00_CV_3P207974-2D.fm Page 1 Friday, September 4, 2009 1:41 PM

INSTALLATION

MANUAL

R410A Split Series

Models

ARX20GV1B

ARX25GV1B

ARX35GV1B

ARX20JV1B

ARX25JV1B

ARX35JV1B

Installation manual

R410A Split series

English

Installationsanleitung

Split-Baureihe R410A

Deutsch

Manuel d’installation

Série split R410A

Français

Montagehandleiding

R410A Split-systeem

Nederlands

Manual de instalación

Serie Split R410A

Español

Manuale d’installazione

Serie Multiambienti R410A

Italiano

Εγχειρßδιο εγκατÜστασηò

διαιροýìενηò σειρÜò R410A

ΕλληνικÜ

Manual de Instalação

Série split R410A

Portugues

3SB64526-9D.fm Page 1 Tuesday, September 15, 2009 1:28 PM

3SB64526-9D

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1

Safety Precautions

• Read these Safety Precautions carefully to ensure correct installation.

• This manual classifies the precautions into WARNING and CAUTION.

Be sure to follow all the precautions below: they are all important for ensuring safety.

WARNING...............Failure to follow any of WARNING is likely to result in such grave consequences as death or serious injury.

CAUTION...............Failure to follow any of CAUTION may result in grave consequences in some cases.

• The following safety symbols are used throughout this manual:

Be sure to observe this instruction.

Be sure to establish an earth connection.

Never attempt.

• After completing installation, test the unit to check for installation errors. Give the user adequate instructions concerning the use and cleaning of the unit according to the Operation Manual.

WARNING

• Installation should be left to the dealer or another professional.

Improper installation may cause water leakage, electrical shock, or fire.

• Install the air conditioner according to the instructions given in this manual.

Incomplete installation may cause water leakage, electrical shock, or fire.

• Be sure to use the supplied or specified installation parts.

Use of other parts may cause the unit to come to lose, water leakage, electrical shock, or fire.

• Install the air conditioner on a solid base that can support the weight of the unit.

An inadequate base or incomplete installation may cause injury in the event the unit falls off the base.

• Electrical work should be carried out in accordance with the installation manual and the national electrical wiring rules or code of practice. Insufficient capacity or incomplete electrical work may cause electrical shock or fire.

• Be sure to use a dedicated power circuit. Never use a power supply shared by another appliance.

• For wiring, use a cable length enough to cover the entire distance with no connection.

Do not use an extension cord. Do not put other loads on the power supply, use a dedicated power circuit.

(Failure to do so may cause abnormal heat, electric shock or fire.)

• Use the specified types of wires for electrical connections between the indoor and outdoor units.

Firmly clamp the interconnecting wires so their terminals receive no external stresses. Incomplete connections or clamping may cause terminal overheating or fire.

• After connecting interconnecting and supply wiring be sure to shape the cables so that they do not put undue force on the electrical covers or panels.

Install covers over the wires. Incomplete cover installation may cause terminal overheating, electrical shock, or fire.

• If any refrigerant has leaked out during the installation work, ventilate the room.

(The refrigerant produces a toxic gas if exposed to flames.)

• After all installation is complete, check to make sure that no refrigerant is leaking out.

(The refrigerant produces a toxic gas if exposed to flames.)

• When installing or relocating the system, be sure to keep the refrigerant circuit free from substances other than the specified refrigerant (R410A), such as air.

(Any presence of air or other foreign substance in the refrigerant circuit causes an abnormal pressure rise or rupture, resulting in injury.)

• During pump-down, stop the compressor before removing the refrigerant piping.

If the compressor is still running and the stop valve is open during pump-down, air will be sucked in when the refrigerant piping is removed, causing abnormal pressure in the freezer cycle which will lead to breakage and even injury.

• During installation, attach the refrigerant piping securely before running the compressor.

If the compressor is not attached and the stop valve is open during pump-down, air will be sucked in when the compressor is run, causing abnormal pressure in the freezer cycle which will lead to breakage and even injury.

• Be sure to establish an earth. Do not earth the unit to a utility pipe, arrester, or telephone earth.

Incomplete earth may cause electrical shock, or fire. A high surge current from lightning or other sources may cause damage to the air conditioner.

• Be sure to install an earth leakage breaker. Failure to install an earth leakage breaker may result in electric shocks, or fire.

CAUTION

• Do not install the air conditioner in a place where there is danger of exposure to inflammable gas leakage.

If the gas leaks and builds up around the unit, it may catch fire.

• Establish drain piping according to the instructions of this manual. Inadequate piping may cause flooding.

• Tighten the flare nut according to the specified method such as with a torque wrench.

If the flare nut is tightened too hard, the flare nut may crack after a long time and cause refrigerant leakage.

• Make sure to provide for adequate measures in order to prevent that the outdoor unit be used as a shelter by small animals.

Small animals making contact with electrical parts can cause malfunctions, smoke or fire. Please instruct the customer to keep the area around the unit clean.

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Accessories

Accessories supplied with the outdoor unit:

(A) Installation Manual

(C) Refrigerant charge label

1

(B) Drain plug (Heat pump-Models)

1

There is on the bottom packing case.

(D) Multilingual fluorinated greenhouse gases label

1

1

Precautions for Selecting the Location

1) Choose a place solid enough to bear the weight and vibration of the unit, where the operation noise will not be amplified.

2) Choose a location where the hot air discharged from the unit or the operation noise will not cause a nuisance to the neighbors of the user.

3) Avoid places near a bedroom and the like, so that the operation noise will cause no trouble.

4) There must be sufficient spaces for carrying the unit into and out of the site.

5) There must be sufficient space for air passage and no obstructions around the air inlet and the air outlet.

6) The site must be free from the possibility of flammable gas leakage in a nearby place.

7) Install units, power cords and inter-unit cables at least 3 meter away from television and radio sets. This is to prevent interference to images and sounds. (Noises may be heard even if they are more than 3 meter away depending on radio wave conditions.)

8) In coastal areas or other places with salty atmosphere of sulfate gas, corrosion may shorten the life of the air conditioner.

9) Since drain flows out of the outdoor unit, do not place under the unit anything which must be kept away from moisture.

NOTE

Cannot be installed hanging from ceiling or stacked.

CAUTION

When operating the air conditioner in a low outdoor ambient temperature, be sure to follow the instructions described below.

1) To prevent exposure to wind, install the outdoor unit with its suction side facing the wall.

2) Never install the outdoor unit at a site where the suction side may be exposed directly to wind.

3) To prevent exposure to wind, it is recommended to install a baffle plate on the air discharge side of the outdoor unit.

4) In heavy snowfall areas, select an installation site where the snow will not affect the unit.

Construct a large canopy.

Construct a pedestal.

Install the unit high enough off the ground to prevent burying in snow.

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Outdoor Unit Installation Drawings

Wrap the insulation pipe with the finishing tape from bottom to top.

Max. allowable length

*

Min. allowable length

Max. allowable height

Additional refrigerant required for refrigerant pipe exceeding

10m in length.

Gas pipe

Liquid pipe

15m

1.5m

12m

20g/m

O.D. 9.5mm

O.D. 6.4mm

* Be sure to add the proper amount of additional refrigerant.

Failure to do so may result in reduced perfomance.

* The suggested shortest pipe length is 1.5m, in order to avoid noise from the outdoor unit and vibration.

(Mechanical noise and vibration may occur depending on how the unit is installed and the environment in which it is used.)

In sites with poor drainage, use block bases for outdoor unit.

Adjust foot height until the unit is leveled. Otherwise, water leakage or pooling of water may occur.

CAUTION

Set the piping length from

1.5m to 15m.

250mm from wall

Stop valve cover

How to remove the stop valve cover.

Remove the screw on the stop valve cover.

Slide the lid downward to remove it.

How to attach the stop valve cover.

Insert the upper part of the stop valve cover into the outdoor unit to install.

Tighten the screws.

300

Foot bolt-hole centres

96

(From unit’s side)

Allow space for piping and electrical servicing.

Where there is a danger of the unit falling, use foot bolts, or wires.

unit: mm

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Installation Guidelines

• Where a wall or other obstacle is in the path of outdoor unit’s intake or exhaust airflow, follow the installation guidelines below.

• For any of the below installation patterns, the wall height on the exhaust side should be 1200mm or less.

Wall facing one side Walls facing two sides

More than 50 More than 100

More than 150

More than 100

1200 or less

More than 50 More than 50

Side view Top view

Walls facing three sides

More than 150

More than 50

Top view

More than 300

Unit: mm

Precautions on Installation

• Check the strength and level of the installation ground so that the unit will not cause any operating vibration or noise after installed.

• In accordance with the foundation drawing, fix the unit securely by means of the foundation bolts. (Prepare four sets of M8 or M10 foundation bolts, nuts and washers each which are available on the market.)

• It is best to screw in the foundation bolts until their length are 20mm from the foundation surface.

Outdoor Unit Installation

1.

Installing outdoor unit.

1) When installing the outdoor unit, refer to “Precautions for Selecting the Location” and the “Outdoor Unit Installation Drawings.”

2) If drain work is necessary, follow the procedures below.

2.

Drain work. (Heat pump-models.)

Drain-water hole

1) Use drain plug for drainage.

2) If the drain port is covered by a mounting base or floor surface, place additional foot bases of at least 30mm in height under the outdoor unit’s feet.

3) In cold areas, do not use a drain hose with the outdoor unit.

(Otherwise, drain water may freeze, impairing heating performance.)

Bottom frame

Drain plug

Hose (available commercially, inner dia. 16mm)

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Outdoor Unit Installation

3.

Flaring the pipe end.

1) Cut the pipe end with a pipe cutter.

2) Remove burrs with the cut surface facing downward so that the chips do not enter the pipe.

3) Put the flare nut on the pipe.

4) Flare the pipe.

5) Check that the flaring is properly made.

(Cut exactly at right angles.) Remove burrs

Clutch-type

Flaring

Set exactly at the position shown below.

A Flare tool for R410A Conventional flare tool

Clutch-type (Rigid-type) Wing-nut type (Imperial-type)

Die A 0-0.5mm

1.0-1.5mm

1.5-2.0mm

Flare’s inner surface must be flaw-free.

Check

The pipe end must be evenly flared in a perfect circle.

Make sure that the flare nut is fitted.

WARNING

1) Do not use mineral oil on flared part.

2) Prevent mineral oil from getting into the system as this would reduce the lifetime of the units.

3) Never use piping which has been used for previous installations. Only use parts which are delivered with the unit.

4) Do never install a drier to this R410A unit in order to guarantee its lifetime.

5) The drying material may dissolve and damage the system.

6) Incomplete flaring may cause refrigerant gas leakage.

4.

Refrigerant piping.

CAUTION

1) Use the flare nut fixed to the main unit. (To prevent cracking of the flare nut by aged deterioration.)

2) To prevent gas leakage, apply refrigeration oil only to the inner surface of the flare. (Use refrigeration oil for R410A.)

3) Use torque wrenches when tightening the flare nuts to prevent damage to the flare nuts and gas leakage.

Align the centres of both flares and tighten the flare nuts 3 or 4 turns by hand. Then tighten them fully with the torque wrenches.

[Apply oil] [Tighten]

Do not apply refrigeration oil to the outer surface.

Apply refrigeration oil to the inner surface of the flare.

Torque wrench

Flare nut

Spanner

Piping union

Flare nut

Do not apply refrigeration oil to the flare nut avoid tightening with over torque.

Flare nut tightening torque

Gas side Liquid side

3/8 inch

(333-407kgf l cm)

1/4 inch

14.2-17.2N l m

(144-175kgf l cm)

Valve cap tightening torque

Gas side Liquid side

3/8 inch

(220-280kgf l cm)

1/4 inch

21.6-27.4N l m

(220-280kgf l cm)

Service port cap tightening torque

10.8~14.7N l m

(110~150kgf l cm)

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5.

Purging air and checking gas leakage.

• When piping work is completed, it is necessary to purge the air and check for gas leakage.

WARNING

1) Do not mix any substance other than the specified refrigerant (R410A) into the refrigeration cycle.

2) When refrigerant gas leaks occur, ventilate the room as soon and as much as possible.

3) R410A, as well as other refrigerants, should always be recovered and never be released directly into the environment.

4) Use a vacuum pump for R410A exclusively. Using the same vacuum pump for different refrigerants may damage the vacuum pump or the unit.

• If using additional refrigerant, perform air purging from the refrigerant pipes and indoor unit using a vacuum pump, then charge additional refrigerant.

• Use a hexagonal wrench (4mm) to operate the stop valve rod.

• All refrigerant pipe joints should be tightened with a torque wrench at the specified tightening torque.

Compound pressure gauge

Pressure meter

Gauge manifold

Low-pressure valve

Highpressure valve

Valve caps

Liquid stop valve

Charging hoses

Vacuum pump

Service port

Gas stop valve

1) Connect projection side of charging hose (which comes from gauge manifold) to gas stop valve’s service port.

2) Fully open gauge manifold’s low-pressure valve (Lo) and completely close its high-pressure valve (Hi).

(High-pressure valve subsequently requires no operation.)

3) Do vacuum pumping and make sure that the compound pressure gauge reads –0.1MPa (–76cmHg)*1.

4) Close gauge manifold’s low-pressure valve (Lo) and stop vacuum pump.

(Keep this state for a few minutes to make sure that the compound pressure gauge pointer does not swing back.)*2.

5) Remove caps from liquid stop valve and gas stop valve.

6) Turn the liquid stop valve’s rod 90 degrees counterclockwise with a hexagonal wrench to open valve.

Close it after 5 seconds, and check for gas leakage.

Using soapy water, check for gas leakage from indoor unit’s flare and outdoor unit’s flare and valve rods.

After the check is complete, wipe all soapy water off.

7) Disconnect charging hose from gas stop valve’s service port, then fully open liquid and gas stop valves.

(Do not attempt to turn valve rod beyond its stop.)

8) Tighten valve caps and service port caps for the liquid and gas stop valves with a torque wrench at the specified torques.

*1. Pipe length vs. vacuum pump run time.

Pipe length

Run time

Up to 15 metres

Not less than 10 min.

*2. If the compound pressure gauge pointer swings back, refrigerant may have water content or a loose pipe joint may exists.

Check all pipe joints and retighten nuts as needed, then repeat steps 2) through 4).

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7

Outdoor Unit Installation

6.

Refilling the refrigerant.

Check the type of refrigerant to be used on the machine nameplate.

Precautions when adding R410A

Fill from the liquid pipe in liquid form.

It is a mixed refrigerant, so adding it in gas form may cause the refrigerant composition to change, preventing normal operation.

1) Before filling, check whether the cylinder has a siphon attached or not. (It should have something like “liquid filling siphon attached” displayed on it.)

Filling a cylinder with an attached siphon

Stand the cylinder upright when filling.

There is a siphon pipe inside, so the cylinder need not be upside-down to fill with liquid.

Filling other cylinders

Turn the cylinder upside-down when filling.

• Be sure to use the R410A tools to ensure pressure and to prevent foreign objects entering.

Important information regarding the refrigerant used

This product contains fluorinated greenhouse gases covered by the Kyoto Protocol. Do not vent gases into the atmosphere.

Refrigerant type: R410A

GWP (1) value: 1975 (1) GWP = global warming potential

The filled out label must be adhered in the proximity of the product charging port (e.g. onto the inside of the stop valve cover).

4

1 factory refrigerant charge of the product: see unit name plate

2 additional refrigerant amount charged in the field

3 total refrigerant charge

Please fill in with indelible ink, n

1 the factory refrigerant charge of the product, n

2 the additional refrigerant amount charged in the field and n

1 + 2 the total refrigerant charge on the refrigerant charge label supplied with the product.

1

2

4 Contains fluorinated greenhouse gases covered by the Kyoto

Protocol

5 outdoor unit

3 6 refrigerant cylinder and manifold for charging

6 5

NOTE

National implementation of EU regulation on certain fluorinated greenhouse gases may require to provide the appropriate official national language on the unit. Therefor an additional multilingual fluorinated greenhouse gases label is supplied with the unit.

Sticking instructions are illustrated on the backside of that label.

7.

Refrigerant piping work.

7-1 Cautions on pipe handling.

1) Protect the open end of the pipe against dust and moisture.

2) All pipe bends should be as gentle as possible. Use a pipe bender for bending.

Rain

7-2 Selection of copper and heat insulation materials.

When using commercial copper pipes and fittings, observe the following:

1) Insulation material: Polyethylene foam

Heat transfer rate: 0.041 to 0.052W/mK (0.035 to 0.045kcal/(mh •°C))

Refrigerant gas pipe’s surface temperature reaches 110°C max.

Choose heat insulation materials that will withstand this temperature.

2) Be sure to insulate both the gas and liquid piping and to provide insulation dimensions as below.

Gas side Liquid side

O.D. 9.5mm

O.D. 6.4mm

Minimum bend radius

30mm or more

Thickness 0.8mm (C1220T-O)

Gas pipe thermal insulation

I.D. 12-15mm

Liquid pipe thermal insulation

I.D. 8-10mm

Thickness 10mm Min.

3) Use separate thermal insulation pipes for gas and liquid refrigerant pipes.

Be sure to place a cap.

If no flare cap is available, cover the flare mouth with tape to keep dirt or water out.

Gas pipe

Inter-unit wiring

Gas pipe insulation

Finishing tape

Wall

Liquid pipe

Liquid pipe insulation

Drain hose

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Pump Down Operation

In order to protect the environment, be sure to pump down when relocating or disposing of the unit.

1) Remove the valve cap from liquid stop valve and gas stop valve.

2) Carry out forced cooling operation.

3) After five to ten minutes, close the liquid stop valve with a hexagonal wrench.

4) After two to three minutes, close the gas stop valve and stop forced cooling operation.

Liquid stop valve

Hexagonal wrench

Close

How to force cooling operation mode

■ Using the indoor unit operation/stop button

Press the indoor unit operation/stop button for at least five seconds. (Operation will start.)

• Forced cooling operation will stop automatically after around 15 minutes.

To force a test run to stop, press the indoor unit operation/stop button.

Gas stop valve Valve cap

■ Using the main unit’s remote controller

1) Press the “operation/stop” button. (Operation will start.)

2) Press the temperature button and the “operation select” button at the same time.

3) Press the “operation select” button twice.

( will be displayed and the unit will enter test run mode.)

4) Press the “operation select” button to return the operation mode to cooling.

• Test run mode will stop automatically after around 30 minutes. To force a test run to stop, press the operation/stop button.

CAUTION

1) When pressing the switch, do not touch the terminal block. It has a high voltage, so doing so may cause electric shock.

2) After closing the liquid stop valve, close the gas stop valve within three minutes, then stop the forced operation.

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Wiring

WARNING

1) Do not use tapped wires, stranded wires, extension cords, or starburst connections, as they may cause overheating, electrical shock, or fire.

2) Do not use locally purchased electrical parts inside the product. (Do not branch the power for the drain pump, etc., from the terminal block.) Doing so may cause electric shock or fire.

3) Be sure to install an earth leakage breaker. (One that can handle higher harmonics.)

(This unit uses an inverter, which means that it must be used an earth leakage breaker capable handling harmonics in order to prevent malfunctioning of the earth leakage breaker itself.)

4) Use an all-pole disconnection type breaker with at least 3mm between the contact point gaps.

• Do not turn ON the safety breaker until all work is completed.

1) Strip the insulation from the wire (20mm).

2) Connect the connection wires between the indoor and outdoor units so that the termi-

nal numbers match. Tighten the terminal screws securely. We recommend a flathead screwdriver be used to tighten the screws.

The screws are packed with the terminal board.

Indoor unit

1

2

3

Firmly fix the wires with the terminal screws.

When wire length exceeds 10m, use 2.0mm diameter wires.

Firmly fix the wires with the terminal screws.

Outdoor unit

1 2 3 L N

H05RN

Use 2.0mm diameter wires.

Safety breaker

16A

Earth leakage circuit breaker

Power supply

50Hz 220-240V

Earth

1

2

3

1 2 3

Power supply terminal block

Shape wires so that the stop valve cover fit securely.

Use the specified wire type and connect it securely.

Firmly secure wire retainer so wire terminations will not receive external stress.

Observe the notes mentioned below when wiring to the power supply terminal board.

Precautions to be taken for power supply wiring.

Use a round crimp-style terminal for connection to the power supply terminal board. In case it cannot be used due to unavoidable reasons, be sure to observe the following instruction.

Place the round crimp-style terminals on the wires up to the covered part and secure in place.

Round crimp-style terminal

Stranded Wire

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CAUTION

When connecting the connection wires to the terminal board using a single core wire, be sure to perform curling.

Problems with the work may cause heat and fires.

Strip wire end to this point.

Good

Excessive strip length may cause electrical shock or leakage.

Wrong

Stripping wire at terminal block

3) Pull the wire and make sure that it does not disconnect. Then fix the wire in place with a wire stop.

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Test Run and Final Check

1.

Trial operation and testing.

1-1 Measure the supply voltage and make sure that it falls in the specified range.

1-2 Trial operation should be carried out in either cooling or heating mode.

■ For heat pump

• In cooling mode, select the lowest programmable temperature; in heating mode, select the highest programmable temperature.

1) Trial operation may be disabled in either mode depending on the room temperature.

2) After trial operation is complete, set the temperature to a normal level (26 °C to 28°C in cooling mode, 20°C to 24°C in heating mode).

3) For protection, the system disables restart operation for 3 minutes after it is turned off.

■ For cooling only

• Select the lowest programmable temperature.

1) Trial operation in cooling mode may be disabled depending on the room temperature.

2) After trial operation is complete, set the temperature to a normal level (26 °C to 28°C).

3) For protection, the unit disables restart operation for 3 minutes after it is turned off.

1-3 Carry out the test operation in accordance with the operation manual to ensure that all functions and parts, such as louver movement, are working properly.

• The air conditioner requires a small amount of power in its standby mode. If the system is not to be used for some time after installation, shut off the circuit breaker to eliminate unnecessary power consumption.

• If the circuit breaker trips to shut off the power to the air conditioner, the system will restore the original operation mode when the circuit breaker is opened again.

2.

Test items.

Test items

Indoor and outdoor units are installed properly on solid bases.

No refrigerant gas leaks.

Symptom

(diagnostic display on RC)

Fall, vibration, noise

Incomplete cooling/heating function

Refrigerant gas and liquid pipes and indoor drain hose extension are thermally insulated.

Water leakage

Draining line is properly installed.

Water leakage

System is properly earthed.

The specified wires are used for interconnecting wire connections.

Indoor or outdoor unit’s air intake or exhaust has clear path of air.

Stop valves are opened.

Indoor unit properly receives remote controller commands.

Electrical leakage

Inoperative or burn damage

Incomplete cooling/heating function

Inoperative

Check

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Two-dimensional bar code is a code for manufacturing.

3P207974-2D M07B064C

(0911) HT