INSTALLATION MANUAL - Orion Air Conditioning And Refrigeration
Contents
1. ch el El S o OS Ey ch El E E LO N Earth screw amp h LO E J E a S y Cord clamp Sheath Earth screw Earth screw Indoor unit terminal block Outdoor unit terminal block Fig 13 10cm 5cm Connector cord CAUTION 1 Match the terminal block numbers and connection cord colors with those of the indoor unit Erroneous wiring may cause burning of the electric parts Connect the connection cords firmly to the terminal 5 block Imperfect installation may cause a fire FINISHING 1 Insulate between pipes For rear right and bottom piping overlap the connection pipe heat insulation and indoor unit pipe heat insulation and bind them with vinyl tape so that there is no gap For left and left rear piping butt the connection pipe heat insulation and indoor unit pipe heat insulation together and bind them with and vinyl tape so that there is no gap For left and left rear piping wrap the area which accommodates the rear piping housing section with cloth tape For left and left rear piping bind the connection cord to the top of the pipe with vinyl tape For left and left rear piping bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section Temporarily fasten the connection cord along the connection pipe with vinyl tape Wra2. ies Flash tool for Conventional R22 flare tool R410A clutch type Clutch type Wing nut type 6 35 mm 1 4 1 0 to 1 5 1 5 to 2 0 9 52 mm 3 8 1 0 to 1 5 1 5 to 2 0 1 Open the front panel 5 Connect the end of the connection cord securely to the terminal block 2 Remove the front cover 6 Secure the connection cord with the cord clamp 3 Remove the cord clamp 7 Install the front cover with the screw 4 Route the connection cord from behind the indoor unit 8 Close the front panel Fig 9 L Front panel i 2 ie aes rr Front cover Cord clamp cs L Screw Screw Connection cord A CAUTION 1 Match the terminal block numbers and connection 3 Always fasten the outside covering of the connec cord colors with those of the outdoor unit tion cord with the cord clamp If the insulator is Erroneous wiring may cause burning of the elec chafed electric leakage may occur tric parts 4 Securely earth the power cord plug Connect the connection cords firmly to the terminal 5 Do not use the earth screw for an external connector block Imperfect installation may cause a fire Only use for interconnection between two units For authorized service personnel only WARNING 1 For the room air conditioner to operate satisfactory install it as outlined in this installation manual 2 Connect the indoor unit and outdoor unit wit
3. Install a leakage circuit breaker in accordance with the related laws and regulations and electric company standards NOTE These equipment shall be connected to a suitable mains network with a main impedance less than the following 1 257Q The product is intended for use only in premises having a service current capacity gt 100A per phase supplied from a distribution network having a nominal voltage of 230 V and instruct the user to determine in consulation with the supply authority if necessary that the service current capacity at the interface point is sufficient for the equipment OUTDOOR UNIT OUTDOOR UNIT INSTALLATION Set the unit on a strong stand such as one made of concrete blocks A WARNING to minimize shock and vibration 1 Install the unit where it will not be tilted by mor Do not set the unit directly on the ground because it will cause trou than 5 ble 2 When installing the outdoor unit where it may ex posed to strong wind fasten it securely Connector cover removal Fig 10 Remove the two mounting screws Installing the connector cover 1 After inserting the three front hooks then insert the rear hook 2 Tighten the two mounting screws Te jjj Tapping screw ML MN AAAI TAT AT ETL Jj Tabs KAA Hill eM Mh y HN iff Electrical cover AIR PURGE Always use a vacuum pump to purge the air A CAUTION Refrigerant for pu
4. with the air filters attached INSTALLING THE DUST BOXES 1 Install the dust boxes with the air filters attached 2 Close the two latches on the ends of each dust box The latches will click when they are closed Latches Latches Indoor unit housing Air filter Dust box TEST RUNNING Install the front panel and intake Perform test operation and check items 1 and 2 below grille securely If installation is For the test operation method refer to the operating manual imperfect the front panel or intake The outdoor unit may not operate depending on the room temperature In this case press grille may fall off and cause injury the test run button on the remote control unit while the air conditioner is running Point the transmitter section of the remote control unit toward the air conditioner and press the test button with the tip of a ball point pen etc le of the fron oe ie fa el oe H ri ak To end test operation press the remote control unit START STOP button ie the base y When the air conditioner is run by pressing the test run button the OPERATION indicator lamp and TIMER indicator lamp will simultaneously flash slowly CUSTOMER GUIDANCE J INDOOR UNIT Explain the following to the customer IN 1 Is operation of each button on the remote control unit normal accordance with the operating manual 2 Does each lamp light normally 1 Starting and stopping method operation Fig 17 Trans
5. Lower projections Wall hook bracket CONNECTING THE PIPING aS Tee CONNECTION ZS 1 Install the outdoor unit wall cap supplied with the optional installation set or procured 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 Torque tight tighten the nut to the specified tightening torque with a torque wrench wrench Table 2 a i To prevent gas leakage coat the flare FLARING Indoor unit pipe Connection pipe surface with refrigerator oil 1 Cut the connection pipe to the necessary sills bbl abetted tO Table 2 Flare nut tightening torque length with a pipe cutter i Tightening torque standard 2 Hold the pipe downward so that cuttings Flare nut Tightening torque NAD n ka wrench will not enter the pipe and remove the 15 7 to 17 6 Nem 3 Insert the flare nut onto the pipe and flare T s the pipe with a flaring tool i 4 to 41 1 Nem Arm strength 9 52 mm dia 300 to 420 kgfecm gt Insert the flare nut always use the flare nut i attached to the indoor and outdoor units Table 3 Pipe outside diameter respectively onto the pipe and perform the flare processing with a flare tool Use the special R410A flare tool or the conv entional for R22 flare tool When using the conventional flare tool always use an allowance adjustment gauge and secure the A dimension shown in table 3 INDOOR UNIT WIRING
6. SPLIT TYPE ROOM AIR CONDITIONER INSTALLATION MANUAL PART NO 9312791019 01 This air conditioner uses new refrigerant HFC R410A The basic installation work procedures are the same as conventional refrigerant R22 models However pay careful attention to the following points 1 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 prevent erroneous charging with conventional refrigerant R22 and for safety Therefore check beforehand The charging port thread diameter for R410A is 1 2 threads per 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 4 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 side whose composition is stable Special tools for R410A Contents of change Pressure Is high and cannot be measured with a conventional gauge To prevent erroneous mix
7. e unit where people pass MIOChy graver oi housing 4 Take you neighbors into consideration so that they are not disturbed p _ Wall cap by air blowing into their windows or by noise The filters comedut Hi Remote 5 Provide the space shown in Fig 2 so that the air flow is not blocked of the front of the control unit Also for efficient operation leave open three of the four directions indoor unit Remate front rear and both sides K conirolkunit holder ls ae WARNING m z w Install at a place that can withstand the weight of the Conform to Type245 IEC57 se s wad indoor and outdoor units and install positively so that OUTDOOR UNIT 10cmorover the units will not topple or fall mA a 60 cm or over LY ss Le LE S CAUTION 1 Do not install where there is the danger of com bustible gas leakage 2 Do not install near heat sources 30 cm or over fl Il filli T f fi ATHITI 10 cm or over AITTEN Ti iii Jj j Jij NNIT 30 cm or Hii HTT ANLLAD ETAL a lt D D iiil HH rl MME Hf m Jiili A 3 If children under 10 years old may approach the unit take preventive measures so that they can not reach the unit 4 Install the indoor unit on the wall where the height from the floors more than 230 cm f i I Mt SSI Z SS P Indoor unit piping direction The pipi
8. ealant ELECTRICAL REQUIREMENT Always make the air conditioner power supply a special branch circuit Battery Tapping screw big and provide a special switch and receptacle Do not extend the power 4x20 cord eyo Remote control unit Tapping screw small holder P FRONT PANEL REMOVAL AND INSTALLATION REMOVING THE INDOOR UNIT HOUSING Fig 20 1 Remove the two screw caps and then remove the two lower tapping screws 2 Open the front panel and then remove the front cover 3 Remove the four upper tapping screws Note One tapping screw is located behind the front cover 4 Unhook the indoor unit housing from the center projection and remove INSTALLING THE INDOOR UNIT HOUSING 1 Insert the six tabs on the indoor unit housing into the indoor unit 2 Hook the indoor unit housing onto the center projection Indoor unit housing 4 Lower tapping SLIPS Upper tapping screws 3 Install the six tapping screws both upper and lower and then install the Screw caps lt screw Caps ad 4 Install the front cover with the screw GEAN housing Note Install the indoor unit housing with the front panel closed CAUTION Install the indoor unit housing securely Intake grille Center If the indoor unit housing is not installed securely it could fall and cause personal injury REMOVING THE DUST BOXES 1 Open the two latches on the ends of each dust box 2 Remove the dust boxes
9. flow freely Fig 4 Wall cap Inside Wall Outside 3 x 4 over 65 mm hole 5 x 6 INSTALLING THE WALL HOOK BRACKET 1 Install the wall hook bracket so that it is correctly positioned horizon Fig 5 tally and vertically If the wall hook bracket is tiled water will drip to the floor 2 Install the wall hook bracket so that it is strong enough to withstand Wall hook bracket the weight of an adult a Leveling method Fasten the wall hook bracket to the wall with 8 or more screws through A a fT the holes near the outer edge of the bracket Check that there is no rattle at the wall hook bracket of o o oo 00 a k 3 So A o o4 Jo WARNING Tapping screw If the wall pipe is not used the cord interconnecting size large quantity 8 the indoor and outdoor units may touch metal and cause electric leakage CAUTION ES Wall hook Weight Install the wall hook bracket horizontally and bracket String perpendicularly FORMING THE DRAIN HOSE AND PIPE Rear piping Right piping Bottom piping Fig 6 Install the indoor unit piping in the direction of the wall hole and bind the drain hose and pipe together with vinyl tape Fig 6 Install the piping so that the drain hose is at the bottom Wrap the pipes of the indoor unit that are visible from the outside with decorative tape Right outle For Left rear pi
10. h the air conditioner piping and cords available standards parts This installation manual describes the correct connections using the standard accessories and the parts specified in this installation manual 3 Have installation work done by authorized service personnel only 4 Never cut the power cord lengthen or shorten the cord or change the plug 5 Also do not use an extension cord 6 Plug in the power cord plug firmly If the receptacle is loose repair it before using the room air conditioner 7 Do not turn on the power until all installation work is complete 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 conditioner is serviced or moved The maximum length of the piping is 15 m The maximum height difference of the piping is 8 m if the units are further apart than these correct operation can not be guaranteed STANDARD ACCESSORIES The following installation accessories are supplied One set of following parts are necessary in istallation of this product Use them as required Name and Shape Name and Shape Wall hook bracket Drain pipe Connection pipe assembly Connection cord Wall pipe CD 2 Decorative tape Q Vinyl tape Wall cap Saddle Drain hose Cloth tape control Tapping screws unit S
11. he specified refrigerant R410A to enter the refrigerant cycle e If air or other gas enters the refrigerant cycle the pressure inside the cycle will rise to an abnormally high value and cause breakage injury etc SELECTING THE MOUNTING INSTALLATION DIAGRAM OF POSITION INDOOR AND OUTDOOR UNITS Decide the mounting position with the customer as follows 1 INDOOR UNIT Fig 2 1 Install the indoor unit level on a strong wall which is not subject to vibration 2 The inlet and outlet ports should not be obstructed the air should INDOOR UNIT be able to blow all over the room 3 Install the unit near an electric outlet or special branch circuit 4 Do not install the unit where it will be exposed to direct sunlight Wall hoakibracket 5 Install the unit where connection to the outdoor unit is easy 6 7 cm or 6 Install the unit where the drain pipe can be easily installed 7 Take servicing etc into consideration and leave the spaces shown in Fig 2 Also install the unit where the dustbox and the filter can be removed 2 OUTDOOR UNIT 1 If possible do not install the unit where it will be exposed to direct 6 5 cm or over Over 5 cm or over 1 Front panel N sunlight If necessary install a blind that does not interfere with S oye the air flow eZ 2 Do not install the unit where a strong wind blows or where it is very eZ dusty Indoor unit 3 Do not install th
12. ing 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 Charge hose To increase pressure resistance the hose material and base size were changed A conventional vacuum pump can be used by installing a 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 Table 1 Thicknesses of Annealed Copper Pipes that the amount of residual oil is less than 40 mg 10m Do not Thickness mm 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 R410A incurs pressure higher than when using R22 it is necessary to choose adequate materials Thicknesses of copper pipes used with R410A are as shown in Table1 Never us copper pipes thinner than 0 8mm even when it is available on the market WARNING 1 Do not use the existing for R22 piping and flare nuts e If the existing materials are used the pressure inside the refrigerant cycle will rise and cause breakage injury etc Use the special R410A materials 2 When installing and relocating the air conditioner do not mix gases other than t
13. mitter section switching temperature adjustment 3 Do the air flow direction louver operate normally timer air flow switching and other 4 Is the drain normal remote control unit operations 2 OUTDOOR UNIT 2 Dustbox filter air filter and top grill 1 Is there any abnormal noise and vibration during operation removal and cleaning and how to use i oe a8 eater aver g 2 Will noise wind or drain water from the unit disturb the Test run button 3 Give the operating and installation neighbors manuals to the customer 3 Is there any gas leakage POWER 1 The rated voltage of this product is 230 V AC 50 Hz 2 Before turning on the power check if the voltage is within the 220 V 10 to 240 V 10 range 3 Always use a special branch circuit and install a special receptacle to supply power to the room air conditioner 2 When the voltage is low and the air conditioner is difficult to start 4 Use a circuit breaker and receptacle matched to the contact the power company the voltage raised CAUTION 1 The power source capacity must be the sum of the air conditioner current and the current of other electrical appliances When the current contracted capacity is insufficient change the contracted capacity capacity of the air conditioner 5 Do not extend the power cord 6 Perform wiring work in accordance with standards so that the air conditioner can be operated safely and positively 7
14. ng can be connected in the five directions indicated by and in Fig 1 When the piping is connected in direction or cut along the piping groove in the side of the front cover with a hacksaw When connecting the piping in direction cut a notch in the thin wall at the front bottom of the front cover Fig 1 Fig 3 Left piping Right piping 32 cm Left rear piping Rear piping Bottom piping Left bottom piping INDOOR UNIT CUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING 1 Cut a 65 mm diameter hole in the wall at the position shown in Fig Fig 4 4 Wall hook bracket Centering marks 2 When cutting the wall hole at the inside of the installation frame cut the hole within the range of the left and right center marks 40 mm below the installation frame When cutting the wall hole at the outside of the installation frame cut the hole at least 10 mm below over Cut the hole so that the outside end is lower 5 to 10 mm than the inside end Always align the center of the wall hole If misaligned water leakage will occur Cut the wall pipe to match the wall thickness stick it into the wall cap Fasten with fasten the cap with vinyl tape and stick the pipe through the hole vinyl tape The connection pipe is supplied in the installation set Fig 4 For left piping and right piping cut the hole a little lower so that drain i f Wall pipe Y water will
15. p to about 1 3 the width of the tape from the bottom of the pipe so that water does not enter Fasten the connection pipe to the outside wall with saddles etc Fill the gap between the outside wall pipe hole and the pipe with sealer so that rain water and wind cannot blow in Fasten the drain hose to the outside wall etc Outside wall cap Sealer putty Pipe Outdoors Always fasten the outside covering of the connec tion cord with the cord clamp If the insulator is chafed electric leakage may occur Securely earth the power cord plug Do not use the earth screw for an external connector Only use for interconnection between two units Fig 14 Overlap the insulation Connection pipe heat insulation Indoor unit pipe heat insullation Bind the pipes together so FE J Vinyl tape that there is no gap Pipe Drain hose Cloth tape Left piping For connection from the left rear Connection Comedii ee Wall pipe cord J cord A Sa AOS Connection eh Drain hose piping Connection piping Drain hose D BAD BAD BAI l Drain hose l x Gl Holder l Included with the piping x xX Vf A set sold separately or i obtained locally Lifted up Bent Immersed in water
16. ping Left piping Interchange the drain cap and the drain hose CAUTION After removing the drain hose do not forget to install the drain cap For left outlet piping cut off the lt piping outlet cutting groove with a hacksaw Indoor unit drain hose Drain cap 2 Insert the drain cap and drain hose until it butts against the drain port N Remove the drain cap by pulling at Drain hose Drain cap the projection at the end of the cap with pliers etc For left piping and left rear piping align the marks on the wall hook bracket and shape the connection pipe Bend the connection piping at the bend radius of 70 mm or more and install no more than 35 mm from the wall After passing the indoor piping and drain hose through the wall hole Wall hook bracket hang the indoor unit on the hooks at the top and bottom of the wall Connection pipin Ali t mark hook bracket piping ignment marks Installing the indoor unit Hang the indoor unit from the hooks at the top of the wall hook bracket Small piping Large piping Insert the spacer etc between the indoor unit and the wall hook bracket and separate the bottom of the indoor unit from the wall Upper hooks XO Indoor unit AN i Spacer Indoor unit After hooking the indoor unit to the top hook hook the fittings of the indoor unit to the two bottom hooks while lowering the unit and pushing it against the wall Lower slots
17. rging the air is not charged in the 1 Refrigerant must not be discharged int outdoor unit at the factory atmosphere Close the high pressure side valve of the gauge manifold fully and do 2 After connecting the piping check the joints fo not operate it during the following work 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 10 Fully open the valve stems of the 2 way valve and 3 way valv using a hexagon wrench After the valve stem begins to tur turn it with a torque of less than 2 9 Nem 30 kgfecm until stops turning 11 Firmly tighten the 2 way valve and 3 way valve blank cap an the charging port cap Fig 11 Gauge manifold Compound pressure gauge 76 cmHg Omron Pressure gi 3 way valve 2 way valve 6 Slowly loosen the flare nut of the 3 way valve and check if air Ea Flare nut 1 bar N enters then retighten the flare nut SS i f High When the flare nut is loosened the operating sound of the SS A Low pressure press vacuum pump changes and the reading of the compound SS side valve siden pressure gauge goes f
18. rom minus to zero SS ii SS xo SSS C SS Or Valve stem Charg 7 Pump down the system for at least 15 minutes then check if the an Blank ca hose compound pressure gauge reads 0 1 MPa 76 cmHg 1 bar gt D N hose ys Charging port OE Charging port cap Vacuum pu 2 8 Atthe 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 Tightening torque charge hose is disconnected it may be difficult to disconnect 19 6 to 24 5 Nem 200 to 250 kgfecm the charge hose 12 3 to 15 7 Nem 125 to 160 kgf cm OUTDOOR UNIT WIRING 1 Remove the outdoor unit connector cover 2 Remove the control box cover 3 Bend the end of the cord as shown in the figure 4 Connect the end of the connection cord fully into the terminal block Fig 12 Control box Control box cover Cord clamp Connection cord wiring Run the connection cord to the rear of the outdoor unit within the range of the arrows shown in the figure The connector cover becomes difficult to install Connector cord 5 Fasten the sheath with a cord clamp 6 Install the control box cover 7 Install the connector cover
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