General ABG14UBBJ Installation Instruction Sheet

Refrigerant
R410A
Floor Console/Under Ceiling Dual Type

INSTALLATION INSTRUCTION

SHEET
(PART NO. 9373244011-03)
This mark indicates procedures which, if improperly performed, might lead to the death or serious injury of
WARNING
the user.
This mark indicates procedures which, if improperly performed, might possibly result in personal harm to
CAUTION
the user, or damage to property.
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.
(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 UNF 20 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 openings 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 Contents of change
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
2
It is recommended the gauge with seals –0.1 to 5.3 MPa (–76 cmHg to 53 kgf/cm ) for high pressure.
–0.1 to 3.8 MPa (–76 cmHg to 38 kgf/cm 2 ) 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
Table 1 Thicknesses of Annealed 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/10 m. Do not use copper pipes having a
Nominal Outer diameter
collapsed, deformed or discolored portion (especially on the interior surface). R410A
diameter (inch) (mm)
Otherwise, the expansion valve or capillary tube may become blocked with
1/4 6.35
0.80
contaminants.
1/2 12.7 0.80
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 Table 1. Never
use copper pipes thinner than 0.8 mm (Nominal diameter is 1/4 in., 1/2 in.),
even when it is available on the market.
For authorized service personnel only.
WARNING
(1) For the room air conditioner to operate satisfactorily, install it as outlined in this installation instruction sheet.
(2) Connect the indoor unit and outdoor unit with the room air conditioner piping and cables available standards parts. This
installation instruction sheet describes the correct connections using the installation set available from our standard parts.
(3) Installation work must be performed in accordance with national wiring standards by authorized personnel only.
(4) 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.
(5) Do not use an extension cable.
(6) Do not turn on the power until all installation work is complete.
• • • • • Be careful not to scratch the room air conditioner when handling it.
• • • • • After installation, explain correct operation to the customer, using the operating manual.
• • • • • Let the customer keep this installation instruction sheet because it is used when the air conditioner is serviced or moved.

SELECTING THE MOUNTING POSITION

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 combustible 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 cannot reach the unit.
Decide the mounting position with the customer as follows:
1. INDOOR UNIT
(1) Install the indoor unit level on a strong wall, floor, ceiling which is not sub-
ject 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
12.7 mm (1/2") dia.
Fig. 1. Also install the unit where the filter can be removed.
Fig. 1
• • • • • Floor console 6.35 mm (1/4") dia.
Outdoor unit
Left Right
30 cm (12") or more 30 cm (12") or more
• • • • • Under ceiling
Ceiling
Left Right
Indoor unit
15 cm (6") or more 30 cm (12") or more
Ceiling
Indoor unit
2 cm (3/4") or more
STANDARD PARTS
The following installation parts are furnished. Use them as required.
INDOOR UNIT ACCESSORIES
Q'ty Application
Name and Shape
Drain hose
Cover plate (left)
1
Cover plate (right) Insulation (drain hose)
1
Tapping screw (ø4 × 10) VT wire
2
Installation template For positioning the indoor Remote controller
unit
1 For under ceiling type
Bracket (left) For suspending the indoor
unit from ceiling
1
Battery (penlight)
Bracket (right)
1
Remote controller holder
Special nut
4
Wall bracket For suspending the indoor
Tapping screw (ø3 × 12)
unit on the wall.
2
Tapping screw (ø4 × 20)
For fixing the wall bracket.
OUTDOOR UNIT ACCESSORIES
6
Drain pipe
Coupler heat insulator For indoor side pipe joint
(large) (Large pipe)
1
Drain cap
Coupler heat insulator For indoor side pipe joint
(small) (Small pipe)
1 OPTIONAL PARTS FOR INDOOR UNIT
Nylon fastener For fixing the drain hose Joint pipe-A
1
Thickness (mm)
[ref.] R22
0.80
0.80

2. OUTDOOR UNIT

WARNING
(1) Install the unit where it will not be tilted by more than 5˚.
(2) When installing the outdoor unit where it may exposed to strong wind, fasten it securely.
(1) If possible, do not install the unit where it will exposed to direct sunlight. (If necessary, install a blind that does not interfere with the air flow.)
(2) Install the outdoor unit in a place where it will be free from being dirty or getting wet by rain as much as possible.
(3) Install the unit when connection to the indoor unit is easy.
(4) During heating operation, drain water flows from the outdoor unit. Therefore, install the outdoor unit in a place where the drain water flow will not be
obstructed. (Reverse cycle model only)
(5) Do not place animals and plants in the path of the warm air.
(6) Take the air conditioner weight into account and select a place where noise and vibration are small.
(7) Select a place so that the warm air and noise from the air conditioner do not disturb neighbors.
(8) 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.
Fig. 2
10 cm (4")
or over
10 cm (4")
or over
60 cm (2')
or over
60 cm (2')
or over
60 cm (2')
or over
CONNECTION PIPE REQUIREMENT
Table 2
Diameter Maximum Height
Maximum
(between indoor
length
Small Large
and outdoor)
6.35 mm (1/4 in.) 12.7 mm (1/2 in.) 15 m (49 ft) 8 m (26 ft)
• • • • • Use pipe with water-resistant heat insulation.
12.7 mm (1/2") dia.
CAUTION
Install heat insulation around both the gas and liquid pipes.
Failure to do so may cause water leaks.
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 expected to exceed 70%, install
heat insulation around the refrigerant piping. If the ex-
pected humidity level is 70-80%, use heat insulation that
is 15 mm or thicker and if 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 specified,
condensation may form on the surface of the insulation.
In addition, use heat insulation with heat conductivity of
0.045 W/(m·K) or less (at 20 °C).
INSTALLATION PROCEDURE
Install the room air conditioner as follows:
Name and Shape Q'ty Application
1

PREPARING INDOOR UNIT

1

INSTALLATION

Adhesive type 70 × 230 1. REMOVE THE INTAKE GRILLE
1
Open the intake grille and remove the three screws (Fig. 3).
Fig. 3
Machine screw
For fixing the drain hose
1 L 280 mm
Tapping screw
Use for air conditioner
operation
1
Intake grille
For remote controller
2
Remark: The main unit can be wired before the indoor unit is in-
stalled. Select the most appropriate installation order.
Use as remote controller
holder
2
1
INDOOR UNIT INSTALLATION

A. FLOOR CONSOLE TYPE

For remote controller holder
1. DRILLING FOR PIPING
installation
2
Select piping and drain directions (Fig. 4).
The piping and drain can be made in three directions as shown below.
Fig. 4
Name and Shape Q'ty Application
1 For outdoor unit drain piping
work
[Heat & Cool model
(Reverse cycle) only]
2
The drain hose can be connected to either the left or right side (Fig. 5).
Fig. 5
Name and Shape Part No. Application
For indoor side pipe joint
Drain hose
9302812021
(Left side)
When the directions are selected, drill a 10 cm (4") dia. hole on the wall so
that the hole is tilted downward toward the outdoor for smooth water flow.
When the pipe is led out from the rear, make a hole in Fig. 6, at the posi-
tion shown.
Fig. 6
Wall
6 mm (1/4")
100 mm (4")
Indoor side Outdoor side
3

OUTDOOR UNIT INSTALLATION

1. OUTDOOR UNIT PROCESSING

WARNING
(1) Install the unit where it will not be tilted by more than 5˚.
(2) When installing the outdoor unit where it may exposed
to strong wind, fasten it securely.
• Set the unit on a strong stand, such as one made of concrete blocks to
minimize shock and vibration.
• Do not set the unit directly on the ground because it will cause trouble.
• Since the drain water flows out of the outdoor unit during heating op-
eration, install the drain pipe and connect it to an commercial 16 mm
hose. (Heat & Cool model (Reverse cycle) only)
• When installing the drain pipe, plug all the holes (• hole at one place)
other than the drain pipe mounting hole in the bottom of the outdoor
unit with putty so there is no water leakage. (Fig. 22) (Heat & Cool model
(Reverse cycle) only)
CAUTION
Installation in cold regions. 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 extremely cold weather.)
Fig. 22
Hole
Drain cap
Hole
Drain cap
Indoor unit Drain pipe
Bottom of outdoor unit
Drain hose
(commercial hose,
inside diameter 16 mm)
Drain pipe hole
Bottom plate
Drain pipe
2. OUTDOOR UNIT CONNECTION CABLE AND
PIPE CONNECTION PREPARATIONS
Remove outdoor unit terminal cover.
6.35 mm (1/4") dia.
Fig. 23
* After removing the screws,
remove terminal cover.
Outdoor unit
Terminal cover
When installing set to wall install the accessory wall bracket at the posi- B. UNDER CEILING TYPE
tion shown in Fig. 7, and mount the set to it.
Using the installation template, drill holes for piping and suspension bolts
Fig. 7
99 cm (39") (for holes) (Fig. 12).
24.5 cm
50 cm (20")
Fig. 12
(9-5/8") Wall bracket
Side of set
200 mm
6.5 cm (2-1/2")
(7-7/8" )
10 cm (4") hole
5 cm (2") hole
12.5 cm (5") 10 cm (4")
Tapping screw
2. INSTALLING THE DRAIN HOSE 1. DRILLING FOR PIPING
Select whether the drain hose will be connected to the left or right side
Select piping and drain directions (Fig. 13).
(Fig. 5).
Fig. 13
Insert the drain hose into the drain pan, then secure the drain hose with a
nylon fastener (Fig. 8).
Fig. 8
Drain pan
Nylon fastener
Drain hose
Wrap the insulation (drain hose) around the drain hose connection
Install the drain hose at the rear; it should not be installed
(Fig. 9).
on the top or right side.
Fig. 9
Drain pan
When the directions are selected, drill 80 mm (3-1/8") and 50 mm (2") or
150 mm (6") dia. hole on the wall so that the hole is tilted downward to-
ward the outdoor for smooth water flow.
Insulation (Drain hose)
Fig. 14
Drain hose
Be sure to arrange the drain hose so that it is leveled lower than the drain
hose connecting port of the indoor unit.
Fig. 10
2. DRILLING THE HOLES AND ATTACHING THE
SUSPENSION BOLTS
Drill ø25 mm holes at the suspension bolt locations, then install the bolts
(Fig. 15).
Bolt Strength
Fig. 15
Arrange the drain
Drain hose
hose lower than
this portion.
CAUTION
[If using anchor bolts]
Do not install the unit so that the drain hose side is too
Drill holes for anchor bolts at the locations at which you will set the sus-
high. Height A should be less than 5 mm (Fig. 11).
pension bolts.
Drain hose
Note that anchor bolts are M10 bolts (to be obtained locally) (Fig. 16).
(Right side)
Fig. 11
Anchor-Bolt Strength
Fig. 16
Drain hose
4
CONNECTING THE PIPING 2. FLARING PROCESSING
(1) Cut the connection pipe to the necessary length with a pipe cutter.
(2) Hold the pipe downward so that cuttings will not enter the pipe and
remove the burrs.
WARNING
(3) Insert the flare nut (always use the flare nut attached to the indoor
and outdoor units respectively) onto the pipe and perform the flare
Do not use the existing (for R22) piping and flare nuts.
processing with a flare tool.
• If the existing materials are used, the pressure inside the
Use the special R410A flare tool, or the conventional (for R22) flare
refrigerant cycle will rise and cause breakage, injury, etc.
tool.
(Use the special R410A materials.) When using the conventional flare tool, always use an allowance ad-
justment gauge and secure the A dimension shown in table 4.
CAUTION
Fig. 25
(1) Do not use mineral oil on flared part.
Prevent mineral oil from getting into the system as this
would reduce the lifetime of the units.
(2) Never use piping which has been used for previous
installations. Only use parts which are delivered with
L
the unit.
(3) While welding the pipes, be sure to blow dry nitrogen
gas through them.
Pipe outside
diameter
CAUTION
6.35 mm (1/4 in.)
The maximum lengths of this product are shown in table 3.
12.7mm (1/2 in.)
If the units are further apart than this, correct operation
can not be guaranteed.
3. BENDING PIPES
1. LIMITATION OF REFRIGERANT PIPING LENGTH
(1) When bending the pipe, be careful not to crush it.
(2) To prevent crushing of the pipe, do not bend the pipe at a radius cur-
vature of 100 mm or over.
Table 3
(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.
Max length (L) 20 m (66 ft)
Max height difference (H) 8 m (20 ft) 4. CONNECTION PIPES
(1) Centering the pipe against port on the indoor unit, turn the flare nut
Fig. 24
with your hand (Fig. 26).
Indoor unit Be sure that the small pipe is completely installed before connecting
Outdoor unit
L the large the pipe.
Fig. 26
H
Optional parts
H
L
Be sure to apply the pipe against the port on the indoor
unit correctly. If the centering is improper, the flare nut
cannot be tightened smoothly. If the flare nut is forced to
turn, the threads will be damaged.
3. INSTALLING BRACKETS
Install the bracket with nuts, spring washers (Fig. 17).
Fig. 17
900 mm (35-7/16")
Bracket (Left)
Drilling position
Ceiling panel
for suspension Special nut A
bolt
Installation (Accessories)
template
Ceiling
Bracket
Wall
Spring washer Bracket (Right)
(Field supply)
Drilling position M10 Nut (Field supply)
for piping M10 Nut (Field supply)
4. INSTALLING INDOOR UNIT
Top Reset the hex bolts as shown in Fig. 18.
Rear (Install the
drain hose in this Fig. 18
direction.)
Hex bolt
Right
Indoor unit 8 to 13 mm
(5/16" to 1/2")
CAUTION
Apply the indoor unit to the brackets (Fig. 19).
Fig. 19
Bracket
Bolt
Indoor unit
Wall
Now, securely tighten the hex bolts in both sides.
6 mm (1/4")

5. INSTALLING THE DRAIN HOSE

Select whether the drain hose will be connected to the left or right side
Indoor side Outdoor side (Fig. 5).
Insert the drain hose into the drain pan, then secure the drain hose with a
nylon fastener (Fig. 8).
Wrap the insulation (drain hose) around the drain hose connection
(Fig. 9).
Be sure to arrange the drain hose so that it is leveled lower than the drain
hose connecting port of the indoor unit (Fig. 20).
Fig. 20
980 to 1470 N (100 to 150 kgf) Remove the hole cover.
Ceiling panel
20 to 50 mm ø25 mm Drain hose
Arrange the drain hose
lower than this portion.
OK NO
When drain hose is arranged backward.
Secure the drain hose with the VT wire (Fig. 21).
980 to 1470 N (100 to 150 kgf) Fig. 21
Piping hole
Base (Bottom)
Ceiling
VT wire
hole
20 to
50 mm Intake grille
Pass the drain hose Drain hose
Cut the grille
M10 Anchor bolt
through here.
(Field supply)
(2) Install the outdoor unit wall cap (supplied with the optional installation
set or procured at the site) to the wall hole pipe.
(3) Connect the outdoor unit and indoor unit piping.
(4) 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.
Fig. 27
Tighten with 2 wrenches.
Wrench (fixed)
Flare nut
Check if [L] is flared uniformly
Torque wrench
and is not cracked or scratched.
Indoor unit
To prevent gas leakage,
pipe Connection pipe
Die
coat the flare surface with
alkylbenzene oil (HAB).
A
Do not use mineral oil.
Pipe
Table 5 Flare nut tightening torque
Table 4 Pipe outside diameter
Flare nut Tightening torque
A (mm)
6.35 mm (1/4 in.) dia. 14 to 18 N · m (140 to 180 kgf · cm)
Flare tool for Conventional (R22) flare tool
R410A, clutch type Clutch type Wing nut type
12.7 mm (1/2 in.) dia. 50 to 62 N · m (500 to 620 kgf · cm)
0 to 0.5 1.0 to 1.5 1.5 to 2.0
0 to 0.5 1.0 to 1.5 2.0 to 2.5 Do not remove the cap from the connection pipe before connecting
the pipe.
CAUTION
Be sure to connect the large pipe after connecting the small
pipe completely.
5. HEAT INSULATION ON THE PIPE JOINTS
(INDOOR SIDE ONLY)
Put coupler heat insulator on the joints (indoor side only) (Fig. 28).
Fig. 28
Indoor unit
Indoor unit side
No gap
Coupler heat
Coupler heat
insulator
insulator (small)
(large)
Be sure to overlap
the insulation
CAUTION
Large pipe Small pipe
No gap
Coupler heat
insulation
- Continued on back -
VT wire