Sharp AY-ZP25TR, AY-ZP35TR, AE-Z25TR, AE-Z35TR Manual

SAFETY PRECAUTIONS

• Installation must be made in accordance with the installation manual by qualified service personnel.
  Incorrect work will cause electric shock, water leak, fire.
• Be sure to use the attached accessories parts and specified parts for installation.
  Use of the other parts will cause electric shock, water leak, fire, the unit failing.
• The appliance shall be installed in accordance with national wiring regulations.
  Wrong connection can cause overheating or fire.
• After installation has complete, check that there is no leakage of refrigerant gas.
  If the refrigerant gas contact with fire, it may generate toxic gas.
• Ventilate the room if refrigerant gas leaks during installation.
  If the refrigerant gas contact with fire, it may generate toxic gas.
• Use the specified electrical cable.
  Make sure the cable is secured in place and that the terminals are free of any excess force from the cable. Otherwise overheating or fire may result.
• Form the cable so that the control box cover, the cord holder and cable holder are not loose.
  Otherwise overheating, fire or electric shock may result.
• Tighten the flare nut with a torque wrench according to the specified method.
  If the flare nut is tightened too hard, the flare nut may be broken after a long time and cause refrigerant gas leakage.
• When installing the unit, take care not to enter air substance other than the specified refrigerant (R410A) in the refrigerant cycle.
  Otherwise, it will cause burst and injury as a result of abnormal high pressure in the refrigerant cycle.
• Be sure to connect the refrigerant pipe before running the compressor.
  Otherwise, it will cause burst and injury as a result of abnormal high pressure in the refrigerant cycle.
• Earth the unit.
  Incomplete earth may cause electrical shock.
• If national legislations or type of installation requires earth leakage breaker, the legislation must be followed.
• Arrange the drain hose to ensure smooth drainage.
  Insufficient drainage may cause wetting of the room, furniture, etc.
• This room air/air heat pump uses refrigerant R410A.
  Use the pipe, flare nut and tools exclusively for R410A.

ACCESSORIES

ITEMS	Q'ty	APPLICATION
	1	To mount the indoor unit on the wall.
	9	To fix the mounting plate with the long screws(7). To fix the remote control with the special screw(2).
	7	To fix the mounting plate with the wall plugs.
	1	To control remotely.
	2	For the remote control. AAA batteries.
	2	To mount the remote control on the wall. To mount the remote control holder on the wall.
	1	To mount the remote control on the wall.
	1	To secure the terminal cover.
	1	To secure the electrical cable.
	1	Installation manual
	1	Operation manual
	1	To firmly secure the electrical cable.
	1	To check the drain hose.

NOTES ON LOCATIONS

Indoor unit

1. Keep the air outlet clear of any obstacle so that outgoing air flows smoothly in the entire room.
2. Make a drain hose hole for easy drainage.
3. Provide sufficient space on both sides and above the unit.
4. The air filters should be easily taken in and out.
5. Keep TV set, radio and the like 1m or more away from the unit and the remote control.
6. Keep the air inlet clear of obstacles that could block incoming air.
7. The remote control may not function properly in a room equipped with an electronic simultaneous-start or rapid-start fluorescent lighting.
8. Select a location that does not cause loud operation noise and extreme vibrations.

Outdoor unit

1. Place the outdoor unit on a stable base.
2. Provided sufficient space around the unit. It should also be well ventilated.
3. The unit should not be exposed to strong wind nor splashed with rain water.
4. Water drain from the unit should be let out without problem. Lay a drain hose if required. In cold regions, installation of the drain pipe is not advisable as freezing could result.
5. Keep TV set, radio and the like 1m or more away from the unit.
6. Avoid locations exposed to machine oil vapor, salty air (facing the seashore, for example), hot vapor sulfur gas, etc. Such location can cause breakdown.
7. Avoid locations exposed to muddy water (along a road, for example) or where the unit can be tampered with.
8. Select a location where the outgoing air or operating noise cannot annoy others.
9. Keep the air outlet opening free of any obstacle. This could affect the performance of the unit and create loud noises.

INSTALLATION DIAGRAM

PIPING

• Standard piping length is 5m.
• When the outdoor unit is placed at a higher level than the indoor unit, provide a trap near the hose's lead-in port.

Use the refrigerant pipes shown in the table below.

• The thermal insulation should cover both the gas and liquid pipes.

Carefully read and follow these instructions for smooth and trouble-free installation.

After installation, be sure to explain to the customer enough about the system.

PLACING THE MOUNTING PLATE AND MAKING A PIPING HOLE

1. Referring to the figure below, mark the location for the wall plugs and the piping hole.
   • Recommended fixing holes are marked in circle around the hole. (7 points)
   • Make sure that the mounting plate is horizontally.
     
     
2. Drill diameter 6.5 mm, depth 32 mm holes and fit the wall plug.
   
   
3. Secure the mounting plate to the wall with the long screws and check the stiffness.
   
   
4. Drill a piping hole with 70mm diameter concrete drill or a hole saw with a 5mm downward slant to the outside.
5. Set the sleeve and caps.
   

SETTING UP THE INDOOR UNIT

Piping route

For directions 1, 2, 4 and 5, cut out the specific zone without leaving any sharp edge.

Panel cover

Installation is easily achieved by removing the panel cover.

Mounting the indoor unit

For right side piping

1. Pass the pipes and the drain hose through the piping hole.
2. Hook the unit onto the mounting plate.
3. Pull the connecting cable into the indoor unit.
4. Push the unit and apply the bottom hooks to the mounting plate's support.
5. Pull the bottom of the unit to check that the unit is fixed in place.

For left side piping

1. Reverse the positions of the drain hose and drain cap. Refer to NOTES ON DRAIN HOSE.
2. Connect the pipes and wrap tape around the insulation of the piping joints tightly not to become thick.
3. Pass the pipes, connecting cable and the drain hose through the piping hole.
4. Hook the unit onto the mounting plate.
5. Push the unit and apply the bottom hooks to the mounting plate's support.
6. Pull the bottom of the unit to check that the unit is fixed in place.

Detaching the unit from the mounting plate

Push the "" marks at the bottom of the indoor unit and pull the bottom of the unit. When the hooks are released from the mounting plate, support the bottom of the unit and lift the unit upwards.

CONNECTING THE CABLE TO THE INDOOR UNIT

1. Process the end of the electrical cable for the indoor side.
   • Use a copper cable. (Cross-section area 1.5mm² )
   • Use a cable which is not lighter than polychloropene sheathed flexible cord (code designation 60245 IEC 57).
2. Open the open panel.
3. Connect the cable.
   • Be very careful not to confuse the terminal connections. Wrong cabling may damage the internal control circuit.
   • The markings on the indoor unit's terminal board must match with those of the outdoor unit.
4. Attach the terminal cover with the short screw.
5. Close the open panel.

CONNECTING THE DRAIN HOSE

Connecting the drain hose

1. Connect a drain hose.
2. Tape over the connecting part.
   

Checking drainage

1. Open the open panel.
2. Remove air filter.
3. Slowly pour some water on evaporator.
   
   • If the water flows fast, water may splash into indoor unit, which will cause water leakage or other trouble.
4. Check the water drains smoothly.
5. Replace the air filter.
6. Close the open panel.

Notes:

• Be sure to lay the drain hose downward for smooth drainflow.
• Be careful not to allow the drain hose to rise, form a trap or leave its end in water, as shown below.
• Coil thermal insulation around a drain hose extension, if running in the room.
  

NOTES ON DRAIN HOSE

The drain hose can be connected at either side of the indoor unit.

1. Remove the fixed screw in the hose holder at the end of the drain hose.
2. Hold the end of the drain hose, and pull it out.
3. Pull out the drain cap.
4. Reconnect the drain hose to the right and insert the drain cap to the left.
   • Fully insert the drain hose until it stops and use the screw that was previously removed in STEP 1 to secure the hose holder to the drain pan.
   • Insert a hexagon socket screw key (4 mm diagonal) into the drain cap, and press it fully.
     

After replacing, make sure that both the drain hose and drain cap are firmly sealed.

OUTDOOR UNIT INSTALLATION

Referring to the figure, firmly fasten the outdoor unit with bolts.

CONNECTING THE REFRIGERANT PIPES

Flaring the pipe end

1. Cutting with a pipe cutter
   Cut at a right angle.
   
   
2. Deburring
   Allow no cuttings in the pipe.
3. Putting in the flare nut
4. Flaring
   Flare processing dimensions(A)
   
   
   
5. Checking
   To be flared perfectly circular.
   Flare nut not missing.

Connecting the pipes

Connect the pipes for the indoor unit first and then for the outdoor unit.

1. Tighten the flare nuts by hand for the first 3-4 turns.
2. Use a wrench and torque wrench to tighten up the pipes.
   
   • Do not over tighten the pipes. It may be deformed or damaged.

Flare nut tightening torque

AIR REMOVAL

Use a vacuum pump, gauge manifold and hoses exclusively for R410A.

1. Remove both valve shaft caps of the 2 and 3-way valves.
2. Remove the service port cap of the 3-way valve.
3. Connect the gauge manifold hose to the service port and the vacuum pump. Be sure that the hose end to be connected to the service port has a valve core pusher.
4. Open the gauge manifold low-pressure valve(Lo) and operate the vacuum pump for 10-15 minutes. Make sure the compound gauge reads -0.1MPa(-76cmHg).
5. Close the gauge manifold valve.
6. Turn off the vacuum pump. Leave as it for 1-2 minutes and make sure the needle of the compound gauge does not go back.
7. Open the 2-way valve 90° counterclockwise by turning the hexagon wrench. Close it after 5 second, and check for gas leakage.*
8. Disconnect the gauge manifold hose from the service port.
9. Fully open the 2-way valve with hexagon wrench.
10. Fully open the 3-way valve with hexagon wrench.
11. Firmly tighten the service port cap and both valve shaft caps with a torque wrench at the specified tightening torque.

* Check the pipe connections for gas leak using a leakage detector or soapy water. Regarding leakage detector, use high-sensitivity type designed specially for R410A.

* If a high pressure test is mandatory in your country, make sure to follow the local legislation.

Valve shaft cap tightening torque

Service port cap tightening torque

CONNECTING THE CABLE TO THE OUTDOOR UNIT

1. Process the end of the connecting cable and the power supply cable for the outdoor unit.
   • Use a copper cable.
     
   • For power supply cable, securely clamp a round terminal to each end of the stripped cable.
   • Use a cable which is not lighter than polychloropene sheathed flexible cord (code designation 60245 IEC 57).
2. Remove the control box cover and cable cover.
3. Remove the cable holder connect the cables. Be sure that the terminal connections as specified.
4. Fix the cable sheaths with the cable holder and the screw.
5. Double-check that the cables are securely in place.
6. Place the control box cover back in the reverse order.

* If the cable sheaths are not firmly secured with the cable holder, put the SHEET on the cable holder base.

• Be sure to put the cable leads deep into the terminal board and tighten up the screws. Poor contact can cause overheating or fire, or malfunction,
• Be very careful not to confuse the terminal connections. Wrong cabling may damage the internal control circuit
• Be sure to connect the cable to match the markings on the indoor unit's terminal board and those of the outdoor unit.

POWER CABLING

Prepare a dedicated power supply circuit.

• Fit a disconnect switch, having a contact separation of at least 3mm in all poles, to the electricity power line.
  

HANGING THE REMOTE CONTROL

1. Fit the special screw to the wall with the wall plug.
2. Hang the remote control to the screw head.

or

1. Fix the remote control holder to the wall with screws.
2. Put remote control into holder.
   

TEST RUN

1. Start the operation with the remote control.
2. To start test run in cooling, hold down the AUX button on the unit for over 5 seconds until a beep sound is heard and an operation lamp flashes.
   
   
3. To put the system in the heating test run mode, select heat mode on the remote control while the unit is in cooling test run mode.
4. Make sure the system runs well. To stop the operation, press the AUX button again.

ITEMS TO CHECK

Is the specified power supply voltage used?
Is the connecting cable fixed to terminal board firmly?
Is the earth wire connected properly arranged?
Is the drainage properly?
Is the indoor unit hooked to the mounting plate firmly?
Is the re any gas leakage at the pipe connection?

Explanation to the customer

• Explain to the customer how to use and maintain the system, referring to the operation manual.
• Ask the customer to carefully read the operation manual.
• When the system has been set up, hand the installation manual to the customer.

PUMP DOWN

(Pump down is adopted in the case of unit removal for re-installation, abandonment, repair etc.)

Pump down is to collect the refrigerant into the outdoor unit by control of the 2 and 3-way valves and the compressor.

1. Stop the air conditioner operation.
2. Remove both valve shaft caps of the 2 and 3-way valves.
3. Run the air conditioner at cooling test run mode (Refer to TEST RUN). If pump down is performed at normal cooling operation, the protection system may engage and stop the operation.
4. After 5~10 minutes, fully close the 2-way valve by turning the hexagon socket screw key clockwise.
5. After 2~3 minutes, immediately close the 3-way valve fully.
6. Stop the test run operation.
7. Replace both valve shaft caps tightly.
8. Disconnect both refrigerant pipes.

Make sure that the compressor is turned off before removing the refrigerant pipes. Otherwise, it will cause burst and injury.

TINS-B617JBRZ