Name and Shape
Q’ty
Application
SPLIT TYPE AIR CONDITIONER
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9360461094)
For authorized service personnel only.
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 models.
However, pay careful attention to the following points:
1
Since the working pressure is 1.6 times higher than that of conventional refrigerant models, some of the piping and
installation and service tools are special. (See the table below.)
Especially, when replacing a conventional refrigerant 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 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 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.
5
When moving, if the compressor stops during pump down, close the valve immediately.
Special tools for R410A
Copper pipes
- 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
Ceiling Suspension Type
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) Install the outdoor unit in a location which can withstand the weight of the unit and vibration, and which can install horizontally.
(2) Provide the indicated space to ensure good airflow.
(3) 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 airflow.)
(4) Do not install the unit near a source of heat, steam, or flammable gas.
(5) 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)
(6) Do not install the unit where strong wind blows or where it is very dusty.
(7) Do not install the unit where people pass.
(8) Install the outdoor unit in a place where it will be free from being dirty or getting wet by rain as much as possible.
(9) Install the unit where connection to the indoor unit is easy.
4
CONNECTING THE PIPE
CONNECTION PIPE REQUIREMENT
ELECTRICAL REQUIREMENT
•••••
Electric wire size and breaker capacity:
2. BENDING PIPES
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.
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
0.80 mm
0.80 mm
0.80 mm
1.00 mm
1.20 mm
Pipe outside diameter
Thickness
Thicknesses of Annealed Copper Pipes (R410A)
SELECTING THE MOUNTING POSITION
Decide the mounting position with the customer as follows:
1
INSTALLATION PROCEDURE
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 expected 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).
•••••
Use pipe with water-resistant heat insulation.
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) Do not install the unit where it will be exposed to direct sunlight.
(4) Install the unit where connection to the outdoor unit is easy.
(5) Install the unit where the drain pipe can be easily installed.
(6) Take servicing, etc., into consideration and leave the spaces shown
in the figure. Also install the unit where the filter can be removed.
WARNING
Select installation locations that can properly support the weight of the indoor and outdoor units. Install the units securely so
that they do not topple or fall.
CAUTION
1
Do not install where there is the danger of combustible gas leakage.
2
Do not install the unit near heat source of heat, steam, or flammable gas.
3
If children under 10 years old may approach the unit, take preventive measures so that they cannot reach the unit.
[FOR HALF CONCEALED INSTALLATION]
Ceiling panel
Ceiling panel
INDOOR UNIT
80 mm
or over
150 mm
or over
10 mm
or over
2
PREPARING INDOOR UNIT
INSTALLATION
REMOVE THE INTAKE GRILLE AND SIDE COVER
(1) Remove the two Air filters.
(2) Remove the two Intake grilles.
•
For
4
Left rear drain and
5
Left drain: Remove air filters and intake
grilles at three places. (Refer to “
2
INDOOR UNIT INSTALLATION”.)
(3) Remove the Side cover A (Right side) and Side cover B (Right and
Left side).
•
For
5
Left drain : Remove both the Side cover A (Right and Left
side). (Refer to “
2
INDOOR UNIT INSTALLATION”.)
(4) This air conditioner can be set up to intake fresh air. For information
about how to install for fresh-air intake, refer to “
B
FRESH-AIR INTAKE”.
INDOOR UNIT INSTALLATION
You can use the accessory template to help you install the indoor unit.
The template helps you determine the appropriate locations for suspen-
sion bolts and pipe opening (drain pipe and connection cord).
[For Half-Concealed Installation]
•••••
Suspension-bolt pitch should be as shown in the figure.
2. SELECT PIPING DIRECTION
Select connection piping and drain piping directions.
[FOR
4
Left rear piping,
5
Left piping]
•••••
Transfer the Drain cap and Drain cap seal.
Drain cap seal
Drain cap
Indoor unit
Drain pan
Drain cap seal
Drain cap
Push cap all the way on
(as far as it will go).
[If using anchor bolts]
(1) Drill holes for anchor bolts at the locations at which you will set the
suspension bolts. Note that anchor bolts are M10 bolts (to be ob-
tained locally).
(2) Install the anchor bolts, then temporarily attach special nut “B” (in-
cluded) and a locally-procured M10 nut to each of the bolts.
Anchor-Bolt Strength
980 to 1470 N (100 to 150 kgf)
4. INSTALLING THE INDOOR UNIT
(1) Lift unit so that suspension bolts pass through the suspension fittings
at the sides (four places), and slide the unit back.
Wall
Ceiling
Ceiling
M10 Anchor Bolt
(Obtained locally)
Special nut B
(Included)
M10 Nut
(Obtained locally)
10 to 15 mm
1. LOCATION OF CEILING SUSPENSION BOLTS
30 mm
Suspension bolt pitch 1600 mm
Dimensions
(Space Required
for Installation)
30 mm
10 mm
155 mm
300 mm
INDOOR UNIT (TOP VIEW)
INDOOR UNIT
Suspension bolt should
extend outward 30 to 75 mm.
3. DRILLING THE HOLES AND ATTACHING THE
SUSPENSION BOLTS
(1) Drill ø25 mm holes at the suspension-bolt locations.
(2) Install the bolts, then temporarily attach Special nuts A and B and a
normal M10 nut to each bolt. (The two special nuts are provided with
the unit. The M10 nut must be obtained locally.) Refer to the figure.
Bolt Strength
980 to 1470 N (100 to 150 kgf)
Ceiling panel
Special nut A (Included)
Special nut B (Included)
M10 Nut (Obtained locally)
10 to 15 mm
INDOOR UNIT
Wall
Ceiling panel
(2) Fasten the indoor unit into place by tightening-up the special “B” bolts
and the M10 nuts. Make sure that unit is secure and will not shift back
and forth.
[For Half-Concealed Installation]
When installing the indoor unit in a semi-concealed orientation, make sure
to reinforce the insulation of the unit on all sides. Drops of water may fall
from the unit if it is not thoroughly insulated.
Glass wool insulate
(10 to 20 mm thick)
INDOOR UNIT
(Top view)
Wall
Ceiling panel
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
piping may lead to water leaks.
•••••
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
38 mm].
•••••
During installation of the drain pipe, be careful to avoid applying
pressure to the drain port of the indoor unit.
•••••
When the pipe is long, install supporters.
•••••
Do not perform air bleeding.
•••••
Always heat insulate (8 mm or over thick) the indoor side of the drain
pipe.
GOOD
BAD
BAD
Drain pipe
Arrange the drain pipe
lower than this portion.
Lifted up
Wave
End in water
Supporter
1.5 to 2 m
(1) Install insulation for the drain pipe.
Cut the included insulation material to an appropriate size and adhere
it to the pipe.
Drain pipe
Insulation for drain pipe
(To be obtained locally. Length
should be at least 8 mm.)
Drain pipe insulation (accessories)
Indoor unit (drain port)
(2) If “
1
Right rear piping” : fasten the drain pipe with VT wire so that the
pipe slopes correctly within the indoor unit.
Indoor unit (rear view)
VT wire
Drain hose
Drain pipe insulation
Drain pipe
No gap
10 mm or over
Indoor unit
OUTDOOR UNIT ACCESSORIES
For outdoor unit drain
piping work (May not be
supplied, depending on
the model.)
For filling in a gap at the
entrance of connection
cords
1
2
1
Drain pipe
Drain cap
Insulation (seal)
STANDARD PARTS
The following installation parts are furnished.
Use them as required.
INDOOR UNIT ACCESSORIES
Q’ty
1
2
1
2
1
1
2
1
Name and Shape
Remote
control unit
Battery (penlight)
Remote
control
unit holder
Tapping screw
(ø3
×
12)
Drain hose insulation
VT wire
Coupler heat insulator (large)
Coupler heat insulator (small)
Nylon fastener
Special nut A
(large flange)
Special nut B
(small flange)
Installation
template
Auxiliary pipe assembly
Application
Use for air conditioner
operation
For remote control unit
For mounting the remote
control unit
For remote control unit
holder installation
Adhesive type 70
×
230
For fixing the drain hose
L 280 mm
For indoor side pipe joint
(Gas pipe)
For indoor side pipe joint
(Liquid pipe)
For fixing the coupler heat
insulator
For installing indoor unit
For installing indoor unit
For positioning the indoor
unit
For connecting the piping
Large
4
Small
4
4
4
1
1
OPTIONAL PARTS
The following options are available.
•••••
DRAIN PUMP UNIT: UTR-DPB241 (P/N 9034087001)
•••••
When there are obstacles at the back side.
•••••
When there are obstacles at the back and front sides.
•••••
When there are obstacles at the back side with the installation of
more than one unit.
AIR
100 mm
or more
600 mm
or more
100 mm
or more
250 mm
or more
250 mm
or more
300 mm
or more
AIR
100-300 mm*
250 mm or more
(Service space)
300 mm
or more
600-1000 mm*
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 the
table. If the units are further apart than this, correct
operation can not be guaranteed.
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 flare tool.
When using conventional flare tools to flare R410A pipes, the dimension
A should be approximately 0.5 mm more than indicated in the table (for
flaring with R410A flare tools) to achieve the specified flaring. Use a thick-
ness gauge to measure the dimension A.
Pipe outside
diameter
Width across flats
of Flare nut
Width across flats
Check if [L] is flared uniformly
and is not cracked or scratched.
B
Die
A
Pipe
3. CONNECTION PIPES
Indoor unit
(1) Detach the caps and plugs from the pipes.
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.
(2) Centering the pipe against port on the indoor unit, turn the flare nut
with your hand.
To prevent gas leakage, coat the flare
surface with alkylbenzene oil (HAB).
Do not use mineral oil.
(3) Remove the filter guide.
Indoor unit
Filter guide
(4) Attach the connection pipe.
Connection pipe (Liquid)
Indoor unit
Connection pipe (Gas)
•
For
2
Top piping and
3
Right piping connections, use the Auxiliary
pipe (Gas pipe) provided.
2
Top piping
Connection pipe (Gas)
Indoor unit (rear)
Connection pipe (Gas)
3
Right piping
Auxiliary pipe (Gas pipe)
(5) When the flare nut is tightened properly by your hand, use a torque
wrench to finally tighten it.
Torque wrench
Holding spanner
Body side
CAUTION
Hold the torque wrench at its grip, keeping it in the right
angle with the pipe, in order to tighten the flare nut
correctly.
Outdoor unit
Tighten the flare nut of the connection pipe at the outdoor unit valve con-
nector. The tightening method is the same as that as at the indoor side.
3-way valve
(Liquid)
Flare nut
Connection pipe
(Liquid)
3-way valve
(Gas)
Flare nut
Connection pipe
(Gas)
3
OUTDOOR UNIT
INSTALLATION
1. OUTDOOR UNIT PROCESSING
(1) Outdoor unit to be fasten with bolts at the four places indicated by the
arrows without fail.
(2) Fix securely with bolts on a solid block. (Use 4 sets of commercially
available M10 bolt, nut and washer.)
(3) Since the drain water flows out of the outdoor unit during heating
operation, install the drain pipe and connect it to a commercial 16 mm
hose. (Reverse cycle model only)
(4) When installing the drain pipe, plug all the holes other than the drain
pipe mounting hole in the bottom of the outdoor unit with putty so
there is no water leakage. (Reverse cycle model only)
Drain pipe mounting hole
Base
Drain pipe
Bottom side
Drain cap
mounting place
Drain pipe
mounting place
650 mm
4-ø 12 hole
370 mm
Bolt
Nut
Block
Flare nut
Tightening torque
6.35 mm (1/4 in.) dia.
9.52 mm (3/8 in.) dia.
12.70 mm (1/2 in.) dia.
15.88 mm (5/8 in.) dia.
19.05 mm (3/4 in.) dia.
Ceiling
INDOOR UNIT
80 mm
or over
Ceiling
150 mm
or over
10 mm
or over
1
Right rear piping
5
Left piping
(Drain pipe only)
4
Left rear piping
(Drain pipe only)
2
Top piping
(Connection pipe only)
3
Right
piping
Cut off the piping outlet cutting groove
with a hacksaw, etc.
INDOOR UNIT (TOP VIEW)
•••••
When there are obstacles at the back, side(s), and top.
Air filter
Intake grille
Tapping screw
INDOOR UNIT
Side cover A (Right side)
Side cover B
(Left side)
Side cover B (Right side)
MAX.
50 m
Diameter
Pipe length
Gas
36 Type
45, 54 Type
15.88 mm (5/8 in.) 19.05 mm (3/4 in.)
Liquid
9.52 mm (3/8 in.)
MIN.
5 m
30 m
Maximum height
(between indoor
and outdoor)
Drilling position for Suspension bolt
Ceiling
Wall
Template
Drilling position for piping
40 mm
Ceiling Opening: 1580 mm
40 mm
Ceiling panel
Ceiling Opening: 640 mm
15 mm
Suspension bolt should
extend outward 30 to 50 mm.
INDOOR UNIT
Ceiling panel
CAUTION
In order to check the drainage, be sure to use a level
during installation of the indoor unit. If the installation site
of the indoor unit is not level, water leakage may occur.
5. DRAIN PIPING
CAUTION
The maximum lengths of this product are shown in the following table. If the units are further apart than this, correct operation
can not be guaranteed.
MIN.
1.0
Power supply cord (mm )
Connection cord (mm )
20
Breaker capacity (A)
MAX.
4.0
MIN.
2.5
MAX.
2.5
CAUTION
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 extremely cold weather. (Reverse cycle model
only)
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
0 to 0.5
Pipe outside diameter
Dimension A
(mm)
Flare tool for R410A, clutch type
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
9.1
13.2
16.6
19.7
24.0
Pipe outside diameter
Dimension B
(mm)
0
-0.4
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.70 mm (1/2 in.)
15.88 mm (5/8 in.)
19.05 mm (3/4 in.)
17 mm
22 mm
26 mm
29 mm
36 mm
The pipes are shaped by your hands. Be careful not to collapse them.
Do not bend the pipes in an angle more than 90
°.
When pipes are repeatedly bend 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.
14 to 18 N·m (140 to 180 kgf·cm)
33 to 42 N·m (330 to 420 kgf·cm)
50 to 62 N·m (500 to 620 kgf·cm)
63 to 77 N·m (630 to 770 kgf·cm)
100 to 110 N·m (1000 to 1100 kgf·cm)
•••••
Always use H07RN-F or equivalent to the connection cord.
•••••
Install all electrical works in accordance to the standard.
•••••
Install the disconnect device with a contact gap of at least 3 mm in all poles nearby the units. (Both indoor unit and outdoor unit)
•••••
Install the circuit breaker nearby the units.
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
conventional refrigerant, it is necessary to choose adequate materials.
Thicknesses of copper pipes used with R410A are as shown in the table. Never
use copper pipes thinner than that in the table even when it is available on
the market.
2
2
*
If the space is larger than that is stated, the condition
will be the same as that there are no obstacles.
HM04K358_IM_front.p65
12/3/04, 3:30 PM
1
