Panasonic | KE30NKUA | Installation manual | Panasonic KE30NKUA Installation Manual

INSTALLATION INSTRUCTIONS
Split System Air Conditioner
$/09(08*54+0:054,8;9,9:/,8,-80.,8(4:"
NOTE
Contents
>:,84(2+0(3,:,85-9,8<0*,658:"
Page
IMPORTANT!
Please Read Before Starting .................................. 2
Model Combinations
1.
GENERAL .......................................................... 4
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation
2.
INSTALLATION SITE SELECTION ................... 5
2-1. Indoor Unit
2-2. Outdoor Unit
3.
HOW TO INSTALL THE INDOOR UNIT ........... 13
3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Removing and Installing the Grille
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
3-7. Wire Size and Length
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Frame Fastening Method
3-11. Drain Hose
4.
HOW TO INSTALL THE OUTDOOR UNIT ....... 23
4-1. Wiring Instructions for the Outdoor Unit
4-2. Routing the Tubing and Wiring
5.
REFRIGERANT TUBING .................................. 24
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................................................... 26
Air Purging with a Vacuum Pump (for Test Run)
Basic Functions of the Service Valves
Pump Down
Service Valve Connections
7.
REMOTE CONTROLLER INSTALLATION
POSITION ......................................................... 30
7-1. Mounting on a Wall
8.
ADDRESS SWITCH .......................................... 31
8-1. Address Setting of the Remote Controller
Combine indoor and outdoor units only as listed
below.
Model No.
Indoor Unit
CS-KE30NKU
CS-KE36NKU
Outdoor Unit
CU-KE30NKU
CU-KE36NKU
Power Source:
60 Hz, single-phase, 230/208 V
&
IMPORTANT!
Please Read Before Starting
When Transporting
Be careful when picking up and moving the indoor and outdoor units. Get a partner to help, and bend your knees when
lifting to reduce strain on your back. Sharp edges or thin aluminum fins on the air conditioner can cut your fingers.
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.
When Installing…
Select an installation location which is rigid and strong
enough to support or hold the unit, and select a location for
easy maintenance.
For safe installation and trouble-free operation, you
must:
Carefully read this instruction booklet before beginning.
Follow each installation or repair step exactly as shown.
Observe all local, state, and national electrical codes.
Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard
or unsafe practice which can
WARNING
result in severe personal injury
or death.
This symbol refers to a hazard
or unsafe practice which can
CAUTION
result in personal injury or product or property damage.
…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.
Keep the fire alarm and the air
outlet at least 1.5 m away from
CAUTION
the unit.
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 Moist or Uneven Locations
In Case of Improper Installation
…In an Area with High Winds
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.
Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.
The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to
follow the instructions in this document.
…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.
SPECIAL PRECAUTIONS
WARNING
‡
‡
‡
‡
‡
When Connecting Refrigerant Tubing
When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.
'RQRWVXSSO\SRZHUWRWKHXQLWXQWLODOOZLULQJDQGWXELQJ
are completed or reconnected and checked.
+LJKO\GDQJHURXVHOHFWULFDOYROWDJHVDUHXVHGLQWKLV
system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or
death.
*URXQGWKHXQLW following local electrical codes.
&RQQHFWDOOZLULQJWLJKWO\/RRVHZLULQJPD\FDXVHRYHU
heating at connection points and a possible fire hazard.
7RSUHYHQWSRVVLEOHKD]DUGVIURPLQVXODWLRQIDLOXUH
the unit must be grounded.
WARNING
‡ :KHQSHUIRUPLQJpiping work
do not mix air except for specified refrigerant (R410A) in
refrigeration cycle. It causes
capacity down, and risk of
explosion and injury due to
high tension inside the refrigerant cycle.
‡ 5HIULJHUDQWJDVOHDNDJHPD\
cause fire.
‡ 'RQRWDGGRUUHSODFHUHIULJHUDQW
other than specified type.
It may cause product damage,
burst and injury etc.
‡ 9HQWLODWHWKHURRPZHOOLQWKHHYHQWWKDWUHIULJHUDQW
gas leaks during the installation. Be careful not to allow
contact of the refrigerant gas with a flame as this will
cause the generation of poisonous gas.
2
Others
‡ 8VHWKHIODUHPHWKRGIRUFRQQHFWLQJWXELQJ
‡ $SSO\UHIULJHUDQWOXEULFDQWWRWKHPDWFKLQJVXUIDFHVRI
the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leakfree connection.
CAUTION
‡ &KHFNFDUHIXOO\IRUOHDNVEHIRUHVWDUWLQJWKHWHVWUXQ
‡ 9HQWLODWHDQ\HQFORVHGDUHDVZKHQLQVWDOOLQJRUWHVWLQJ
the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously
toxic gas.
‡ 'RQRWOHDNUHIULJHUDQWZKLOHSLSLQJZRUNIRUDQLQVWDOODWLRQ
or re-installation, and while repairing refrigeration parts.
Handle liquid refrigerant carefully as it may cause frostbite.
‡ &RQILUPXSRQFRPSOHWLQJLQVWDOODWLRQWKDWQRUHIULJHUDQW
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.
When Servicing
‡ 7XUQWKHSRZHU2)) DWWKHPDLQSRZHUER[PDLQV
before opening the unit to check or repair electrical
parts and wiring.
‡ 'RQRWWRXFKWKHDLULQOHWRUWKHVKDUSDOXPLQXP
fins of the outdoor unit. You may get injured.
‡ .HHS\RXUILQJHUVDQGFORWKLQJDZD\IURPDQ\PRYLQJ
parts.
‡ 'RQRWVLWRUVWHSRQWKHXQLW\RXPD\IDOOGRZQ
accidentally.
‡ &OHDQXSWKHVLWHDIWHU\RXILQLVKUHPHPEHULQJWRFKHFN
that no metal scraps or bits of wiring have been left inside
the unit being serviced.
‡ 'RQRWVWLFNDQ\REMHFWLQWRWKH)$1&$6(
You may be injured and the unit may be damaged.
NOTE
The illustrations are based on the typical appearance of
a standard model. Consequently, the shape may differ
from that of the air conditioner that you are installing.
3
1. General
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
This booklet briefly outlines where and how to install the
air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and make
sure all accessory parts listed are with the system before
beginning.
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
5. Carpenter’s level
Sabre saw or key hole saw
Hacksaw
Core bits
Hammer
Drill
Tube cutter
Tube flaring tool
Torque wrench
Adjustable wrench
Reamer (for deburring)
1-2. Accessories Supplied with Unit
Table 1
Parts
Figure
Q’ty
Parts
Figure
Q’ty
Parts
",35:,
*54:8522,8
$(6604.9*8,=
$8;99/,(+
/022069
× ×
33
"(=262;.
",35:,*54:852
/52+,8
$(6604.9*8,=
$8;99/,(+
/022069
× ×
33
8(04/59,
(+(6:,8
(21(204,
)(::,8?
2(8,049;2(:054
Figure
Q’ty
1-3. Optional Copper Tubing Kit
2.
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or air conditioning workshop.
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.
Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6.
Wiring Instructions for details.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from
a local source, you will need:
1.
CAUTION
Deoxidized annealed copper tube for refrigerant tubing 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
Narrow Tube
Model
Wide Tube
Outer Dia.
Thickness
Outer Dia.
Thickness
CS-KE30NKU
3/8" (9.52 mm)
0.0314" (0.8 mm)
5/8" (15.88 mm)
0.0393" (1.0 mm)
CS-KE36NKU
3/8" (9.52 mm)
0.0314" (0.8 mm)
5/8" (15.88 mm)
0.0393" (1.0 mm)
4
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
1-5. Additional Materials Required for Installation
1.
2.
Indoor unit
Refrigeration (armored) tape
Insulated staples or clamps for connecting wire
(See local codes.)
Putty
Refrigeration lubricant
Clamps or saddles to secure refrigerant tubing
3.
4.
5.
Drain hose
2. Installation Site Selection
Outside drainage
2-1. Indoor Unit
Fig. 1
WARNING
To prevent abnormal heat generation and the possibility of fire, do
not place obstacles, enclosures
and grilles in front of or surrounding the air conditioner in a way
that may block air flow.
*3
304
*3
304
*3
304
AVOID:
direct sunlight.
nearby heat sources that may affect performance of the unit.
areas where leakage of flammable gas may be expected.
places where large amounts of oil mist exist.
Front View
Fig. 2
Tubing length (L)
INDOOR
UNIT
DO:
select an appropriate position from which every corner of
the room can be uniformly cooled. (High on a wall is best.)
select a location that will hold the weight of the unit.
select a location where tubing and drain hose have the
shortest run to the outside. (Fig. 1)
allow room for operation and maintenance as well as unrestricted air flow around the unit. (Fig. 2)
install the unit within the maximum elevation difference (H)
above or below the outdoor unit and within the maximum tubing length (L) from the outdoor unit as detailed in Table 3 and
Fig. 3a.
Elevation
difference (H)
OUTDOOR
UNIT
Fig. 3a
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.
CAUTION
Indoor unit
For stable operation of the
air conditioner, do not
install wall-mounted type
indoor units less than 5'
(1.5 m) from floor level.
Minimum height
from floor level
5' (1.5 m)
Floor level
Fig. 3b
Table 3
Model
Charge-less Tubing
Length (Actual Length)
(ft.)
Maximum Tubing
Length (L)
(ft.)
CS-KE30NKU
CS-KE36NKU
10 to 100
164
Maximum Elevation Difference (H)
(ft.)
If the outdoor unit is higher
100
If the outdoor unit is lower
50
Required Amount
of Additional Refrigerant
(oz./ft.)*
0.43
* If total tubing length becomes 100 to 164 ft. (Max.), charge additional refrigerant (R410A) by 0.43 oz./ft.
No additional charge of compressor oil is necessary. For more detailed charging information, refer to the Technical & Service Manual.
5
Wall
2-2. Outdoor Unit
NO
AVOID:
Heat source
DO:
Outdoor unit
choose a place as cool as possible.
choose a place that is well ventilated.
install in a location where at least two sides are unobstructed, so that the flow of air at the intake port or
exhaust port is not blocked, and so that sufficient
space is ensured for maintenance to be carried out
without trouble. In general the top also must be unobstructed. (Fig. 5a)
provide a solid base (level concrete pad, concrete block,
6" x 1'4" (15 x 40 cm) beams or equal), a minimum of 6"
(15 cm) above ground level to reduce humidity and protect the unit against possible water damage and
decreased service life. (Figs. 5b and 5c)
)9:(*2,()5<,
*3
0804:(1,
A
04
*3
*2
04
*3
A solid base must not cover
the hole of the bottom plate.
CAUTION
Fig. 4
08+09*/(8.,
*4
04
*3
B
C
)9:(*2,
Hot air
heat sources, exhaust fans, etc. (Fig. 4)
damp, humid or uneven locations.
08+09*/(8.,
Exhaust fan
*1
B85;4+
install cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5d)
use lug bolts or equal to bolt down unit, reducing
vibration and noise.
install in a location where no antenna of a television
or radio exists within 10' (3 m).
Fig. 5a
04
*3
0804:(1,
CAUTION
Concerning air-intake side distance “A” (Fig. 5a)
The minimum for distance “A” is 6" if there are no
obstructions on the air-discharge side (wall *1 side)
and *2 or *4 is not present. In all other cases, the minimum for distance “A” is 8".
If wall *1 is on the air-discharge side (Fig. 5a), or if
obstructions are present on all 3 sides *2, *3, and *4
(Fig. 5a), then the minimum distance for “B” and “C” is
39-3/8". Even if there is no wall on the air-discharge
side, a minimum of 39-3/8" is required.
8(04/52,9
Fig. 5b
4*/58)52:9
6*9
0804:(1,
04*3
54*8,:,
58,7;(2
)5;
*3
:
)5;
;9/0548;)),8
5*(22?6;8*/(9,+
*3
:
Fig. 5c
Fig. 5d
6
2-2-1. Installing the Unit in an Area with High Winds
and in a Snowy Area
425*(:0549=0://0./=04+9(=04+6855-+;*:
08+09*/(8.,
9/5;2+),-0::,+(4++08,*:,>659;8,:5:/,=04+
9/5;2+),(<50+,+(93;*/(965990)2,0.,
08E
+09*/(8.,
48,.0549=0:/90.40-0*(4:945=-(22:/,5;:+558;40:
9/5;2+),685<0+,+=0:/(62(:-583(4+945=6855-
+;*:0.-
08+09*/(8.,
Countermeasures against snow and wind
48,.0549=0:/945=(4+9:854.=04+:/,-5225=04.
685)2,393(?5**;8=/,4:/,5;:+558;40:0945:
685<0+,+=0:/(62(:-583(4++;*:04.
08+09*/(8.,
Fig. 5e
( $/,5;:+558-(43(?45:8;4(4++(3(.,:5:/,
;40:3(?5**;8
) $/,8,3(?),45(08-25=
;:+558;40:
;*:E
* $/,:;)04.3(?-8,,D,(4+);89:
+ $/,*54+,49,868,99;8,3(?+856),*(;9,5-
9:854.=04+(4+:/,04+558;40:3(?-8,,D,
2-2-2. Precautions for Installation in a Snowy Area
$/,62(:-5839/5;2+),/0./,8:/(4:/,3(>03;3
945=+,6:/0..
E
6:/
/, +,
:
4 5=
:/( 94
,8 ;3
/
.
0 (>03
3
084:(1,E
$/,(4*/5804.-,,:5-:/,5;:+558;40:9/5;2+
),;9,+-58:/,62(:-583(4+:/,62(:-5839/5;2+
),049:(22,+),4,(:/:/,(0804:(1,90+,5-5;:+558
;40:
:E
0./
,
0:/
084:(1,E
4
$/,62(:-583-5;4+(:0543;9:),-083(4+:/,;40:
3;9:),9,*;8,+=0:/(4*/58)52:9
5-
;:
;
:/,
2(:-583-5;4+(:054E
5
)
4*(9,5-049:(22(:05454(855-9;)C,*::59:854.
=04+*5;4:,83,(9;8,93;9:),:(1,4:568,<,4:
:/,;40:-853),04.)25=45<,8
Fig. 5f
'0:/5;:945=
6855-+;*:04.
5=62(:-583
'0:/5;:945=
6855-+;*:04.
0./62(:-583
Fig. 5g
7
E
2-2-3. Dimensions of Wind-proof Duct
25/32"
Air Intake
13/32"
Reference diagram for CU-KE30NKU, CU-KE36NKU
25-31/32"
13-3/8"
1
1
(4-11/32")
37-1/32"
2-11/16"
21-25/32"
(12-9/16")
11-13/16"
13-3/8"
Air
discharge
22-7/8"
35-13/16"
25-3/16"
Air discharge
Air
discharge
Air
discharge
Hole for anchor bolt (4-R1/4") / Anchor bolt : 3/8" or M10
(6-21/32")
6-11/16"
Air
discharge
14-31/32"
Air
discharge
25/32"
Air Intake
25/32"
Unit: inch
Air
discharge
6-5/16"
Air discharge
Reference diagram for wind-proof duct (locally purchased): STK-DGV160E
(1-31/32")
8
18-15/16"
(1-31/32")
Equivalent to the reverse side
22-7/8"
8-21/32"
(1-31/32")
1-3/16"
23-7/16"
(1/4")
21-9/16"
4-31/32"
1-5/16"
11-13/16"
le
"ho
22-1/4"
(4-31/32")
1/4
4-
15/16"
21-25/32"
(9/16")
11-13/16"
Unit: inch
Required space around the outdoor unit
-:/,=04+6855-+;*:09;9,+:/,96(*,9/5=4),25=3;9:),9,*;8,+(85;4+:/,5;:+558;40:
-:/,;40:09;9,+=0:/5;::/,8,7;08,+96(*,(685:,*:0<,+,<0*,3(?(*:0<(:,68,<,4:04.:/,;40:-85356,8(:04.
04
58358,
0458358,
#04.2,;40:049:(22(:054
%40:04*/
CAUTION
$/,:56(4+)5:/90+,93;9:8,3(0456,4-:/,8,(8,5)9:(*2,9:5:/,-854:(4+8,(85:/,5;:+558;40::/,5)9:(*2,(:,0:/,8:/,-854:588,(83;9:),45:(22,8:/(4:/,/,0./:5:/,5;:+558;40:
;2:062,;40:049:(22(:054
58,:/(4
58,:/(4
58,:/(4
49:(22(:054042(:,8(285=9
58,:/(4
%40:04*/
CAUTION
$/,-854:(4+:563;9:8,3(0456,4
$/,5)9:(*2,93;9:),45:(22,8:/(4:/,/,0./:5-:/,5;:+558;40:
49:(22(:05404-854:8,(885=9
49:(22(:054=0:/04:(1,9-(*04.
04:(1,9585;:2,:9-(*04.5;:2,:9
49:(22(:054=0:/04:(1,9-(*04.5;:2,:9
58,:/(4
58,:/(4
58,:/(4
%40:04*/
CAUTION
$/,-854:(4+)5:/90+,93;9:8,3(0456,4
9
2-2-4. Dimensions of Snow-proof Duct
Reference diagram for CU-KE30NKU, CU-KE36NKU
27-5/8"
Air Intake
Unit: inch
(11-5/8")
13-3/8" 25/32"
14-31/32" 13/32"
1 Hole for anchor bolt (4-R1/4") / Anchor bolt: 3/8" or M10
25/32"
25/32"
Air discharge
1
(8-15/16")
25-31/32"
4-11/32"
39-1/4"
25-13/32"
(11-15/16")
13-3/8"
16-15/16"
3/32"
Air
discharge
28-15/16"
35-15/16"
27-7/32"
7-1/32"
Air Intake
Reference diagram for snow-proof duct (locally purchased): STK-BDV80E
Unit: inch
5
1
Fastened by screws at 14 locations
28-3/16"
Fastened by screws
(Same on the
reverse side)
6-1/32"
1
3 Unit left, snow-proof duct
1
4 Unit front, snow-proof duct
1
5 Unit reverse side, snow-proof duct
1
6 Unit reverse side, snow-proof duct
1
Unit reverse side, reinforcement bracket
7 for snow-proof duct
1
Unit left, reinforcement bracket for snowproof duct
1
8
9/32"X13/32"hole
4-1/32"
Fixing with
5/16"
rear panel
2- 9/32"hole
8
Fixing with
rear panel 3-15/16"
7
3-27/32"
24-3/16"
28-3/16"
Fastened by screws
at 2 locations
10
2
5-13/32"
1-9/16"
4
13-7/8"
6
11-7/8"
9-1/8"
9-7/32"
25/32"
4-27/32"
2- 9/32"hole
Fixing with
top panel
"hole
9/32 h
2wit
g
in
Fix panel 23
t
fron
2-7/32"
15-11/32"
1
2 Unit right, snow-proof duct
5-1/8"
Fastened by screws
at 2 locations
(Same on the
reverse side)
5/8"
1-15/16"
20-13/32"
31/32"
28-13/16"
16-15/16"
9-1/8"
25-13/32"
17-9/16"
20-7/8"
3
4-11/32"
5-7/8"
Fastened by screws
at 3 locations
1 Unit top, snow-proof duct
2U 9
(U
nit nit a /32"h
fixe nch ole
4-23/32"
db
o
ott r hol
om
es
pla
te)
28-/13/16"
34-23/32"
27-9/16"
16-15/16"
1/16"
Reference diagram for snow-proof duct
Space requirements for setting
CU-KE30NKU, CU-KE36NKU with STK-BDV80E
[Obstacle to the front of unit]
[Obstacle to the rear of unit]
$560956,4
$560956,4
#04.2,;40:049:(22(:054
04
58358,
04
58358,
;2:062,;40:049:(22(:05458358,;40:9
04
58358,
;2:062,;40:049:(22(:05458358,;40:9
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
#04.2,;40:049:(22(:054 )9:(*2,954)5:/90+,9
04
58358,
04
58358,
04
58358,
Note:
4*(9,9(4+:/,/,0./:5-:/,5)9:(*2,3;9:),
45:(22,8:/(4:/,/,0./:5-:/,5;:+558;40:
$5609)25*1,+)?(45)9:(*2,
$5609)25*1,+)?(45)9:(*2,
0458358,
11
04
58358,
0458358,
0458358,
[Obstacles to the front and rear of unit]
$/,:56(4+)5:/90+,93;9:8,3(0456,40:/,8:/,5)9:(*2,:5:/,-854:58
:/,5)9:(*2,:5:/,8,(83;9:),45:(22,8:/(4:/,/,0./:5-:/,5;:+558 ;40:
04
58358,
04
58358,
04
58358,
#04.2,;40:049:(22(:054
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
)9:(*2,954)5:/90+,9
49:(22(:0540965990)2,=0:/:/,3(>03;35;:+558;40:9
[Installation in front-rear rows]
$/,:56(4+)5:/90+,93;9:8,3(0456,40:/,8:/,5)9:(*2,:5:/,-854:58:/,5)9:(*2,
:5:/,8,(83;9:),45:(22,8:/(4:/,/,0./:5-:/,5;:+558 ;40:
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
04
58358,
%40:04*/
12
3. How to Install the Indoor Unit
3-1. Remove the Rear Panel from the Unit
(1) Remove and discard the set screw on the rear panel.
(Fig. 6)
(2) Press the 2 marks on the frame cover and disengage
the stationary tabs from the frame. (Fig. 7a)
Set screw only for transportation
Fig. 6
(3) Remove the rear panel by grasping the sections shown
in Fig. 7b and pulling it in the direction shown by the
arrow.
Rear panel
NOTE
Tubing can be extended in 6 directions as shown in Fig. 8.
Select the direction you need providing the shortest run to
the outside unit.
When left tubing is to be done, switch the drain hose and
drain cap. (For details, refer to “Switching drain hose and
drain cap” on page 21.)
marks
Fig. 7a
3-2. Make a Hole
Rear panel
(1) Place the rear panel from the indoor unit on the wall at
the location selected. Make sure the panel is horizontal,
using a carpenter’s level or tape measure to measure
down from the ceiling. Wait until after cutting 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. 9)
NOTE
Fig. 7b
In the case of left-rear tubing, use the measurement points
6-7/32" (158 mm) from the marked position on the rear
panel for precise placement of the hose outlet. (Fig. 9)
Rear panel
(3) Before making the hole, check carefully that no studs or
pipes are directly run behind the spot to be cut.
CAUTION
Also avoid areas where electrical wiring or conduits are
located.
Fig. 7c
The above precautions are also applicable if tubing
goes through the wall in any other location.
,-:
:;)04.
"0./:8,(8
:;)04.
8,*533,4+,+
,-:8,(8
:;)04.
"0./:
:;)04.
,-:+5=4=(8+
:;)04.
33
"0./:+5=4=(8+
:;)04.
Fig. 8
33
Fig. 9
13
(4) Using a sabre saw, key hole saw or hole-cutting drill
attachment, cut a hole in the wall. See Table 4 and
Fig. 10.
NOTE
Hole should be made at a slight downward slant to the
outdoor side.
Table 4
Indoor
side
Hole Dia.
Outdoor
side
3-5/32" (80 mm)
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 1/4" (6 mm) shorter than the thickness of
the wall. (Fig. 11)
Fig. 10
PVC pipe (Locally purchased)
(6) Place the plastic cover over the end of the pipe (for
indoor side only) and insert the pipe in the wall. (Fig.
12)
3-3. Install the Rear Panel on the Wall
Cut at slight angle
Be sure to confirm that the wall is strong enough to suspend the unit.
Fig. 11
INSIDE
There are a number of screw holes on the rear panel.
Using the 8 screw holes with
mark is recommended
to attach the rear panel securely to the wall.
OUTSIDE
Wall
Plastic cover
(Locally purchased)
PVC pipe
Slight
angle
See either Item a) or b) below depending on the wall type.
a) If Wooden Wall
Fig. 12
(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 the stud locations and then mount the
rear panel.
Fig. 13
(2) Double check with a carpenter’s level or tape measure that the panel is level. This is important to
install the unit properly. (Fig. 14)
(3) Make sure the panel is flush against the wall. Any
space between the wall and unit will cause noise
and vibration.
Fig. 14
b) If Block, Brick, Concrete or Similar Type Wall
Make 3/16" (4.8 mm) dia. holes in the wall. Insert rawl
plugs for appropriate mounting screws. (Fig. 15)
3/16"
(4.8 mm) dia. hole
Rawl plug
Fig. 15
14
Front panel
3-4. Removing and Installing the Grille
Arm
Basically, these models can be installed and wired without removing the grille. If access to any internal part is
needed, follow the steps as given below.
How to remove the grille
(1) Open the front panel until it is nearly horizontal, grasp
the sections near the front panel arms on both sides,
and then remove the panel by pushing the arms
towards the outside while pulling the panel towards
you.
If the front panel is difficult to remove, grasp both
ends of it and lift it up slightly. Move it to the left and
disengage the left arm, then move it to the right and
disengage the right arm. (Fig. 16)
(2) Lift the anti-mold filter up slightly to disengage it from
the protrusions on the unit, and then pull downward
to remove the filter from the unit. (Fig. 16)
(3) Remove the 3 screws from the front of the unit and
remove the screw covers on the bottom surface. Then
remove the 2 screws. (Fig. 17)
(4) Remove the screw on the right side cover plate and
remove the cover. (Fig. 17a)
(5) Remove the lower flap by disengaging 4 pins of the
lower flap in order. (Figs. 17b and 17c)
(The flap is so flexible that it can be easily removed.)
(6) Lift up the grille in the direction shown by the arrow
and pull the grille towards you to remove it. (Fig. 17d)
Anti-mold filter
Protrusions
Fig. 16
Grille
Screw (on the cover)
Screw (on the front)
Screw (on the bottom)
Screw
Bottom surface
Screw cover
Fig. 17a
Grille
Upper flap
Lower flap
How to replace the grille
(1) While aligning the top edge of the grille with the
frame, move the grille horizontally and insert the top
and bottom into the frame.
(2) Press the grille firmly with your hand to ensure no gap
exists between the frame and grille.
(3) Tighten the 6 screws. And fix the removed covers in
place.
(4) Grasp the sections near the front panel arms on both
sides, and hold the front panel so that it is nearly horizontal. Push the arm shafts towards the outside so
that they come into contact with the top of the indentations on the right and left sides of the air conditioner. Then push firmly until the arm shafts click into
place. (Fig. 18)
(5) Remount the lower flap.
(In remounting the flap, it cannot be turned end for
end because the right and left pins of the flap differ in
form. (Fig. 17c))
(6) Insert the top of the anti-mold filter, and then secure
the bottom of the filter with the protrusions on the unit.
(7) When closing the front panel, push the central part of
the front panel first and then press the bottom right
and left corners in place until you feel a click. (Fig. 19)
Pin
Fig. 17b
Fig. 17c
Lower flap
Fig. 17d
854:6(4,2
4+,4:(:054
83
04
Fig. 18
NOTE
Check that no gap exists between the frame and the
grille.
Fig. 19
15
3-5. Shape the Indoor Side Tubing
(1) Arrangement of tubing by direction
8(3,
a) Right or left tubing
Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)
,-::;)04.
5;:2,:
b) Right-rear or left-rear tubing
In this case, the corner of the frame need not be
cut.
(2) To mount the indoor unit on the rear panel:
Fig. 20
Hang the 3 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)
Frame
3-6. Wiring Instructions
General precautions on wiring
Right tubing
outlet
(1) Before wiring, confirm the rated voltage of the unit as
shown on its nameplate, then carry out the wiring
closely following the wiring diagram.
(2) Provide a power outlet to be used exclusively for
each unit, with a power supply disconnect and circuit breaker for overcurrent protection provided in
the exclusive line.
Fig. 21
(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 or become
damaged.
Fig. 22
(5) Do not allow wiring to touch the refrigerant tubing,
compressor, or any moving parts of the fan.
(6) Unauthorized changes in the internal wiring can be
very dangerous. The manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.
16
3-7. Wire Size and Length
Regulations on wiring diameter differ from locality to locality. For field wiring requirements, please refer to your local electrical codes. Carefully observe these regulations when carrying out the installation.
NOTE
Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in Table 5.
Refer to your local codes or in the absence of local codes see the National Electric Code: ANSI/NFPA70.
Table 5
Model
(A) POWER SUPPLY WIRING
Wire Size
CU-KE30NKU
CU-KE36NKU
Length
Fuse or Circuit
Breaker Capacity
(B) POWER LINE
AWG12 (min.) or bigger (*1) for CU-KE30NKU
AWG10 (min.) or bigger (*1) for CU-KE36NKU
(C) CONTROL LINE
AWG14 or bigger
AWG14 or bigger
It depends on wire specification and
supply voltage level (*2)
180 ft. (max.)
180 ft. (max.)
35A for CU-KE30NKU
45A for CU-KE36NKU
Disconnect switch
(15A)
(AWG: American Wire Gauge)
(*1) It depends on supply voltage level and wire specification. Consider temperature rating
of wire, ambient temperature, and the number of wires inside the conduit.
(*2) Requirement of supply voltage level: AC187V to 253V (Measure voltage level at terminal plate inside the outdoor unit.)
WARNING
Be sure to comply with local codes on running the wire
from the indoor unit to the outdoor unit (size of wire and
wiring method, etc.).
Each wire must be firmly connected.
No wire should be allowed to touch refrigerant tubing, the
compressor, or any moving part.
" 09*544,*:
A
%$
9=0:*/
%$"
%$
0,2+9;662?
$,8304(2
(B)
(C)
B85;4+04.204,
WARNING
(A)
(B)
To avoid the risk of electric shock, each air conditioner
unit must be grounded.
For the installation of a grounding device, please
observe local electrical codes.
Grounding is necessary, especially for units using
inverter circuits, in order to release charged electricity
and electrical noise caused by high tension.
Otherwise, electrical shock may occur.
Place a dedicated ground more than 7' (2 m) away from
other grounds and do not have it shared with other electric appliances.
B85;4+04.
204,
Fig. 23
*
NOTE
Disconnect switch may be required by
national or local codes.
CAUTION
Always comply with national and local code
requirements.
CAUTION
$,8304(2
5=,89;662?
#04.2,6/(9,
&
D
WIRING SYSTEM DIAGRAM
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.
Do not run wiring for antenna, signal, or power lines of television, radio, stereo, telephone,
security system, or intercom any closer than 3'4" (1 m) from the power cable and wires
between the indoor and outdoor units. Electrical noise may affect the operation.
17
3-8. Wiring Instructions for Inter-unit Connections
(1) Insert the inter-unit wiring (according to local codes)
into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10" (25 cm)
to extend from the wall face. (Fig. 24)
",(8
6(4,2
'(22
2(9:0*
*5<,8
(2) Grasp both ends of the front panel, push the arms
towards the outside, and remove the front panel by
opening it towards the front and pulling it towards
you. If the front panel is difficult to remove, grasp
both ends of it and lift it up slightly. Move it to the left
and disengage the left arm, then move it to the right
and disengage the right arm.
'0804.
*3
Fig. 24
(3) Remove the screw on the right side cover plate and
open the cover. (Fig. 25)
Cover
(4) Route the inter-unit wiring from the back of the
indoor unit and pull it toward the front for connection. (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.
NOTE
Fig. 25
When closing the front panel, push the central part of
the front panel first and then press the bottom right and
left corners in place until you feel a click. (Fig. 27)
$,8304(262(:,
Please refer to “How to replace the grille” on page 15 for
installing the air intake grille.
Fig. 26a
Fig. 27
$565-*54+;0:
*544,*:58
4:,8;40:
=0804.
(8:/62(:,
5*14;:
Fig. 26b
18
WARNING
Loose wiring may cause the
terminal to overheat or result
in unit malfunction. A fire
hazard may also exist. Therefore, be sure all wiring is
tightly connected.
When connecting each power wire to the corresponding
terminal, follow the instructions “How to connect wiring
to the terminal” and fasten the wire securely tight with
the fixing screw of the terminal plate.
STRIP
SIZE
How to connect wiring to the terminal
9/32"
(7 mm) (ACTUAL
SIZE)
a) For Indoor Unit
Fig. 28
Strip 15/16" (25 mm)
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the wire about 9/32" (7 mm).
See the label (Fig. 28) near the terminal plate.
(2) Using a screwdriver, loosen the terminal screw on
the terminal plate.
(3) Insert the wire and tighten the terminal screw completely using a screwdriver.
Solid wire
Loop
Insulation
b) For Outdoor Unit
Fig. 29
For solid core wiring (or F-cable)
Strip 3/8" (10 mm)
(1) Cut the wire end with a cutting pliers, then strip the
insulation to expose the solid wire about 15/16" (25
mm). (Fig. 29)
(2) Using a screwdriver, remove the terminal screw(s)
on the terminal plate.
Stranded wire
Ring
connector
(3) Using the pliers, bend the solid wire to form a loop
suitable for the terminal screw.
Fig. 30
(4) Shape the loop wire properly, place it on the terminal plate and fix it securely with the removed terminal screw using a screwdriver.
Twist wire ends
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)
Fig. 31
(2) Using a screwdriver, remove the terminal screw(s)
on the terminal plate.
Special
washer
(3) Using a ring connector fastener or pliers, securely
clamp each stripped wire end with a ring connector.
(Fig. 30)
Screw
Ring connector
Wire
(4) Place the ring connector wire, and replace and
tighten the removed terminal screw using a screwdriver. (Fig. 32)
Terminal plate
Wire
Fig. 32
19
Screw and
special washer
Ring
connector
3-9. Mounting
(1) To install the indoor unit, mount the indoor unit onto
the 3 tabs on the upper part of the rear plate.
(2) Hold down the air discharge outlet and press the
lower part of the indoor unit until it clicks to securely
fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)
Push
NOTE
For tubing, choose either the right or left tubing direction
and follow the steps below. Also, extend the support on
the back of the indoor unit as a stand to make your work
easier. (Fig. 34)
Fig. 33
Rear panel
Right-side tubing
(1) Shape the refrigerant tubing so that it can easily go
into the wall hole. (Fig. 35)
(2) Push the wiring, refrigerant tubing, and drain hose
through the hole in 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 25.)
The drain hose should come straight down the wall
to a point where water runoff won’t stain the wall.
Fig. 34
Rear panel
Cover
Refrigerant
tubing
(4) Connect the refrigerant tubing to the outdoor unit.
(After performing a leak test on the connecting part,
insulate it with the tubing insulation. (Fig. 37a)) Also,
refer to Section 5-4. Connecting Tubing between
Indoor and Outdoor Units.
Inter-unit
wiring
Drain hose
(5) Assemble the refrigerant tubing, drain hose, and
conduit (including inter-unit wiring) as shown in
Fig. 37b.
Fig. 35
Refrigerant tubing
Flare
insulation
Fig. 37a
Conduit
Drain hose
Inter-unit wiring
Fig. 37b
20
Fig. 36
Left-side tubing
(1) Lead the tubing and drain hose through the wall,
allowing sufficient length for connection. Then bend
the tubing using a tube bender to make the attachment. (Fig. 38)
Rear panel
Hole in wall
(2) Switch the drain hose and drain cap.
Switching drain hose and drain cap
Bent part
(a) Locate the drain hose and the drain cap.
(Fig. 39)
Narrow tube
Wide tube
Fig. 38
(b) Remove the screw fastening the drain hose on
the right side, and pull out the drain hose to
remove it. (Fig. 39)
Drain cap
(c) Apply moderate force to pull off the drain cap
on the left side. (If you cannot pull it off by hand,
use a long-nose pliers.)
Clamp
Drain hose
(d) Reattach the drain hose to the left side and the
drain cap to the right side. (Fig. 40a)
Fig. 39
Drain hose
Slide the drain hose fully onto the drain pan outlet.
(It will be easy to slide when water is added.) 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. 40b)
Drain hose
Clamp
Drain cap
Drain cap
Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)
Fig. 40a
(3) Install the indoor unit on the rear panel.
Drain pan outlet
(4) Connect the tubing and wiring led inside from outdoors.
Drain bracket
Drain hose
Screw hole
(5) After completing a leak test, bundle the tubing
together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Figs. 40a and 41)
Screw
Drain hose
Screw
Drain bracket
Fig. 40b
Refrigerant tubing
Inter-unit wiring
Conduit
Fig. 41
21
To unmount indoor unit
Press the 2 marks on the lower part of the indoor unit
and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)
3-10. Frame Fastening Method
(1) Remove the screw cover on the bottom surface.
(Fig. 43)
(2) Fasten the frame to the rear panel using the 2 supplied tapping screws 5/32" x 13/32" (4 x 10 mm).
(Fig. 43)
NOTE
Push
Under normal conditions, the installation design calls for
a less than 3/32" (2 mm) gap between the air conditioner
unit and the wall.
Confirm that the gap is appropriate (less than 2 mm).
Fig. 42
3-11. Drain Hose
a)
The drain hose should be slanted downward to the
outdoors. (Fig. 44)
b)
Never form a trap in the course of 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. 45)
Screw
cover
Screw
* Foamed polyethylene or its equivalent is recommended.
Fig. 43
WARNING
Do not supply power to the
unit or operate it until all
tubing and wiring to the outside unit are completed.
Slant
Risk of Electric Shock
Indoor
unit
Drain
hose
Fig. 44
Condensation
Insulation material
(Locally purchased)
must be used.
Fig. 45
22
4. How to Install the Outdoor Unit
496,*:0546(4,2
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Regulations on wire size differ from locality to locality. For
field wiring requirements, please refer to your local electrical codes. Make sure that the installation fully complies
with all local and national regulations.
#*8,=
(1) Remove the 3 screws from the inspection panel.
(Fig. 46a)
Remove the inspection panel by sliding it downward
and pulling it toward you. (Fig. 46b)
Fig.46a
(2) Connect the inter-unit and power supply line according to the wiring system diagram on the inspection
panel. (Fig. 46c)
Fig.46b
()04,:
(3) When connections are completed, check that all
connections are correct as shown in the wiring system diagram.
(4) Be sure to ground the unit according to your local
codes.
$,8304(262(:,
4-2. Routing the Tubing and Wiring
The tubing and wiring can be extended out in 3 directions: front, rear, and right. Use a nipper or similar
tool to cut out the knockout holes for the inter-unit
control wiring outlet, power wiring outlet, and tubing
outlet from the appropriate covers A and B. (Fig. 46d)
Fig.46c
CAUTION
'0804.5;:2,:
Route the tubing so that it does not contact the
compressor, panel, or other parts inside the unit.
Increased noise will result if the tubing contacts
these parts.
When routing the tubing, use a tube bender to
bend the tubes.
",(8
Cover B
'0804.5;:2,:
854:
$;)04.5;:2,:
Cover A
5=,8 9;662?204,
*54+;0:
Fig.46d
23
"0./:
4:,8;40:
65=,8204,
*54+;0:
5. Refrigerant Tubing
Deburring
After
Before
5-1. Use of the Flaring Method
Many of the conventional split system air conditioners
employ the flaring method to connect refrigerant tubes
which run between indoor and outdoor units. In this
method, the copper tubes are flared at each end and
connected with flare nuts.
5-2. Flaring Procedure with a Flare Tool
(1) Cut the copper tube to the required length with a
tube cutter. It is recommended to cut approx. 12" to
20" (30 to 50 cm) longer than the tubing length you
estimate.
Fig. 47
Copper
tubing
(2) Remove burrs at the end of the copper tube with a
tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 47)
Reamer
NOTE
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)
Fig. 48
If the special R410A
flare tool is used:
(3) Remove the flare nut from the unit and be sure to
mount it on the copper tube.
(4) Make a flare at the end of copper tube with a flare
tool.* (Figs. 49a and 49b)
0 to 0.0196"
(0 to 0.5 mm)
(*Use “RIDGID” or equivalent.)
If the previous flare tool
(clutch-type) is used:
0.0472" (1.2 mm)
Adjust so that the amount of tube
protrusion is as shown in the figure.
Fig. 49a
NOTE
A good flare should have the following characteristics:
inside surface is glossy and smooth.
edge is smooth.
tapered sides are of uniform length.
Flare nut
Copper
tubing
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 lubricant to the matching surfaces of the flare and union before connecting them together. This is effective for reducing gas
leaks. (Fig. 50)
c)
Flare tool
Fig. 49b
Apply refrigerant
lubricant here and here
Fig. 50
For proper connection, align the union tube and
flare tube straight with each other, then screw in the
flare nut lightly at first to obtain a smooth match.
(Fig. 51)
Union
Flare nut
Fig. 51
24
5-4. Connecting Tubing between Indoor and
Outdoor Units
a)
b)
Torque wrench
Tightly connect the indoor side refrigerant tubing extended from the wall with the outdoor side tubing. (Fig. 52)
Spanner
Indoor unit
To fasten the flare nuts, apply specified torque as:
Table 6
Outdoor unit
Tube Dia.
Nut
Tightening Torque
1/4" (6.35 mm)
21/32" (17 mm)
Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)
3/8" (9.52 mm)
7/8" (22 mm)
Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)
1/2" (12.70 mm)
1-1/32" (26 mm)
Approx. 430 – 480 lbs·in (490 – 550 kgf·cm)
5/8" (15.88 mm)
1-5/32" (29 mm)
Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)
Fig. 52
2(8,
049;2(:054
5-5. Insulation of Refrigerant Tubing
Fig. 53
IMPORTANT
To prevent heat loss and wet floors due to dripping of condensation, both tubes must be well insulated with a
proper insulation material. (Fig. 53)
The thickness of the insulation should be a minimum 5/16"
(8 mm). (Fig. 54)
Insulation
Thickness:
min. 5/16"
(8 mm)
Min.
5/16"
(8 mm)
5-6. Taping the Tubes
CAUTION
Fig. 54
After a tube has been insulated, never try to bend it into a
narrow curve, as this may
cause the tube to break or
crack.
(1) At this time, the 2 refrigerant tubes (and electrical wire
if local codes permit) should be taped together with
armoring tape. The drain hose may also be included
and taped together as 1 bundle with the tubing.
Clamp
Insulated tubes
(2) Wrap the armoring tape from the bottom of the outdoor
unit to the top of the tubing where it enters the wall. As
you wrap the tubing, overlap half of each previous tape
turn. (Fig. 55)
(3) Clamp the tubing bundle to wall, using 1 clamp approx.
every 47" (120 cm).
Fig. 55
Apply putty here
NOTE
Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the condensation drain hose splits away from the bundle and drips
clear of the unit and the tubing.
Tubing
5-7. Finishing the Installation
Fig. 56
After finishing insulating and taping over the tubing, use
sealing putty to seal off the hole in the wall to prevent rain
and draft from entering. (Fig. 56)
25
6. Air Purging
Indoor unit
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below. Therefore,
they must be purged completely.
pressure in the system rises
operating current rises
cooling (or heating) efficiency drops
moisture in the air may freeze and block capillary tubing
water may lead to corrosion of parts in the refrigerant
system
Outdoor unit
Air Purging with a Vacuum Pump (for Test Run)
(1) Check that each tube (both narrow and wide tubes)
between the indoor and outdoor units have been
properly connected and all wiring for the test run
has been completed. Note that both narrow and
wide tube service valves on the outdoor unit are
kept closed at this stage.
(2) Using an adjustable wrench or box wrench, remove
the valve caps from the service valve on both narrow and wide tubes.
Manifold valve
(Exclusively for R410A)
(3) Connect a vacuum pump and a manifold valve (with
pressure gauges) to the service port on the wide
tube service valve. (Fig. 57)
CAUTION
Pressure
gauge
Lo
Hi
The service port on the wide tube
service valve uses a Schrader core
valve to access the refrigerant system. The valve core is similar to
those used in automobile tires.
Therefore, be sure to use a vacuum
hose connector which has a pushpin inside.
Charging hose
(Exclusively for R410A)
Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)
Vacuum pump
CAUTION
Be sure to use a manifold valve
for air purging. If it is not available, use a stop valve (field supply) for this purpose. The “Hi”
knob of the manifold valve must
always be kept closed.
Fig. 57
NOTE
To prevent other refrigerants from being mistakenly
charged to units which use R410A, the size of the
charge port on the service valve is different from the
one for other refrigerant types. For servicing such as
recharging, the specified charging hose, manifold and
vacuum pump adapter (with reverse flow prevention)
for R410A must be used.
(4) With the “Lo” knob of the manifold valve open, run
the vacuum pump. The operation time for the vacuum pump varies with tubing length and the capacity
of the pump. The following table shows the amount
of time for evacuation:
Table 7
Required time for evacuation when
100 liter/h vacuum pump is used
If tubing length is
less than 33 ft. (10 m)
If tubing length is
more than 33 ft. (10 m)
10 min. or more
15 min. or more
NOTE
The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.
26
(5) With the vacuum pump still running, close the “Lo”
knob of the manifold valve. Then stop the vacuum
pump.
90 (1/4 turn)
Vacuum hose to manifold valve
(6) With the hex wrench, turn the valve stem on the narrow tube service valve counter-clockwise by 90
degrees (1/4 turn) for 10 seconds, and then turn the
stem clockwise to close it again. (Fig. 58)
CAUTION
Hex wrench
Be sure to completely insert
the hex wrench before
attempting to turn the valve.
Valve cap
Narrow tube
Wide tube
(7) Leak test all joints at the tubing (both indoor and outdoors) with soapy water. Bubbles indicate a leak. Tighten the joint more when leaks, then check if there is no
leak. Be sure to wipe off the soap with a clean cloth.
Fig. 58
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the valve.
(9) Turn the narrow tube service valve stem counterclockwise to fully open the valve.
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
CAUTION
This may cause the refrigerant gas to leak. In order to
avoid this, take off the hose
quickly.
(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 air conditioner is running, apply liquid
soap to check for any gas leaks around the service
valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and the
air conditioner is ready for actual operation.
27
How to Test Run the Air Conditioner
After turning on the power of the air conditioner, use the
remote controller and follow the steps below to conduct the
test run.
(1) Set the remote controller in Test Run mode.
(Fig. 59a)
a) Press and hold the QUIET button and the 1HR.
TIMER button.
b) Then press and hold the ACL (Reset) button with a
pointed object such as the tip of a pen. After 5 seconds, release the ACL button first.
!%$
);::54
c) Then release the QUIET and 1HR. TIMER buttons.
d)
56,8(:054
);::54
"
$"
);::54
appears and “oP-1” blinks in the remote controller
clock display area. (Fig. 59b)
(2) Start Cooling mode test run by pressing the ON/OFF
operation button of the remote controller. (Fig. 59a)
‡ 7KLVVWDUWVWKHIDQSURGXFLQJXQFRROHGIRUFHGDLUZLWK
the 3 indicator lamps (OPERATION lamp, TIMER
lamp, and
) on the main unit blinking. (Fig. 59c)
‡ $IWHUPLQXWHVWKHV\VWHPVKLIWVLQWRFRROLQJRSHUD
tion, and cool air will start to be felt. Cooling mode test
run is unaffected by the room temperature.
",9,:
);::54
(3) Press the ON/OFF operation button of the remote controller again to stop the test run. (Fig. 59a)
(4) Finally press the ACL (Reset) button of the remote controller to release it from Test Run mode to return to normal mode. (Fig. 59a)
Fig. 59a
‡ ´ µDQG´R3µZLOOGLVDSSHDUIURPWKHUHPRWHFRQ
troller clock display area.
NOTE
Troubleshooting:
In the event that the green OPERATION lamp is blinking
upon powering up the system, an error condition exists. In
this case, refer to the self-diagnostics procedure on the
inside of the front cover.
Fig. 59b
"$2(36
IMPORTANT
$"2(36
After the test run is completed, be sure to press the ACL
(Reset) button to return to normal mode. The air conditioner
will not operate correctly if this is not done.
Fig. 59c
28
Basic Functions of the Service Valves
The basic functions of the service valves are given in Table 8 below.
Table 8
Narrow Tube Service
Valve (2-Way)
Action
Wide Tube Service
Valve (3-Way)
O-ring
CLOSED
Valve cap
Stem
Shipping
Fully OPEN
Operating and
test running
the air conditioner
Fully OPEN
Measuring pressure
*
and gas charging
CLOSED
Air purging with
* The service port on the wide tube service valve uses a Schrader core valve
to access the refrigerant system.
Therefore, be sure to use a hose connector which has a push-pin inside.
(Fig. 60a)
*
a vacuum pump
Service valve
Hose with push-pin
CAUTION
Close
When opening or closing the service valve
stem, use the hex
wrench. Be sure to fully
seat the wrench before
turning the valve.
PUSH
Open
Hex
wrench
NOTE
External diameter of service port
R410A: 5/16"
Fig. 60b
Fig. 60a
Pump Down
(2) Using a hex wrench, turn the narrow tube service
valve clockwise all the way to close the service
valve. (Be sure to confirm that the wide tube service
valve is fully open.)
Pump down means collecting all refrigerant gas in the
system back into the outdoor unit without losing any of
the gas. Pump down is used when the unit is to be
moved or before servicing the refrigerant circuit.
(3) Press the operation button and start cooling operation.
Pump Down Procedure
(4) When the low pressure gauge reading falls to 14.2 to
7.1 psi (1 to 0.5 kg/cm2), fully close the wide tube
valve stem. Then quickly stop the unit.
Be sure to carry out pump down with the unit in
cooling mode.
(1) Connect the Lo side charging hose of the manifold
valve to the service port on the wide tube service
valve.
(5) Disconnect all gauges and hoses, and replace the
valve caps as they were before.
29
Service Valve Connections
(
$,3658(8?*544,*:054
#*8,=04@:;849)?/(4+0.
*
)
$5-(9:,4:/,-2(8,4;:9(662?96,*0-0,+:587;,
(9$()2,(4+0.
+
$587;,=8,4*/
Table 9
Tube Dia.
Nut
Fig. 60c
Tightening Torque
1/4" (6.35 mm)
21/32" (17 mm)
Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)
3/8" (9.52 mm)
7/8" (22 mm)
Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)
1/2" (12.70 mm)
1-1/32" (26 mm)
Approx. 430 – 480 lbs·in (490 – 550 kgf·cm)
5/8" (15.88 mm)
1-5/32" (29 mm)
Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)
Fig. 60d
CAUTION
Be sure to tighten the
flare nut using the
prescribed torque.
If the nut is overtightened, refrigerant
leakage may occur.
7. Remote Controller Installation Position
The remote controller can be operated from either a
non-fixed position or a wall-mounted position.
To ensure that the air conditioner operates correctly, do
not install the remote controller in the following places:
In direct sunlight
Behind a curtain or other place where it is covered
More than 26' (8 m) away from the air conditioner
In the path of the air conditioner’s airstream
Where it may become extremely hot or cold
Where it may be subject to electrical or magnetic
interference
Where there is an obstacle between the remote con-
troller and the air conditioner (since a check signal is
sent from the remote controller every 5 minutes)
7-1. Mounting on a Wall
Before mounting the remote controller, 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 it has received the signal.
Rear side
Remote control
holder
Press
Set in
place
Hole
$568,<,4:25995-:/,8,35:,*54:8522,8
?5;*(4*544,*::/,8,35:,*54:8522,8
:5:/,/52+,8)?6(9904.(9:804.:/85;./
:/,8,35:,*54:8522,8(4+(::(*/3,4:/52,
Mounting screws
5/32 13/16" (4 20 mm)
(included)
To take out the remote controller, pull it forward.
Fig. 61
30
8. Address Switch
Tab
8-1. Address Setting of the Remote Controller
The address can be set in order to prevent interference
between remote controllers when 2 indoor units are
installed near each other. The address is normally set to
“A.” To set a different address, it is necessary to change
the address on the second remote controller.
Fig. 62
NOTE
Once changed, you cannot restore the original address
setting of the air conditioner.
(1) Switch on the power source.
(2) Break the address-setting tab marked “A” on the
second remote controller to change the address
(Fig. 62). When the tab is removed, the address is
automatically set to B (Fig. 63).
);::54
(3) Press and hold the remote controller QUIET button
and 1HR. TIMER button. Then press and hold the
ACL (Reset) button with a pointed object such as
the tip of a pen. After 5 seconds, release the ACL
button first, then release the QUIET and 1HR.
TIMER buttons. “oP-1” (Test Run) appears, blinking
in the remote controller clock display area.
Fig. 63
(4) Each time the 1HR. TIMER button is pressed, the
display changes as shown below. Press this button
3 times to change the display to “oP-7” (Address
setting). (Fig. 64)
$,9:8;435+,
56,8(:054
);::54
!%$
);::54
#,2-+0(.459:0*35+,
"
$"
);::54
++8,999,::04.35+,
(5) “oP-7” has now been selected for address setting.
(6) Press the ON/OFF operation button on the remote
controller. (Fig. 64) Check that the “beep”signalreceived sound is heard from the second indoor unit
(approximately 5 times). The sound you hear is the
signal that the remote controller address has been
changed.
(7) Finally press the remote controller ACL (Reset) button to cancel the blinking “oP-7” display.
(Fig. 64)
",9,:
);::54
Changing of the second remote controller address is
now completed.
Fig. 64
31
DC1111-0
Download PDF

advertising