INSTALLATION MANUAL
Contents
1. Connection cable eee Power supply cable Cable clamp 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 Z CAUTION Before starting work check that power is not being supplied to the indoor unit and outdoor unit 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 cable firmly to the terminal block Imperfect installation may cause a fire Always fasten the outside covering of the connection cable with the cord clamp If the insulator is chafed electric leakage may occur Securely earth ground the power cable Do not use the earth ground screw for an external connector Only use for intercon nection between two units En 4 5 3 Connecting the piping BENDING PIPES 1 When bending the pipe be careful not to crush it 2 To prevent breaking of the pipe avoid sharp Check if L is flared uniformly and bends is not cracked or scratched Bend the pipe with a radius of curvature of 150 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 L FLARING 1 Cut the connection pipe to the necessary lengt2. E 4 B PUMP Ra 6 Notes This 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 sure to read this manual thoroughly before the installation Hand this manual together with the operating manual to the customer Request the customer to keep them on hand for future use such as for relocating or repairing the unit After the installation explain correct operation to the customer by using the operating manual 1 SAFETY PRECAUTIONS 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 such as for relocating or repairing the unit A This mark indicates procedures which if improperly performed WARNING might lead to the death or serious injury of the user This mark indicates procedures which if improperly performed A CAUTION might possibly result in personal harm to the user or damage to property Never touch electrical components immediately after the power supply has been turned off Electrical shock may occur After turning
3. 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 units blocked with snow it might become difficult to get warm 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 5 1 Outdoor unit installation ae 2 poo Tapping screw Connector cover removal e Remove the tapping screw Installing the connector cover 1 After inserting the four hooks then slide the cover 2 Tighten the tapping screw Front hooks Rear hooks Connector cover 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 Outdoor unit wiring 1 CONNECTION DIAGRAMS Power supply EARTH 2 Power line N L 3 2 2 1 EARTH GROUND Control line EARTH S Outdoor unit side terminal Indoor unit side terminal Earth Ground line 2 CABLE PREPARATION When stripping off the coating of a lead wire always use a special tool such as a wire stripper If there is no special tool available carefully strip the coating with a knife etc Keep the earth ground wire longer than the other wires Connection cable and power cable
4. 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 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 table below Never use copper pipes thinner than 0 8mm even when it is available on the market Thicknesses of Annealed Copper Pipes 2 5 Pipe outside diameter 6 95 mm 140 Scare ai ies 9 52 mm 3 8 in Installation Manual This manual 12 70 mm 1 2 in 15 88 mm 5 8 in 19 05 mm 3 4 in 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 Drain pipe For outdoor unit drain piping work 0 7 i 2 6 Limitation of refrigerant piping length A The
5. 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 children 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 R4 refrigerant The basic installation work procedures are the same as conventional refrigerant R22 models Ho
6. 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 rupture 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 t
7. the vacuum pump and start pump down 5 Check that the compound pressure gauge reads 0 1 MPa 76 cmHg operate the vacuum pump for at least 1 hour 6 At the end of pump down close the valve of the gauge manifold fully and stop the vacuum pump It checks that leave as it is for about 10 minutes and a needle does not return 7 Disconnect the charge hose from the 3 way valve charging port 8 Remove the blank caps and fully open the spindles of the 2 way and 3 way valves with a hexagon wrench torque 6 to 7 N m 60 to 70 kgf cm 9 Tighten the blank caps and charging port cap of the 2 way valve and 3 way valve to the specified torque Checking gas leaks with nitrogen gas 1 Check if the piping connections are secure Remove the cap of 3 way valve and connect the gauge manifold charge hoses to the charging port of the 3 way valve 3 Pressurize with nitrogen gas using the 3 way valve charging port 4 Do not pressurize up to the specified pressure all at once but do so gradually Increase the pressure up to 0 5 MPa 5 kgf cm let it sit for about five minutes and then check for any decrease in pressure Increase the pressure up to 1 5 MPa 15 kgf cm let it sit for about five minutes and then check for any decrease in pressure Increase the pressure up to the specified pressure the pressure designed for the product and then make a note of it 5 Let it sit at the specified pressure and if there is
8. total maximum pipe lengths and height difference of this product are shown in the table A WARNING If the units are further apart than this correct operation cannot be guaranteed 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 Always use a special branch circuit and install a special receptacle to supply power to the room air conditioner Pipe length Maximum height i d Use a circuit breaker and receptacle matched to the capacity of the air conditioner Peien atl Do not extend the power cable Perform wiring work in accordance with standards so that the air conditioner can be operated safely and positively 2 7 Additional Install leakage circuit breaker in accordance with the related laws and regulations Refrigerant suitable for a piping length of 15 is charged the outdoor unit at the factory and electric company standards When the piping is longer than 15 m additional charging is necessary For the additional amount see the table below The circuit breaker is installed in the permanent wiring Always use a circuit that can Pipe length trip all the poles of the wi
9. 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 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 rupture and even injury En 6
10. AIR CONDITIONER OUTDOOR UNIT INSTALLATION MANUAL INSTALLATION MANUAL For authorized service personnel only ili ill iilii Mi MI TM I m INSTALLATIONSANLEITUNG Nur f r autorisiertes Personal il iili Ji iiil iil iil MANUEL D INSTALLATION Pour le personnel agr uniquement MANUAL DE INSTALACI N Solo para personal autorizado Espa ol Fran ais Deutsch English MANUALE D INSTALLAZIONE Ad uso esclusivo del personale autorizzato Italiano ETXEIPIAIO ET KATAZTAZHZ Fia EEOUDIOSOTNUEVO CEPBiIC MANUAL DE INSTALAGAO Apenas para t cnicos autorizados KURULUM KILAVUZU Yetkili servis personeli i indir T rk e Portugu s EAAnvika PART No 9377863195 AIR CONDITIONER OUTDOOR UNIT INSTALLATION MANUAL 9377863195 Contents 1 2 fase 1 3 SELECTING THE MOUNTING POSITION 3 4 INSTALLATION DIAGRAM 3 Be INSTABLATIION
11. Earth Ground wire x Za How to connect wiring to the terminal Caution when wiring cable 1 Use crimp type terminals with insulating sleeves as shown in the figure to connect to the terminal block 2 Securely clamp 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 screwdriver 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 Strip 10mm Screw with special washer Crimp type terminal Sleeve Screw with special washer g Crimp type terminal 2 Wire Crimp type terminal RR Terminal blocks Wire Tightening torque N m kgf cm 1 2 to 1 8 12 to 18 screw 3 OUTDOOR UNIT 1 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 Control box Cable clamp screw screw
12. ange 198 264 V CAUTION Operation cannot be guaranteed if the correct combination of pipes valves etc is not Cable Cable size mm _ used to connect the indoor and outdoor units Type 60245 2cable Earth Power supply cable IEC66 Ground 19230V 2 9 Heat insulation around connection pipes 4 0 60245 3cable Earth requirements IEC57 Ground 1 230V 1 Selected sample Select the correct cable type and size according to the country A CAUTION region s regulations 7 a Max wire length Set a length so that the voltage drop is less than 2 Increase the Install heat insulation around both the gas and liquid pipes wire diameter when the wire length is long Failure to do so may cause water leaks i Use heat insulation with heat resistance above 120 C Reverse cycle model only In addition if the humidity level at the installation location of the refrigerant piping is Connection cable _ i expected to exceed 70 install heat insulation around the refrigerant piping If the Circuit breaker over current Current 25 A expected humidity level is 70 80 use heat insulation that is 15 mm or thicker and if Earth leakage breaker Leakage current 30mA 0 1sec or less the expected humidity exceeds 80 use heat insulation that is 20 mm or thicker If heat insulation is used that is not as thick as specifie
13. d condensation may form on 2 Select the appropriate breaker of the described specification according to the national the surface of the insulation of regional standards In addition use heat insulation with heat conductivity of 0 045 W m kK or less Select the breaker that enough load current can pass through it at 20 Before starting work check that power is not being supplied to all poles of the indoor unit and outdoor unit Connect the connection pipes according to 5 3 Connecting the piping in this installation Install all electrical works in accordance to the national standard manual 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 e Install the circuit breaker nearby the units En 2 3 SELECTING THE MOUNTING POSITION With considering written conditions below select an appropriate installing location in consultation with the customer Securely install the outdoor unit at a location that can withstand the weight of the unit Otherwise the outdoor unit may fall and cause injury 600mm or more Be sure to install the outdoor unit as prescribed so that it can withstand earthquakes or strong winds Improper installation can cause the unit to topple or fall or other accidents Do not install the outdoor unit in the following areas Area with high salt content such as at the seaside It will deteriorate meta
14. h 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 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 Tighten with two wrenches Wrench fixed Torque Flare nut wrench To prevent gas leakage coat the flare Connection pipe surface with refrigerator oil Indoor unit pipe Table 1 Flare nut size and tightening torque Flare nut mm in 6 35 1 4 dia 9 52 3 8 dia 12 70 1 2 dia 15 88 5 8 dia 19 05 3 4 dia Tightening torque Nem kgfecm 16 to 18 160 to 180 32 to 42 320 to 420 49 to 61 490 to 610 63 to 75 630 to 750 90 to 110 900 to 1100 Table 2 Pipe outside diamete
15. l parts causing the parts to fail or the unit to leak water Area filled with mineral oil or containing a large amount of splashed oil or steam It will deteriorate plastic parts causing the parts to fail or the unit to leak water If the space is larger than that is stated the condition will be the same as that there are Area that generates substances that adversely affect the equipment such as sulfuric no obstacles gas chlorine gas acid or alkali It will cause the copper pipes and brazed joints to 2 corrode which can cause refrigerant leakage Area containing equipment that generates electromagnetic interference It will cause the control system to malfunction preventing the unit from operating normally Area that can cause combustible gas to leak contains suspended carbon fibers or flammable dust or volatile inflammables such as paint thinner or gasoline If gas leaks and settles around the unit it can cause a fire Area that has heat sources vapors or the risk of the leakage of flammable gas in the vicinity where small animals may live It may cause failure smoke or fire if small ani mals enter and touch internal electrical parts Area where animals may urinate on the unit or ammonia may be generated When there are obstacles at the back side with the installation of more than one unit 1 If possible do not install the unit where it will be exposed to direct
16. no decrease in pressure then it is satisfactory If a pressure decrease is confirmed there is a leak so it is necessary to specify the leak location and make minor adjustments Discharge the nitrogen gas and starting removing the gas with a vacuum pump Open the valve of the gauge manifold fully 8 Operate the vacuum pump and start pump down Check that the compound pressure gauge reads 0 1 MPa 76 cmHg operate the vacuum pump for at least 1 hour 10 At the end of pump down close the valve of the gauge manifold fully and stop the vacuum pump 11 Disconnect the charge hose from the 3 way valve charging port 12 Remove the blank caps and fully open the spindles of the 2 way and 3 way valves with a hexagon wrench torque 6 to 7 N m 60 to 70 kgf cm 13 Tighten the blank caps and charging port cap of the 2 way valve and 3 way valve to the specified torque Gauge manifold Compound pressure gauge Pressure gauge 2 0 1 3 way valve way valve 76 cmHg Flare nut 1b S3 SS High SS Low pressure pressure SS side valve side valve tt SS closed SS SS SSS Val t SS alve stem SS Charge Blank cap Charge hose Charging port D Vacuum pump 6 35 mm 1 4 in 20 to 25 N m 200 to 250 kgf cm 9 52 mm 3 8 in 20 to 25 N m 200 to 250 kgf cm Blank cap 12 70 mm 1 2 in 28 to 32 N m 280 to 320 kgf cm Charging port cap 15 88 mm 5 8 in 30
17. o 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 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 rupture and even injury En 1 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
18. r Pipe outside diameter Dimension A mm i Gaol 6 35 1 4 9 52 3 8 12 70 1 2 0100 5 15 88 5 8 19 05 3 4 N CAUTION Fasten flare nut with a torque wrench as instructed this manual If fastened too tight the flare nut may be broken after a long period of time and cause a leakage of refrigerant 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 4 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 Gas leak checks are performed using either vacuum or nitrogen gas so select the proper one depending on the situation En 5 Checking gas leaks with vacuum 1 Check if the piping connections are secure 2 Remove the cap of 3 way valve and connect the gauge manifold charge hoses to the charging port of the 3 way valve 3 Open the valve of the gauge manifold fully 4 Operate
19. ring and has an isolation distance of at least 3 mm between the contacts of each pole Additional amount 1009 2009 3009 When adding refrigerant add the refrigerant from the charging port at the completion of work N 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 The maximum length of the piping is 30 m The maximum height difference of the piping is 20 m if the units are further apart than these correct operation cannot be guaran teed When the voltage is low and the air conditioner is difficult to start contact the power company the voltage raised 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 2 4 Electric requirement CEEE A CAUTION The diameters of the connection pipes differ according to the capacity of the indoor unit Refer to the following table for the proper diameters of the connection pipes between the Be sure to install a breaker of the specified capacity _ indoor and outdoor units A 7 i Gas pipe size Liquid pipe size fecha of cables and breaker differs from each locality refer in accordance with Capacity of indoor unit thicknese mim Voltage rating 1 230 V 50 Hz Operating r
20. 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 you neighbors into consideration so that they not disturbed by air blowing into their windows or by noise 5 Provide the space shown in figure so that the air flow is not blocked Also for ef ficient operation leave open three of the four directions front rear and both sides 6 Install the unit where keep away more than 3m from the antenna of TV set and Radio 4 INSTALLATION DIAGRAM 7 Outdoor unit should be set to a place where both drainage and itself will not be af fected when heating INDOOR UNIT When there are obstacles at the back side OUTDOOR UNIT Power supply cable When there are obstacles at the back and front sides 5 cm or over Bolt Fix securely with bolts on a solid block Use 4 sets of commercially Block available M10 bolt nut and washer Do not directly install it on the ground otherwise it will cause failure N E Y we When there are obstacles at the back side s and top Outdoor unit bottom Drain hose En 3 Z CAUTION When the outdoor temperature is 0 C or less do not use the accessory drain pipe and drain cap If the drain pipe and
21. to 35 N m 300 to 350 kgf cm 19 05 mm 3 4 in 35 to 40 N m 350 to 400 kgf cm Charging port cap 12 5 to 16 N m 125 to 160 kgf cm 5 5 Test run 1 Make a TEST RUN in accordance with installation instruction sheet for the indoor unit CHECK ITEMS INDOOR UNIT 1 15 operation of each button on the remote control unit normal 2 Does each lamp light normally 3 Do the air flow direction louver operate normally 4 Is the drain normal 5 Is there any abnormal noise and vibration during operation 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 Do not operate the air conditioner the test running state for a long time For the operation method refer to the operating manual and perform operation check 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
22. wever 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 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
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