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IMPORTANT! 
Please Read Before Starting

This air conditioning system meets strict safety and operating
standards. As the installer or service person, it is an important
part of your job to install or service the system so it operates
safely and efficiently. 

For safe installation and trouble-free operation, you
must:

G

Carefully read this instruction booklet before beginning.

G

Follow each installation or repair step exactly as shown.

G

Observe all local, state, and national electrical codes.

G

Pay close attention to all warning and caution notices
given in this manual.

This symbol refers to a hazard
or unsafe practice which can
result in severe personal injury
or death.

This symbol refers to a hazard
or unsafe practice which can
result in personal injury or prod-
uct or property damage.

If Necessary, Get Help

These instructions are all you need for most installation
sites and maintenance conditions. If you require help for a
special problem, contact our sales/service outlet or your
certified dealer for additional instructions. 

In Case of Improper Installation

The manufacturer shall in no way be responsible for improp-
er installation or maintenance service, including failure to
follow the instructions in this document. 

SPECIAL PRECAUTIONS

When Wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM. 

• Do not supply power to the unit until all wiring and tubing

are completed or reconnected and checked.

• Highly dangerous electrical voltages are used in this

system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or
death.

• Ground the unit following local electrical codes.
• Connect all wiring tightly. Loose wiring may cause over-

heating at connection points and a possible fire hazard.

When Transporting

Be careful when picking up and moving the indoor and out-
door units. Get a partner to help, and bend your knees when
lifting to reduce strain on your back. Sharp edges or thin alu-
minum fins on the air conditioner can cut your fingers. 

When Installing…

…In a Ceiling or Wall

Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.

…In a Room

Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle. 

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is higher
than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces of

the flare and union tubes before connecting them, then
tighten the nut with a torque wrench for a leak-free
connection.

• Check carefully for leaks before starting the test run.

When Servicing

• Turn the power OFF at the main power box (mains) before

opening the unit to check or repair electrical parts and
wiring.

• Keep your fingers and clothing away from any moving

parts.

• Clean up the site after you finish, remembering to check

that no metal scraps or bits of wiring have been left inside
the unit being serviced.

Others

• Ventilate any enclosed areas when installing or testing

the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously
toxic gas. 

• Confirm upon completing installation that no refrigerant

gas is leaking. If escaped gas comes in contact with a
stove, gas water heater, electric room heater or other heat
source, it can produce dangerously toxic gas.

WARNING

WARNING

CAUTION

CAUTION

05-326 AirCon_85264189988000  12/5/05  3:35 PM  Page 2

Summary of Contents for C1872

Page 1: ...DOOR UNIT 17 4 1 Wiring Instructions for the Outdoor Unit 5 REFRIGERANT TUBING 18 5 1 Use of the Flaring Method 5 2 Flaring Procedure with a Flare Tool 5 3 Caution before Connecting Tubes Tightly 5 4 Connecting Tubing between Indoor and Outdoor Units 5 5 Insulation of Refrigerant Tubing 5 6 Taping the Tubes 5 7 Finishing the Installation 6 AIR PURGING 20 I Air Purging with a Vacuum Pump for Test R...

Page 2: ...orting Be careful when picking up and moving the indoor and out door units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin alu minum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or meta...

Page 3: ...tely from a local source you will need 1 Deoxidized annealed copper tube for refrigerant tub ing as detailed in Table 2 Cut each tube to the appropriate lengths 1 to 1 4 30 cm to 40 cm to dampen vibration between units Table 2 2 Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing Wall thickness of the insulation should be not less than 5 16 8 mm 3 ...

Page 4: ...le 3 and Fig 3a G Install the indoor unit more than 3 3 1 m away from any antenna or power lines or connecting wires used for television radio telephone security system or intercom Electrical noise from any of these sources may affect operation Drain hose Indoor unit Outside drainage Fig 1 2 5 cm min 6 15 cm min Front View 2 5 cm min Fig 2 INDOOR UNIT Tubing length L OUTDOOR UNIT Elevation differe...

Page 5: ...olts or equal to bolt down unit reducing vibration and noise G Install in a location where no antenna of a television or radio exists within 10 3 m Outdoor unit Hot air Heat source Exhaust fan NO Fig 4 Fig 5c Air intake Min 4 10 cm Air discharge Min 2 5 cm Min 1 4 40 cm Valve side Min 10 25 cm Min 7 2 m Min 7 2 m Ground Obstacle Obstacle above Air discharge Min 4 10 cm Air intake Air intake Concre...

Page 6: ... wind like seasonal winds with low air tempera ture in winter baffle plates must be installed in front of the outdoor unit Fig 5f This unit is designed so that the fan of the outdoor unit runs at low speed when the air conditioner is operated at low outdoor air temperatures When the outdoor unit is exposed to strong wind the system pressure drops because of the freeze protector NOTE Fig 5f Air dis...

Page 7: ...ose and drain cap on page 14 3 2 Make a Hole 1 Place the rear panel from the indoor unit on the wall at the location selected Make sure the panel is hori zontal using a carpenter s level or tape measure to measure down from the ceiling Wait until after cut ting the hole before attaching the rear panel to the wall 2 Determine which side of the unit you should make the hole for tubing and wiring Fig...

Page 8: ...is strong enough to sus pend the unit See either Item a or b below depending on the wall type a If Wooden Wall 1 Attach the rear panel to the wall with the 8 screws provided Fig 13 If you are not able to line up the holes in the rear panel with the beam locations marked on the wall use rawl plugs or toggle bolts to go through the holes on the panel or drill 3 16 5 mm dia holes in the panel over th...

Page 9: ...grille into the frame first Fig 18b Then insert the tabs on the top of the grille and on the front face into the frame 2 Make sure that the grille and frame are firmly fitted together by engaging the tabs 3 Attach the thermistor on the grille Fig 17a 4 Close the cover and replace the screw Fig 17a 5 Affix the grille with the 3 previously removed screws Fig 16b 6 Install the air intake grille a All...

Page 10: ...agram 2 Provide a power outlet to be used exclusively for each unit with a power supply disconnect and cir cuit breaker for overcurrent protection provided in the exclusive line 3 To prevent possible hazards due to insulation failure the unit must be grounded 4 Each wiring connection must be done tightly and in accordance with the wiring system diagram Wrong wiring may cause the unit to misoperate...

Page 11: ...bing the compressor or any moving part Disconnect switch 1 2 3 1 2 3 4 5 6 Grounding line 230 208V 230 208V 230 208V INDOOR UNIT OUTDOOR UNIT Field supply Grounding line L1 L2 Power supply Single phase 230 208V 60HZ Terminal Terminal A B C B CAUTION G Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram The indoor unit draws its power from the outdoor unit G ...

Page 12: ... unit wiring from the back of the indoor unit and pull it toward the front for connec tion Fig 26a 26b 5 Connect the inter unit wiring to the corresponding terminals on the terminal plate Fig 26a 26b while referring to the wiring diagram 6 Be sure to secure the wiring with the provided clamp When closing the air intake grille press the bottom right and left corners and center Fig 27 Please refer t...

Page 13: ...the terminal screw 4 Shape the loop wire properly place it on the termi nal plate and fix it securely with the removed termi nal screw using a screwdriver I For stranded wiring 1 Cut the wire end with a cutting pliers then strip the insulation to expose the stranded wiring about 3 8 10 mm and tightly twist the wire ends Figs 30 and 31 2 Using a screwdriver remove the terminal screw s on the termin...

Page 14: ...the wall Adjust the indoor unit so it is securely seated on the rear panel Fig 36 3 Carefully bend the tubing if necessary to run along the wall in the direction of the outdoor unit and then tape as far as the fittings See Caution on page 18 The drain hose should come straight down the wall to a point where water runoff won t stain the wall 4 Connect the refrigerant tubing to the outdoor unit Afte...

Page 15: ...the drain hose fully onto the drain pan outlet until the drain hose edge is pushed into the insula tion Check that the screw holes in the drain bracket and the drain pan outlet are aligned and securely in contact then fasten them with the screw After attaching the drain hose check that it is attached securely Fig 40c Drain cap Use a Phillips screwdriver to push the drain cap in firmly If it is dif...

Page 16: ...f the hose c If the drain hose will run in the room insulate the hose with insulation so that chilled condensation will not damage furniture or floors Fig 44 Foamed polyethylene or its equivalent is recom mended WARNING Risk of Electric Shock Do not supply power to the unit or operate it until all tubing and wiring to the out side unit are completed Condensation Insulation material Locally purchas...

Page 17: ...s 1 Remove access panel C Fig 46 2 Connect the inter unit and power supply line accord ing to the drawing on the panel side 3 Be sure to size each wire allowing approx 4 10 cm longer than the required length for wiring Store excess wiring inside the cabinet 4 When connections are completed check that all connections are correct as shown in the wiring sys tem diagram on panel side 5 Be sure to grou...

Page 18: ...ool Figs 49a and 49b Use RIGID or equivalent A good flare should have the following characteristics G inside surface is glossy and smooth G edge is smooth G tapered sides are of uniform length 5 3 Caution before Connecting Tubes Tightly a Be sure to apply a sealing cap or water proof tape to prevent dust or water from getting into the tubes before they are used b Be sure to apply refrigerant lubri...

Page 19: ...half of each previous tape turn Fig 55 3 Clamp the tubing bundle to wall using 1 clamp approx every 47 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the con densation drain hose splits away from the bundle and drips clear of the unit and the tubing 5 7 Finishing the Installation After finishing insulating and taping over the tubin...

Page 20: ... time for evacuation Table 7 Hi Lo Indoor unit Outdoor unit Manifold valve Exclusively for R410A Pressure gauge Vacuum pump Charging hose Exclusively for R410A Vacuum pump adapter Exclusively for R410A with reverse flow prevention Fig 57 CAUTION Be sure to use a manifold valve for air purging If it is not avail able use a stop valve field sup ply for this purpose The Hi knob of the manifold valve ...

Page 21: ...rt slightly to release the pressure Then remove the hose 11 Fasten the valve cap on the wide tube service port securely with an adjustable wrench or box wrench Next mount the valve cap on the service valve and tighten it to 170 lbs in 200 kgf cm with a torque wrench This process is very important to prevent gas from leaking from the system 12 Test run the air conditioner See next page 13 While the...

Page 22: ...ng uncooled forced air with the 4 indicator lamps OPERATION lamp TIMER lamp QUIET lamp and ION lamp on the main unit blinking Fig 59c After 3 minutes the system shifts into cooling opera tion and cool air will start to be felt Cool mode test run is unaffected by the room temperature 3 Press the ON OFF operation button of the remote con troller again to stop the test run Fig 59a 4 Finally press the...

Page 23: ...m2 fully close the wide tube valve stem Then quickly stop the unit 5 Disconnect all gauges and hoses and replace the valve caps as they were before I Basic Functions of the Service Valves The basic functions of the service valves are given in Table 8 below Action Narrow Tube Service Valve 2 Way Wide Tube Service Valve 3 Way CLOSED Fully OPEN Fully OPEN Shipping Operating and test running the air c...

Page 24: ...there is an obstacle between the remote con trol unit and the air conditioner since a check signal is sent from the remote control unit every 5 minutes 7 1 Mounting on a Wall Before mounting the remote control unit press the ON OFF operation button at the mounting location to make sure that the air conditioner operates from that location The indoor unit should make a beeping sound to indicate that...

Page 25: ... object such as the tip of a pen to press the ACL button When this has been done oP 1 test run appears blinking in the remote controller clock display area 4 Each time the 1 HR TIMER button is pressed the display changes as shown below Press this button 2 times to change the display to oP 7 address setting Fig 64 5 oP 7 has now been selected for address setting 6 Press the ON OFF operation button ...

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