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SPLIT TYPE ROOM AIR CONDITIONER
INSTALLATION MANUAL
(PART No. 9314963032-01)
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) mod-
els, 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.
(2) 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.]
(3) 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
Tool name
Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous
mixing of other refrigerants, the diameter of each port has been changed.
Gauge manifold
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.
Vacuum pump
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
It is necessary to use seamless copper pipes and it is desirable
that the amount of residual oil is less than 40 mg/10m. Do not
use copper pipes having a collapsed, deformed or discolored
portion (especially on the interior surface). Otherwise, the ex-
pansion value or capillary tube may become blocked with con-
taminants.
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 use copper pipes thinner than that in the
table when it is available on the market.
(1) 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 breakage, injury,
etc.(Use the special R410A materials.)
(2) 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 breakage, injury, etc.
When installing pipes shorter than 3m, sound of the outdoor unit will be transferred to the indoor unit, which will
cause large operating sound or some abnormal sound.
SELECTING THE MOUNTING
POSITION
Decide the mounting position with the customer as follows:
1. INDOOR UNIT
(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
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.
(5) Install the unit where connection to the outdoor unit is easy.
(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
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 your neighbors into consideration so that they are not dis-
turbed by air blowing into their windows or by noise.
(5) Provide the space shown in Fig. 2 so that the air flow is not blocked.
Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
WARNING
Install at a place that can withstand the weight of the
indoor and outdoor units and install positively so that
the units will not topple or fall.
CAUTION
(1) Do not install where there is the danger of com-
bustible gas leakage.
(2) Do not install near heat sources.
(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.
[Indoor unit piping direction]
The piping can be connected in the six directions indicated by 1,
2, 3, 4, 5 and 6 in (Fig. 1). When the piping is connected in
direction 1 or 6, cut along the piping groove in the side of the
front panel with a hacksaw.
When connecting the piping in direction 2 or 4, cut a notch in the
thin wall at the front bottom of the front panel.
Fig. 1
6Left piping
1Right piping
5Left-rear piping
3Rear piping
4Left-bottom
2Bottom piping
piping
06J005_9314963032-01
1
(Z24LB)
Contents of change
Table 1 Thicknesses of Annealed Copper Pipes
Thickness (mm)
Nominal
Outer diameter
R410A
diameter
(mm)
1/4
6.35
0.80
5/8
15.88
1.0
WARNING
CAUTION
INSTALLATION DIAGRAM OF
INDOOR AND OUTDOOR UNITS
Fig. 2
[INDOOR UNIT]
Wall hook bracket
6.7 cm or
over
6.5 cm or over
Front panel
40 cm
150 cm or over
or over
(Wall cap)
230 cm or
over
Remote
*The filters come out
control unit
of the front of the
indoor unit.
Remote
control unit
holder
Connection Cord
Conform to Type245 IEC57
60 cm or over
[OUTDOOR UNIT]
10 cm or over
10 cm or over
60 cm or over
• Do not directly install it on
the ground, otherwise it will
5 cm or over
cause failure.
• To obtain better operation efficiency,
when the outdoor unit is installed,
be sure to open the front and left
side.
CAUTION
(1) 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 extremety cold weather.(Reverse cycle model
only)
(2) 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).
For authorized service personnel only.
(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 with 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) Also do not use an extension cord.
(5) Do not turn on the power until all installation work is complete.
(6) When connecting pipes, be sure to install the JOINT PIPE included on the indoor unit.
(7) When connecting outdoor units, do not alter the pipe diameter from 15.88 mm to 12.7 mm.
● 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 30 m. The maximum height difference of the piping is 20 m,
if the units are further apart than these, correct operation can not be guaranteed.
STANDARD ACCESSORIES
The following installation accessories are supplied.
Use them as required.
Name and Shape
Q'ty
Name and Shape
Drain pipe
Wall hook bracket
1
Cloth tape
Tapping screw(big)
Remote control unit
1
Tapping screw(small)
Battery
Seal A
2
Insulation (seal)
Remote control unit
holder
Joint pipe
1
#Length: 600 mm
FRONT PANEL REMOVAL AND INSTALLATION
REMOVING THE FRONT PANEL
(1) Open the open panel, and then remove the top cover and dust box. (For the re-
moval method of dust box, please refer to the OPERATING MANUAL or Dust Box)
(2) Remove the top grille. (For the removal method of top grille, please refer to
the OPERATING MANUAL)
(3) Remove the screw cap, and then remove the fixed screws (3 places).
(4) Press the under cover with hand at [] mark and pull out, and remove inside
hooks (2 places) from the wall hook bracket.
(5) Remove the top hooks of under cover (2 places at left and right).
5 cm or over
(6) Remove the front fixed screws (7 places).
(7) Push the lower side of front panel to outside, and remove the lower hooks
from the body.
(8) After pull out the upper hooks inside the front panel (2 places at right side and
left upper body, 1 place in the center upper body), pull them back, and re-
Open panel
move the front panel.
INSTALLING THE FRONT PANEL
(1) Cover the front panel onto the body from the front side, and mount the upper,
central and lower hooks.
(2) Install the front fixed screws (2 places at left and right side above the body, 1
place in the center of the body, 2 places under the body, 2 places in the center,
altogether 7 places).
JOINT
(3) Install the top hooks of under cover (2 places at left and right).
PIPE
(4) Install the inside hooks (2 places) and front hooks (2 places) of under cover.
(5) Install fixed screws (3 places) and screw cap.
(6) Install the top grille.
(7) Fix with screws, install top cover and dust box.
CAUTION
● Be sure to remove the top grille at the position where
the front panel is installed and removed.
• Be careful that the top grille may fall and cause per-
sonal injury.
CAUTION
25 cm or
To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal, recover refrig-
over
Install the open panel and top
erant 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.)
grill securely. If installation is
1 Do the air purging of the charge hose by connecting the charging hose of gauge manifold to the
imperfect, the open panel or
2 Close the valve stem of 2 way valve completely.
top grill may fall off and
3 Start the cooling operation or following forced cooling operation.
cause injury.
CUSTOMER GUIDANCE
Explain the following to the cus-
tomer in accordance with the oper-
ating manual:
4 Close the valve stem of 3 way valve when the reading on the compound pressure gage becomes
(1) Starting and stopping method,
operation switching, tempera-
5 Stop the operation.
ture adjustment, timer, air flow
switching, and other remote
control unit operations.
(2) Dustbox, air filter and top grill
removal and cleaning, and how
to use the air louvers.
(3) Give the operating and instal-
lation manuals to the cus-
tomer.
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 recep-
tacle to supply power to the room air conditioner.
(4)
Use a circuit breaker and receptacle matched to the capacity of
the air conditioner.
(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.
(2)
When the voltage is low and the air conditioner is difficult to start, contact the power company the voltage raised.
2006.09.26, 15:40
WARNING
One set of following parts are necessary in istallation of this product.
Q'ty
Connection pipe assembly
Connection cord
1
Wall pipe
Decorative tape
Vinyl tape
Wall cap
1
Saddle
Drain hose
Tapping screws
Sealant
8
ELECTRICAL REQUIREMENT
2
• Electric wire size and fuse capacity:
Power supply cord (mm
)
2
1
Connection cord (mm
)
2
Fuse capaclity (A)
• Install the disconnect device with a contact gap of at
least 3 mm nearby the units. (Both indoor unit and out-
1
door unit)
• Always make the air conditioner power supply a spe-
cial branch circuit and provide a special breaker.
• Always use Type245 IEC57 or equivalent as the power
supply cord and the connection cord.
1
Fig. 4
[] mark
Screw cap
Front fixed screws (7 places)
Upper holes (2 places at left and right)
Upper middle hooks
Central fixed
places (2 places)
Body
Lower fixed places (2 places)
PUMP DOWN OPERATION (FORCED COOLING OPERATION)
charging port of 3 way valve and opening the low-pressure valve slightly.
When using the remote control unit
Press the TEST RUN button after starting the cooling operation by the remote control unit.
The operation indicator lamp and timer indicator lamp will begin to flash simultaneously during test run.
When using the MANUAL AUTO button of the indoor unit (The remote control unit is lost, and so on.)
Keep on pressing the MANUAL AUTO button of the indoor unit for more than 10 seconds.
(The forced cooling operation cannot start if the MANUAL AUTO button is not kept on pressing for
more than 10 seconds.)
0.05~0 Mpa (0.5~0 kg/cm
2
).
• 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.)
CAUTION
(1) During the pump down operation, make sure that the compressor is turned off before you
remove the refrigerant piping.
(2) 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.
WARNING
(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)
Install a leakage circuit breaker in accordance with the related
laws and regulations and electric company standards.
CAUTION
Name
MAX.
4.0
MIN.
3.5
MAX.
2.5
MIN.
1.5
30
Wall hook bracket
Top hook (2 places at left and right)
Inside hooks (2 places)
Front hook (2 places)
Fixed
screw
Under cover
Front panel
Upper hooks (2 places
at left and right)
Upper central
hooks
Front panel
Central hooks
(2 places)
Lower hooks (2 places)
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