OUTDOOR UNIT ACCESSORIES
SPLIT TYPE AIR CONDITIONER
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9365388044)
WARNING
This mark indicates procedures which, if improperly performed, might lead to the death or serious injury of
the user.
CAUTION
This mark indicates procedures which, if improperly performed, might possibly result in personal harm to
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 con-
ventional 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
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
collapsed, deformed or discolored portion (especially on the interior surface).
Otherwise, the expansion valve 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 Table 1. Never
use copper pipes thinner than 0.8 mm (Nominal diameter is 3/8 in.), 1.0 mm
(Nominal diameter is 5/8 in.) even when it is available on the market.
For authorized service personnel only.
WARNING
1
For the air conditioner to operate satisfactorily, install it as outlined in this installation instruction sheet.
2
Connect the indoor unit and outdoor unit with the air conditioner piping and cords available standards parts. This installa-
tion 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 cord.
6
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 instruction sheet because it is used when the air conditioner is serviced or moved.
SELECTING THE MOUNTING POSITION
- Continued on back -
Refrigerant
R410A
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.
It is recommended the gauge with seals –0.1 to 5.3 MPa (–76 cmHg to 53 kgf/cm
2
) for high pressure.
–0.1 to 3.8 MPa (–76 cmHg to 38 kgf/cm
2
) for low pressure.
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.
Special gas leakage detector for HFC refrigerant R410A.
Tool name
Gauge manifold
Charge hose
Vacuum pump
Gas leakage detector
For outdoor unit drain piping
work
[Heat & Cool model
(Reverse cycle) only]
1
1
Drain pipe
Drain cap
Cassette Type
Table 1 Thicknesses of Annealed Copper Pipes
Nominal
diameter (inch)
3/8
5/8
Thickness (mm)
R410A
[ref.] R22
0.80
0.80
1.00
1.00
Outer diameter
(mm)
9.52
15.88
WARNING
Install at a place that can withstand the weight of the in-
door 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.
Pipe
Pipe
Especially, the installation place is very important for the split type air
conditioner because it is very difficult to move from place to place after the
first installation.
Decide the mounting position together with the customer as follows:
The discharge direction can be selected as shown below.
Fig. 1
CAUTION
Since 2-way outlet as shown below causes performance
problems, do not set it.
(4 directions)
(3 directions)
100 mm (4”) or more
Piping position
(2 directions)
100 mm (4”) or more
100 mm (4”) or more
(2 directions)
1,000 mm (39”) or more
INDOOR UNIT
(1) Install the indoor unit on a place having a sufficient strength so that it
withstands against the weight of the indoor unit.
(2) The inlet and outlet ports should not be obstructed; the air should be
able to blow all over the room.
(3) Leave the space required to service the air conditioner (Fig. 2).
(4) The ceiling rear height as shown in Fig. 3.
(5) A place from where the air can be distributed evenly throughout the
room by the unit.
(6) A place from where drainage can be extracted outdoors easily.
(7) Install the unit where noise and vibrations are not amplified.
Fig. 2
This mechanism enables the cassette body to move 35 mm down-
ward and realizes installation to the space of 200 mm. No special
works and option is needed.
Fig. 3
You can select 2-way setting
Obstruction
Strong and durable ceiling
2,300 mm (91”)
or more
1,000 mm (39”)
or more
1,000 mm (39”
)
or more
Floor
(B) Slender setting
(A) Standard setting
200 mm (7-7/8”)
or more
235 mm (9-1/4”)
or more
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 sun-
light. (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.
(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. 4 so that the air flow is not blocked.
Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
(9) Do not set the unit directly on the ground because it will cause trou-
ble.
(10) Set the unit on a strong stand, such as one made of concrete blocks
to minimize shock and vibration.
Fig. 4
Air
30 cm (1’) or over
30 cm (1’)
or over
30 cm (1’)
or over
60 cm (2’) or over
60 cm (2’)
or over
STANDARD PARTS
The following installation parts are furnished. Use them as required.
INDOOR UNIT ACCESSORIES
Name and Shape
Coupler heat insulation
Special nut A (large flange)
Special nut B (small flange)
Template
Blower cover insulation
Hook wire
Binder (small)
Remote
controller
Tapping screw
(flush heads)
Remote controller cord
Q’ty
2
4
4
1
2
2
Application
For indoor side pipe joint
For installing indoor unit
For installing indoor unit
For ceiling hole cutting
For discharged air
For installing intake grille.
For fixing the remote
controller cord
For installing the remote
controller
For connecting the remote
controller
1
1
2
1
1
INSTALLATION PROCEDURE
Install the air conditioner as follows:
INDOOR UNIT INSTALLATION
WARNING
●
Install the air conditioner in a location which can with-
stand a load do at least five times the weight of the
main unit and which will not amplify sound or vibra-
tion. If the installation location is not strong enough,
the indoor unit may fall and cause injuries.
●
If the job is done with the panel frame only, there is a
risk that the unit will come loose. Please take care.
REMOVING THE INTAKE GRILLE
(1) Push the intake grille pushbuttons (two places).
(2) Open the intake grille.
Fig. 5
OPEN
PUSH
(3) Remove the grille hinge wire.
Fig. 6
A
•
Pull up while pressing the B section (Fig. 7).
Fig. 7 Part A detail view
Fig. 8 Part A section view
B
(4) Remove the intake grille.
REMOVING THE PANEL FRAME
•
Pull up the corner sections (A) of the panel frame as shown in
Fig. 9 (4 locations).
Fig. 9 Part A detail view
Grille hinge wire
A
A
A
A
B
•
Pull up in the direction of the arrow while holding down the C
section of Fig. 10 (4 locations).
Fig. 10 Part B detail view
Panel base
Fig. 11
C
Panel frame
CAUTION
Always remove the panel frame after removing the intake
grille.
1. POSITION THE CEILING HOLE AND HANGING
BOLTS
Fig. 12
940 mm ( 37”)
890 mm ( 35-3/64
”)
750 mm (29-17/32”)
750 mm (29-17/32
”)
Hanging bolt M10
Fig. 14
(A) Standard setting
Hole-in anchor
Hole-in plug
Concrete
Insert
Drain pipe (I.D. 32 mm)
60 mm
(2-3/8
”)
305.5 mm (12”)
298.5 mm (11-3/4”)
(2-3/4
”)
248.5 mm
(9-25/32”)
70 mm
(3-15/16
”)
(5
”)
100 mm
235 mm (9-1/4
”)
127 mm
(B) Slender setting
Drain pipe (I.D. 32 mm)
60 mm
(2-3/8
”)
305.5 mm (12”)
11-3/4” (298.5 mm)
248.5 mm
(9-25/32”)
70 mm
(2-3/4
”)
(3-15/16
”)
(3-5/8
”)
100 mm
92 mm
200 mm (7-7/8
”)
3. BODY INSTALLATION
[The ceiling rear height is 235 mm (9-1/4") or more.] [Standard setting]
[The ceiling rear height is 200 mm (7-7/8") or more.] [Slender setting]
(1) Install special nut A, then special nut B onto the hanging bolt (Fig. 15).
(2) Raise the body and mount its hooks onto the hanging bolt between
the special nuts (Fig. 15).
(3) Turn special nut B to adjust the height of the body (Fig. 15).
(4) Leveling
Using a level, or vinyl hose filled with water, fine adjust so that the
body is level.
WARNING
Perform final tightening by tightening the double nut firmly.
Fig. 15
* Must fit tightly against ceiling
without any gap.
Special nut B
Hanging bolt
Special nut A
30 mm or
more
Hook
Ceiling
After installing the body,
tighten the nuts.
Fig. 16
* Allowable space between the unit and the ceiling 5 mm or less
INSTALLING THE PANEL FRAME
Fig. 17
Vinyl hose
* With slender setting, turn the panel frame 90° as shown in the dia-
gram above.
Grille setting method has been changed at the marked posi-
tions on the panel frame and panel base.
Fig. 18
(A) Standard setting
(B) Slender setting
Fig. 19
(Example)
Panel base
Panel frame
*90° Turn
Mark
Panel frame
No mark
2. HANGING PREPARATIONS
•
Firmly fasten the hanging bolts as shown in Fig. 13 or by another method.
•
Install the hanging bolts at a place where they would be capable of
holding a weight of at least 50 kgf per bolt.
Fig. 13
2
INSTALLING DRAIN PIPE
CAUTION
Install the drain pipe in accordance with the instructions
in this installation instruction sheet and keep the area warm
enough to prevent condensation. Problems with the pip-
ing may lead to water leaks.
NOTE: Install the drain pipe.
•••••
Install the drain pipe with downward gradient (1/50 to 1/100) and so
there are no rises or traps in the pipe.
•••••
Use general hard polyvinyl chloride pipe (VP25) [outside diameter
32 mm (1-1/4”)] and connect it with adhesive (polyvinyl chloride) so
that there is no leakage.
•••••
When the pipe is long, install supporters.
•••••
Do not perform air bleeding.
•••••
Always heat insulate the indoor side of the drain pipe.
•••••
When desiring a high drain pipe height, raise it up to 800 mm (31”) or
less from the ceiling within a range of 150 mm (6”) from the body. A
rise dimension over this range will cause leakage.
Fig. 20
Max. 800 mm (31”)
Rise
Trap
Supporter
1.5 to 2.0 m (5 to 6.5 ft)
Air bleeding
150 mm (6”) or less
3
OUTDOOR UNIT INSTALLATION
1. OUTDOOR UNIT PROCESSING
When the outdoor unit will be exposed to strong wind, fasten it with bolts
at the four places indicated by the arrows (Fig. 21).
Fig. 21
Drain pipe
2. OUTDOOR UNIT CONNECTION CORD AND
PIPE CONNECTION PREPARATIONS
(1) Remove outdoor unit terminal cover.
Fig. 22
(2) Connect the piping, connection cord and power supply cord.
CAUTION
If this product is used in an area where the temperature
falls below freezing for long periods of time, do not con-
nect the drain pipe. Instead, allow the water to drain into a
drain pan.
Bottom
Drain pipe mounting hole
Drain cap
Air flow
Drain pipe mounting hole
Bottom plate
Terminal cover
CONNECTION PIPE REQUIREMENT
Table 2
Diameter
Large
15.88 mm (5/8”)
Maximum
length
25 m (82 ft)
Maximum Height
(between indoor
and outdoor)
15 m (50 ft)
Small
9.52 mm (3/8”)
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. (Re-
verse 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).
ELECTRICAL REQUIREMENT
•••••
Electric wire size and fuse/breaker capacity:
Table 3
•••••
Always use H07RN-F or equivalent to the connection cord.
•••••
Install the disconnect device with a contact gap of at least 3 mm nearby
the units (both indoor unit and outdoor unit).
•••••
Use pipe with water-resistant heat insulation.
Power supply cord (mm
2
)
Connection cord (mm
2
)
Fuse/Breaker capacity (A)
MAX.
MIN.
MAX.
MIN.
4.0
3.5
2.5
1.5
30
1. FLARING
(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.
(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
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 ad-
justment gauge and secure the A dimension shown in table 4.
Fig. 23
CONNECTING THE PIPING
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 breakage, injury, etc.
(Use the special R410A materials.)
CAUTION
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
While welding the pipes, be sure to blow dry nitrogen
gas through them.
3
The maximum lengths of this product are shown in ta-
ble 2. If the units are further apart than this, correct
operation can not be guaranteed.
4
Check if [L] is flared uniformly
and is not cracked or scratched.
Die
A
Pipe
Table 4 Pipe outside diameter
Pipe outside
diameter
9.52 mm (3/8 in.)
15.88 mm (5/8 in.)
A (mm)
Conventional (R22) flare tool
Clutch type
Wing nut type
1.0 to 1.5
1.5 to 2.0
1.0 to 1.5
2.0 to 2.5
Flare tool for
R410A, clutch type
0 to 0.5
0 to 0.5
L
Extend the pipe
by unwinding it.
Cut line
Pipe
Heat insulating pipe
Cutter
2. BENDING PIPES
The pipes are shaped by your hands. Be careful not to collapse them.
Fig. 24
Do not bend the pipes in an angle more than 90°.
When pipes are repeatedly bent or stretched, the material will harden,
making it difficult to bend or stretch them any more. Do not bend or stretch
the pipes more than three times.
When bending the pipe, do not bend it as is. The pipe will be collapsed. In
this case, cut the heat insulating pipe with a sharp cutter as shown in Fig.
25, and bend it after exposing the pipe. After bending the pipe as you
want, be sure to put the heat insulating pipe back on the pipe, and secure
it with tape.
Fig. 25
CAUTION
1
To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150 mm or
over.
2
If the pipe is bent repeatedly at the same place, it will
break.
3. CONNECTION PIPES
(1) Indoor unit side
Fig. 26
CAUTION
1
Be sure to apply the pipe against the port on the in-
door 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.
2
Do not remove the flare nut from the indoor unit pipe
until immediately before connecting the connection
pipe.
Indoor unit
Small pipe
Large pipe
Holding spanner
Body side
Torque wrench
CAUTION
Hold the torque wrench at its grip, keeping it in the right
angle with the pipe as shown in Fig. 27, in order to tighten
the flare nut correctly.
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
Do not use mineral oil.
Table 5 Flare nut tightening torque
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.
(2) Outdoor unit side
Tighten the flare nut of the connection pipe at the outdoor unit valve
connector. The tightening method is the same as that as at the indoor
side.
Fig. 28
Flare nut
9.52 mm (3/8 in.) dia.
15.88 mm (5/8 in.) dia.
Tightening torque
33 to 42 N·m (330 to 420 kgf·cm)
63 to 77 N·m (630 to 770 kgf·cm)
(Large pipe)
(Small pipe)
Connection pipe
Flare nut
3-Way valve
2-Way valve
When the flare nut is tightened properly by your hand, hold the body
side coupling with a separate spanner, then tighten with a torque wrench
(Fig. 27).
Fig. 27
(Hanging bolt position)
(Grille measurement)
(Hanging bolt position)
(Ceiling opening measurement)
* Appearance of slender setting
603 mm
343 mm
* After removing the screws,
remove terminal cover.
