20
10
4
35
20
35
110
Earth screw
Connection cord (Conform to Type245 IEC57)
3G
×
1.5 mm
2
, 2G
×
1.5 mm
2
Be sure that the cord is not
applied inside the hatched
lines.
BAD
Cord clamp
(There is a terminal block inside.)
Right bottom of
indoor unit
Pull
Under cover
●
For left piping and left rear piping, align the marks on the wall hook
bracket and shape the connection pipe.
●
Bend the connection piping at the bend radius of 70 mm or more and
install no more than 35 mm from the wall.
●
After passing the indoor piping and drain hose through the wall hole,
hang the indoor unit on the hooks at the top and bottom of the wall
hook bracket.
[Installing the indoor unit]
●
Hang the indoor unit from the hooks at the top of the wall hook bracket.
●
Insert the spacer, etc. between the indoor unit and the wall hook
bracket and separate the bottom of the indoor unit from the wall.
Fig. 10
After hooking the indoor unit to the top hook, hook the fittings of the
indoor unit to the two bottom hooks while lowering the unit and
pushing it against the wall.
CONNECTING THE PIPING
Connection
(1) Install the outdoor unit wall cap (supplied with the optional installation set
or procured at the site) to the wall pipe.
(2) Connect the outdoor unit and indoor unit piping.
(3) 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.(Table 2)
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 onto the pipe and flare
the pipe with a flaring tool.
Insert the flare nut (always use the flare nut
attached to the indoor and outdoor units re-
spectively) onto the pipe and perform the flare
processing with a flare tool.
Use the special R410A flare tool, or the conv-
entional (for R22) flare tool.
When using the conventional flare tool, always
use an allowance adjustment gauge and se-
cure the A dimension shown in table 3 .
Check if [L] is flared uniformly
and is not cracked or scratched.
Table 2
Flare nut tightening torque
Indoor unit
Wall hook bracket
(Spacer)
Connection pipe
(6.35 mm dia.)
Connection pipe
(9.52 mm dia.)
Align the marks.
Top hooks
Indoor unit
(Fitting)
Bottom hooks
Wall hook
bracket
Fig. 11
Tighten with two wrenches.
Torque
wrench
Wrench (fixed)
Flare nut
Indoor unit pipe
Connection pipe
To prevent gas leakage, coat the flare
surface with refrigerator oil.
Bend (R70) with
a pipe bender
Flare nut
6.35 mm dia.
9.52 mm dia.
Tightening torque
15.7 to 17.6 N•m
(160 to 180 kgf•cm)
29.4 to 41.1 N•m
(300 to 420 kgf•cm)
Tightening torque standard
(using a 20 cm wrench)
Wrist strength
Arm strength
A (mm)
Table 3
Pipe outside diameter
Pipe outside
diameter
ø 6.35 mm (1/4”)
ø 9.52 mm (3/8”)
Flash tool for
R410A, clutch type
0 to 0.5
0 to 0.5
Conventional (R22) flare tool
Clutch type
1.0 to 1.5
1.0 to 1.5
Wing nut type
1.5 to 2.0
1.5 to 2.0
(1) Match the terminal block numbers and connection
cord colors with those of the outdoor unit.
Erroneous wiring may cause burning of the elec-
tric parts.
(2)
Connect the connection cords firmly to the terminal
block. Imperfect installation may cause a fire.
(3) Always fasten the outside covering of the connec-
tion cord with the cord clamp. (If the insulator is
chafed, electric leakage may occur.)
(4) Securely earth the power cord plug.
(5)
Do not use the earth screw for an external connector.
Only use for interconnection between two units.
CAUTION
Die
A
Pipe
Table 4
1. Check if the piping connections are secure.
2. Check that the stems of 2-way valve and 3-way valve are closed
fully.
3. Connect the gauge manifold charge hose to the charging port
of the 3-way valve (side with the projection for pushing in the
valve core).
4. Open the low pressure side valve of the gauge manifold fully.
5. Operate the vacuum pump and start pump down.
6. Slowly loosen the flare nut of the 3-way valve and check if air
enters, then retighten the flare nut.
(When the flare nut is loosened the operating sound of the
vacuum pump changes and the reading of the compound
pressure gauge goes from minus to zero.)
OUTDOOR UNIT
OUTDOOR UNIT INSTALLATION
AIR PURGE
Always use a vacuum pump to purge the air.
Refrigerant for purging the air is not charged in the
outdoor unit at the factory.
Close the high pressure side valve of the gauge manifold fully and do
not operate it during the following work.
●
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.
Connector cover removal
●
Remove the two mounting screws.
●
Put your hand on the back side (
mark) and take out the connec-
tor cover forwards.
Installing the connector cover
(1) After inserting the three front hooks, then insert the rear hook.
(2) Tighten the two mounting screws.
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.
7. Pump down the system for at least 15 minutes, then check if the
compound pressure gauge reads -0.1 MPa (-76 cmHg, -1 bar).
8. At the end of pump down, close the low pressure side gauge of
the gauge manifold fully and stop the vacuum pump.
9. Slowly loosen the valve stem of the 3-way valve. When the
compound pressure gauge reading reaches 0.1-0.2 MPa,
retighten the valve stem and disconnect the charge hose
from the 3-way valve charging port.
(If the stem of the 3-way valve is opened fully before the
charge hose is disconnected, it may be difficult to disconnect
the charge hose.)
10. Fully open the valve stems of the 2-way valve and 3-way
valve using a hexagon wrench. (After the valve stem be-
gins to turn, turn it with a torque of less than 2.9 N•m (30
kgf•cm) until it stops turning.)
11. Firmly tighten the 2-way valve and 3-way valve blank cap
and the charging port cap.
Fig. 13
ø5 mm
tapping screw (special)
(Rear hook)
Connector cover
ø4 mm
skirted screw
Front hook
Always use the screws as shown above.
Do not select the top and bottom screws incorrectly.
Tightening torque
Blank cap
19.6 to 24.5 N•m (200 to 250 kgf•cm)
Charging port cap
12.3 to 15.7 N•m (125 to 160 kgf•cm)
Fig. 14
Outdoor unit
2-way valve
Valve
stem
Charging
port cap
Charging port
3-way valve
Blank
cap
Flare nut
-0.1 MPa
(-76 cmHg
-1 bar)
Compound pressure gauge
Gauge manifold
Pressure
gauge
High
pressure
side valve
(closed)
Low pressure
side valve
Charge hose
(For a description of how to use the
gauge manifold, refer to the gauge
manifold operation manual.)
Charge
hose
Vacuum pump
CAUTION
(1) Refrigerant must not be discharged into atmos-
phere.
(2) After connecting the piping , check the joints
for gas leakage with gas leak detector.
Vacuum pump adapter
CAUTION
(1) When adding refrigerant, add the refrigerant from
the charging port at the completion of work.
(2) The maximum length of the piping is 15 m. If
the units are further apart than this, correct
operation can not be guaranteed.
Additional charge
Refrigerant suitable for a piping length of 7.5 m is charged in the outdoor
unit at the factory.
When the piping is longer than 7.5 m, additional charging is necessary.
For the additional amount, see the table below.
Pipe length
Additional
refrigerant
7.5 m
None
Table 5
10 m
50 g
Between 7.5 m and 15 m, when using a connection pipe other
than that in the table, charge additional refrigerant with 20g/1 m
as the criteria.
OUTDOOR UNIT WIRING
(1) Remove the outdoor unit connector cover.
(2) Remove the control box cover-B.
(3) Bend the end of the cord as shown in the figure.
(4) Connect the end of the connection cord fully into the terminal block.
(5) Fasten the sheath with a cord clamp.
(6) Install the control box cover-B.
(7) Install the connector cover.
15 m
150 g
[Reverse cycle type]
Fig. 15
Connection cord wiring
Run the connection cord to the rear of the outdoor unit within the range of
the arrows shown in the figure.
(The connector cover becomes difficult to install.)
Fig. 16
[Reverse cycle type]
(1) Remove the cord clamp.
(2) Bend the end of the connection cord as shown in the figure.
(3) Connect the end of the connection cord fully into the terminal block.
(4) Match the terminal block numbers and connection cord with those
of the outdoor unit.
(5) Fasten the connection cord with a cord clamp.
Fasten the outside
covering of the
connection cord with
cord clamp.
(Tab)
Connection cord
Insert the tab into the square hole of the indoor
unit and fasten with a screw.
Indoor unit
terminal
block
Cord clamp
Screw
Fig. 12
*unit: mm
INDOOR UNIT
CUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING
(1) Cut a 65 mm diameter hole in the wall at the position shown in (Fig.
7).
(2) When cutting the wall hole at the inside of the installation frame, cut
the hole within the range of the left and right center marks 40 mm
below the installation frame.
When cutting the wall hole at the outside of the installation frame,
cut the hole at least 10 mm below over.
(3) Cut the hole so that the outside end is lower (5 to 10 mm) than the
inside end.
(4) Always align the center of the wall hole. If misaligned, water leakage
will occur.
(5) Cut the wall pipe to match the wall thickness, stick it into the wall cap,
fasten the cap with vinyl tape, and stick the pipe through the hole.
(The connection pipe is supplied in the installation set.) (Fig. 7)
(6) For left piping and right piping, cut the hole a little lower so that drain
water will flow freely. (Fig. 7)
INSTALLING THE WALL HOOK BRACKET
(1) Install the wall hook bracket so that it is correctly positioned horizon-
tally and vertically. If the wall hook bracket is tiled, water will drip to
the floor.
(2) Install the wall hook bracket so that it is strong enough to withstand
the weight of an adult.
Before fastening the wall hook bracket to the wall with the screws,
level it by tapping the hook at the center of bracket to the wall with
the handle of a screwdriver.
●
Fasten the wall hook bracket to the wall with 6 or more screws through
the holes near the outer edge of the bracket.
●
Check that there is no rattle at the wall hook bracket.
FORMING THE DRAIN HOSE AND PIPE
WARNING
If the wall pipe is not used, the cord interconnecting
the indoor and outdoor units may touch metal and
cause electric leakage.
CAUTION
Install the wall hook bracket horizontally and perpen-
dicularly.
[Rear piping, Right piping, Bottom piping]
●
Install the indoor unit piping in the direction of the wall hole and bind
the drain hose and pipe together with vinyl tape. (Fig. 9)
●
Install the piping so that the drain hose is at the bottom.
●
Wrap the pipes of the indoor unit that are visible from the outside
with decorative tape.
[For Left rear piping, Left piping]
Interchange the drain cap and the drain hose.
CAUTION
After removing the drain hose, do not forget to install
the drain cap.
Fig. 7
Lower
65 mm dia. hole
Center mark
10 mm
or over
Fasten with
vinyl tape
(Wall cap)
(Wall pipe)
(Inside)
5 to 10
mm low
Wall
(Outside)
65 mm dia. hole
Fig.8
Wall hook
bracket
Tapping screw
Tapped
Hook
(Handle of
screwdriver)
Center notch
Hook
Wall hook
bracket
(String)
Counter
weight
Fig.9
Cut off the piping
outlet cutting groove
with a hacksaw, etc.
Decorative tape
Right piping
Notch the thin part
of under cover.
Bind with
vinyl tape
Indoor unit drain
hose (bottom)
Rear piping
Pipe (top)
Bottom piping
For left outlet
piping, cut off the
piping outlet
cutting groove
with a hacksaw.
Drain cap
Indoor unit drain hose
Under cover
Remove the drain
cap by pulling at
the projection at
the end of the cap
with pliers, etc.
Lower
10 mm
or over
Insert the drain cap and drain hose
until it butts against the drain port.
Drain cap
Indoor unit
drain hose
(1) Insulate between pipes.
●
For rear, right, and bottom piping, overlap the connection pipe heat insulation and
indoor unit pipe heat insulation and bind them with vinyl tape so that there is no gap.
●
For left and left rear piping, butt the connection pipe heat insulation and indoor unit
pipe heat insulation together and bind them with and vinyl tape so that there is no gap.
●
For left and left rear piping, wrap the area which accommodates the rear piping hous-
ing section with cloth tape.
●
For left and left rear piping, bind the connection cord to the top of the pipe with vinyl
tape.
●
For left and left rear piping, bundle the piping and drain hose together by wrapping
them with cloth tape over the range within which they fit into the rear piping housing
section.
(2) Temporarily fasten the connection cord along the connection pipe with vinyl tape. (Wrap
to about 1/3 the width of the tape from the bottom of the pipe so that water does not
enter.)
(3) Fasten the connection pipe to the outside wall with saddles, etc.
(4) Fill the gap between the outside wall pipe hole and the pipe with sealer so that rain
water and wind cannot blow in.
(5) Fasten the drain hose to the outside wall, etc.
Fig. 18
Pipe
(Saddle)
(Outside wall cap)
(Sealer putty)
(Outdoors)
Check the following:
Drain hose
GOOD
BAD
BAD
BAD
Lifted up
Saddle
Wave
End in water
Wall
Outdoor unit
Connection cord
Terminal block
Earth
screw
After installed the
control box cover-B
Control box
cover-B
Cord clamp
23 mm
12 mm
Connection cord
(Sheath)
Cord
clamp
(Insulator)
Earth
screw
Sheath
Earth
screw
Earth
screw
Indoor unit
terminal block
Connection cord
Outdoor unit
terminal block
(1) Match the terminal block numbers and connection
cord colors with those of the indoor unit.
Erroneous wiring may cause burning of the electric
parts.
(2)
Connect the connection cords firmly to the terminal
block. Imperfect installation may cause a fire.
(3) Always fasten the outside covering of the con-
nection cord with the cord clamp. (If the insula-
tor is chafed, electric leakage may occur.)
(4) Securely earth the power cord plug.
(5)
Do not use the earth screw for an external connector.
Only use for interconnection between two units.
CAUTION
FINISHING
Fig. 17
Overlap the insulation
Bind the pipes together so
that there is no gap.
Connection pipe
(heat insulation)
Indoor unit pipe
(heat insullation)
Vinyl tape
Pipe
Drain hose
Cloth tape
Wrap with cloth tape
Left piping
Connection cord
Pipe
Drain hose
For connection from the left rear
Connection cord
Drain hose
Wall pipe
Connection
pipe
CSH03F100_mary-1
2004.1.29, 6:38 PM
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