During installation make sure that the refrigerant pipe is attached firmly before you run the compressor Do not operate the compressor under the condition of refrigerant piping not attached properly with 2 way or 3 way valve open This may cause abnormal pres sure in the refrigeration cycle that leads to breakage and even injury 5 6 Air purge Always use a vacuum pump to purge the air Refrigerant for purging the air is not charged in the outdoor unit at the factory Close the high pressure side valve of the gauge manifold fully and do not operate it during the following work Refrigerant must not be discharged into atmosphere After connecting the piping check the joints for gas leakage with gas leak detector 1 Check if the piping connections are secure 2 Check that the stems of 2 way valve and 3 way valve are closed fully 3 Connect the gauge manifold charge hose to the charging port of the 3 way valve side with the projection for pushing in the valve core 4 Open the low pressure side valve of the gauge manifold fully 5 Operate the vacuum pump and start pump down 6 Slowly loosen the flare nut of the 3 way
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