INSTALLATION MANUAL
Contents
1. 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 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 Gauge manifold Compound pressure gauge 0 1 MPa oy 76 cmHg 6 Pressure gauge Le 3 way valve 2 way valve E Flare nut 1 bar gt RA L E E o is ZA L2. check beforehand The charging port thread diameter for R410A is 1 2 inch 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 especially on the interior surface Otherwise the expansion value or capillary tube may become blocked with contaminants As an air conditioner using R410
3. 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 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 Check if L is flared uniformly and 1 Cut the connection pipe to the necessary is not cracked or scratched 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 L 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 BENDING PIPES 1 When bending the pipe be careful not to crush it 2 To prevent breaking o
4. 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 rupture and even injury En 1 AN CAUTION Read carefully all security information before use or install the air conditioner Do not attempt to install the air conditioner or a part of the air conditioner by yourself This unit must be installed by qualified personnel with a capacity certificate for handling refrigerant fluids Refer to regulation and laws in use on installation place The installation must be carried out in compliance with regulations in force in the place of installation and the installation instructions of the manufacturer This unit is part of a set constituting an air conditioner It must not be installed alone or with non authorized by the manufacturer The unit must be correctly earthed grounded and the supply line must be equipped with a differential breaker in order to protect the persons The units are not explosion proof and therefore should not be installed in explosive atmosphere This unit contains no user serviceable parts Always consult authorized service personnel to repairs When moving consult authorized service personnel for disconnection and installation of the unit Children should be monitored to ensure they do not play with the device This appliance is not intended for use by persons including chi
5. the remote control unit to stop the operation Press the MANUAL AUTO button when stopping the operation from indoor unit side It is not necessary to press on keeping for more than 10 seconds En 4
6. A 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 30 m 99 ft 20 m 66 ft AN WARNING Nominal Outer E Thickness UP alu diameter diameter length To install a unit that uses R410A refrigerant use dedicated tools and piping materials that have been manufactured specifically for R410A use Because the pressure of R410A refrigerant is approximately 1 6 times higher than R22 failure to use dedicated piping material or improper installation can cause rupture or injury Furthermore it can cause serious accidents such as water leakage electric shock or fire The rated voltage 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 receptacle matched to the capacity of the air conditioner 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 d
7. AIR CONDITIONER OUTDOOR UNIT INSTALLATION MANUAL INSTALLATION MANUAL For authorized service personnel only INSTALLATIONSANLEITUNG Nur f r autorisiertes Personal MANUEL D INSTALLATION Pour le personnel agr uniquement MANUAL DE INSTALACI N Solo para personal autorizado MANUALE D INSTALLAZIONE Ad uso esclusivo del personale autorizzato ET XEIPIAIO ETKATA2TA2H2 ia EGOUCIOdOTNN VO TTPOCWTIIK C PBIC MANUAL DE INSTALA O Apenas para t cnicos autorizados PYKOBOJACTBO TIO YCTAHOBKE Dna ynonHomoseHHoro nepcoHana KURULUM KILAVUZU Yetkili servis personeli i indir ay ams possam EEE Eme pesca a me a PART No 9332809039 AIR CONDITIONER OUTDOOR UNIT INSTALLATION MANUAL 9332809039 Contents 1 SAFETY PRECAUTIONS soe saessosizapasasnonasironimaga srs iaa 1 2 ABOUT TRE UNIT irritada prince 1 3 SELECTING THE MOUNTING POSITION erre ereana 2 4 INSTALLATION DIAGRAM rare 2 5 INSTALLATION sscaassaasenisinocas sala naiondas dos asdi na dona bs COLO cen Ra 3 SS PUMP e e o TO 4 1 SAFETY PRECAUTIONS Be sure to read this manual carefully before installation The warnings and precautions indicated in this manual contain important information pertaining to your safety Be sure to observe them Hand this manual together with the operating manual to the customer Request the customer to keep them on hand for future use suc
8. be Insulation tube Cable clamp Use VW 1 1 0 mm thick PVC tube as the insulation tube 5 4 HOW TO CONNECT THE WIRE TO THE TERMINALS 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 placed 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 e m 20 to 30 kgf cm M4 screw M5 screw Strip Crimp type terminal 10 mm G Screw with special washer Crimp type terminal Pe Terminal board a Terminal block Screw with special washer Wire Crimp type terminal PSP Wire AN 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
9. ct 3 SELECTING THE MOUNTING POSITION Decide the mounting position with the customer as follows 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 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 AN 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 AN CAUTION Do not install where there is the danger of combustible gas leakage Do not install near heat sources If child
10. f 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 Holding spanner E NIK AN Torque wrench To prevent gas leakage coat the flare surface with refrigerator oil Table 1 Flare nut tightening torque Diameter mm x Torque N m 6 35 mm dia 17x16 18 15 88 mm dia 26 X63 75 Table 2 Pipe outside diameter re Conventional R22 Flaring tool R410A clutch type Wing nut type 1 5 to 2 0 1 5 to 2 0 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 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
11. h as for relocating or repairing the unit This mark indicates procedures which if improperly performed A WARNING might lead to the death or serious injury of the user This mark indicates procedures which if improperly performed might possibly result in personal harm to the user or damage to property AN WARNING Never touch electrical components immediately after the power supply has been turned off Electrical shock may occur After turning off the power always wait 10 minutes or more before touching electrical components Request your dealer or a professional installer to install the outdoor unit in accordance with this installation manual an improperly installed unit can cause serious accidents such as water leakage electric shock or fire If the outdoor unit is installed in disregard of the instructions in the installation manual it will void the manufacturer s warranty Do not turn ON the power until all work has been completed Turning ON the power before the work is completed can cause serious accidents such as electric shock or fire If refrigerant leaks while work is being carried out ventilate the area If the refrigerant comes in contact with a flame it produces a toxic gas Installation work must be performed in accordance with national wiring standards by authorized personnel only Do not use this equipment with air or any other unspecified refrigerant in the refrigerant lines Excess pressure can cause a ru
12. istance of at least 3 mm between the contacts of each pole 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 2 4 Electric requirement Electric wire size and fuse capacity Cable Conductor size mm Type Power supply cable MIN Type60245 IEC57 MIN i T 245 IEC57 Connection cable MIN ype60 5 C5 Fuse capacity A 30 2 5 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 Between 15 m and 30 m when using a connection pipe other than that in the table charge additional refrigerant with 20 g 1 m as the criteria For the additional amount see the table below 100 g AN CAUTION When adding refrigerant add the refrigerant from the charging port at the completion of work The maximum length of the piping is 30 m If the units are further apart than this correct operation can not be guaranteed 2 6 Accessories The following installation accessories are supplied Use them as required Installation manual J One set of following parts are necessary installation of this produ
13. ldren with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision or instruction concerning use of the appliance by a person responsible for their safety Children should be supervised to ensure that they do not play with the appliance Do not touch the aluminum fins of heat exchanger built in the indoor or outdoor unit to avoid personal injury when you install or maintain the unit Do not place any other electrical products or household belongings under indoor unit or outdoor unit Dripping condensation from the unit might get them wet and may cause damage or malfunction of your property 2 ABOUT THE UNIT 2 1 Precautions for using R410A refrigerant AN WARNING 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 thread diameter to pre vent erroneous charging with conventional refrigerant R22 and for safety Therefore
14. ow pressure pressure side valve side valve closed Valve stem TS Charge Blank cap hose gt gt Charge hose yp Charging port 7 Charging port cap Vacuum pump Es Tightening torque Blank cap 2 way valve 20 0 to 25 0 N m 200 to 250 kgf cm Charging port cap 12 5 to 16 0 N m 125 to 160 kgf cm Blank cap 3 way valve 28 0 to 32 0 N m 280 to 320 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 When the air conditioner is run by pressing the TEST RUN button the OPERATION indicator lamp and TIMER indicator lamp will simultaneously flash slowly OUTDOOR UNIT 1 Is there any abnormal noise and vibration during operation 2 Will noise wind or drain water from the unit disturb the neighbors 3 Is there any gas leakage Transmitter section TEST RUN button 5 8 CUSTOMER GUIDANCE Explain the followings to the customer in accordance with the operating manual 1 S
15. pture 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 pressure in the refrigeration cycle that leads to rupture and even injury 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 rupture injury etc For the air conditioner to operate satisfactorily install it as outlined in this installation manual Connect the indoor unit and outdoor unit with the air conditioner piping and cable available standards parts This installation manual describes the correct connections using the installation set available from our standard parts Also do not use an extension cable Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation There is not extra refrigerant in the outdoor unit for air purging Using the same vacuum pump for different refrigerants may damage the vacuum pump or the unit Use a clean gauge manifold vacuum pump and charging hose for R410A exclusively During the pump down operation make sure that the compressor is turned off before you remove the refrigerant piping Do
16. ren under 10 years old may approach the unit take preventive measures so that they cannot reach the unit 4 INSTALLATION DIAGRAM INDOOR UNIT 10 cm or over OUTDOOR UNIT 60 cm or over Y AA AA Cf V 30 cm or over 10 cm or over EH 30 cm or over SS 5 cm or over Do not directly install it on the ground otherwise it will cause unit failure To obtain better operation ef ficiency when the outdoor unit is installed be sure to open the front and left side Drain cap SS Drain Es pipe 54 cm 32 cm En 2 When the outdoor temperature is O 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 In the area with heavy snowfall if the intake and outlet of outdoor unit is blocked with snow it might become difficult to get warm and it is likely to cause of the breakdown Please construct a canopy and a pedestal or place the unit on a high stand local configured 5 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 st
17. rong wind fasten it securely 5 2 Connector cover remove Connector cover removal Connector cover e Remove the tapping screws Installing the connector cover mano 1 After inserting the four hooks then push Tapping screw upward Hooks 2 Tighten the tapping screws na ar No Tapping screw 5 3 Outdoor unit wiring Remove the outdoor unit connector cover 2 Bend the end of the 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 Connection cable Connection cable Power supply cable Outdoor unit terminal block Connection cable o E Power supply cable En 3 5 1 Outdoor unit installation Connection cable wiring Run the connection cable to the rear of the outdoor unit within the A range of the arrows shown in the figure The connector cover becomes difficult to install Connection cable Hole 8 cm A 10 cm 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 tu
18. tarting and stopping method operation switching temperature adjustment timer airflow switching and other remote controller operations 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
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