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AIR CONDITIONER

English
INSTALLATION MANUAL
OUTDOOR UNIT
For authorized service personnel only.

MADE IN THAILAND

PART No. 9381069095

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AIR CONDITIONER Do not modify power cable, use extension cable or branch wiring. Improper use may
INSTALLATION MANUAL cause electric shock or fire by poor connection, insufficient insulation or over current.
PART No. 9381069095 Do not purge the air with refrigerants but use a vacuum pump to vacuum the installation.
Outdoor Unit
There is no extra refrigerant in the outdoor unit for air purging.

Contents Using the same vacuum pump for different refrigerants may damage the vacuum pump
or the unit.
1. SAFETY PRECAUTIONS ............................................................................................ 1
Use a clean gauge manifold, vacuum pump and charging hose for R410A exclusively.
2. ABOUT THIS PRODUCT ............................................................................................ 1
Do not modify this unit, such as opening a hole in the cabinet.
2.1. Precautions for using R410A refrigerant ............................................................ 1
2.2. Special tools for R410A refrigerant .................................................................... 2 During the pump-down operation, make sure that the compressor is turned off before
2.3. Accessories ........................................................................................................ 2 you remove the refrigerant piping.
Do not remove the connection pipe while the compressor is in operation with 3-way
3. INSTALLATION WORK ............................................................................................... 2
valve open. This may cause abnormal pressure in the refrigeration cycle that leads to
3.1. Selecting an installation location ........................................................................ 2 rupture and even injury.
3.2. Installation dimensions ....................................................................................... 3
3.3. Placing the unit ................................................................................................... 3
3.4. Secure the unit ................................................................................................... 3 Indicates a potentially hazardous situation that may result in
CAUTION minor or moderate injury or damage to property.
4. PIPE INSTALLATION .................................................................................................. 4
4.1. Selecting the pipe material ................................................................................. 4 This unit must be installed by qualified personnel with a capacity certification of handling
4.2. Pipe requirements .............................................................................................. 4 refrigerant fluids. Refer to regulation and laws in use on installation place.
4.3. Brazing ............................................................................................................... 4 Install the unit by following local codes and regulations in force in the place of
4.4. Pipe connection .................................................................................................. 4 installation, and the instructions provided by manufacturer.
4.5. Sealing test ........................................................................................................ 5 This unit is part of a set constituting an air conditioner. The unit must not be installed
4.6. Vacuum process ................................................................................................ 5 alone or be installed with device not authorized by the manufacturer.
4.7. Additional charging ............................................................................................. 6
When installing pipes shorter than 3 m, sound of the outdoor unit will be transferred to
4.8. Gas leakage inspection ...................................................................................... 6
the indoor unit, which will cause large operating sound or some abnormal sound.
5. ELECTRICAL WIRING ................................................................................................ 6
Always use a separate power supply line protected by a circuit breaker operating on all
5.1. Notes for electrical wiring ................................................................................... 6 wires with a distance between contact of 3 mm for this unit.
5.2. Selecting circuit breaker and wiring ................................................................... 7
To protect the persons, earth (ground) the unit correctly, and use the power cable
5.3. Wiring method .................................................................................................... 7
combined with an Earth Leakage Circuit Breaker (ELCB).
6. TEST RUN ...................................................................................................................8
The units are not explosion proof, and therefore should not be installed in explosive
7. CHECK LIST................................................................................................................ 8 atmosphere.
8. PUMP DOWN OPERATION (FORCED COOLING OPERATION) .............................. 8 This unit contains no user-serviceable part. Always consult experienced service
technician for repairing.
When moving or relocating the air conditioner, consult experienced service technicians
for disconnection and reinstallation of the unit.
Children should be monitored to ensure they do not play with the device.
Note: This manual outlines how to install the air conditioner described above. Handling
This appliance is not intended for use by persons (including children) with reduced
and installation shall only be done by professionals as outlined in this manual.
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
1. SAFETY PRECAUTIONS person responsible for their safety. Children should be supervised to ensure that they
do not play with the appliance.
• Be sure to read this manual thoroughly before installation.
Do not touch the aluminium fins of heat exchanger built-in the indoor or outdoor unit to
• The warnings and precautions indicated in this manual contain important information
avoid personal injury when you install or maintain the unit.
pertaining to your safety. Be sure to observe them.
• Hand this manual, together with the operating manual, to the customer. Request the Do not place any other electrical products or household belongings under indoor unit or
customer to keep them on hand for future use, such as for relocating or repairing the outdoor unit. Dripping condensation from the unit might get them wet, and may cause
product. damage or malfunction of the property.
Indicates a potentially or imminently hazardous situation which, if
WARNING not avoided, could result in death or serious injury.
2. ABOUT THIS PRODUCT
To avoid getting an electric shock, never touch the electrical components soon after the
power supply has been turned off. After turning off the power, always wait 10 minutes or
more before you touch the electrical components. 2.1. Precautions for using R410A refrigerant
Installation of this product must be done by experienced service technicians or
professional installers only in accordance with this manual. Installation by
non-professional or improper installation of the product may cause serious accidents WARNING
such as injury, water leakage, electric shock, or fire. If the product is installed in Do not introduce any substance other than the prescribed refrigerant into the
disregard of the instructions in this manual, it will void the manufacturer’s warranty. refrigeration cycle. If air enters the refrigeration cycle, the pressure in the refrigeration
Do not turn on the power until all work has been completed. Turning on the power cycle will become abnormally high and cause the piping to rupture.
before the work is completed can cause serious accidents such as an electric shock or If there is a refrigerant leak, make sure that it does not exceed the concentration limit.
fire. If a refrigerant leak exceeds the concentration limit, it can lead to accidents such as
If refrigerant leaks when you are working, ventilate the area. If the leaking refrigerant is oxygen starvation.
exposed to a direct flame, it may produce a toxic gas. Do not touch refrigerant that has leaked from the refrigerant pipe connections or other
Installation must be performed in accordance with regulations, codes, or standards for areas. Touching the refrigerant directly can cause frostbite.
electrical wiring and equipment in each country, region, or the installing place. If a refrigerant leak occurs during operation, immediately vacate the premises and
Do not use this equipment with air or any other unspecified refrigerant in the refrigerant thoroughly ventilate the area. If the refrigerant comes in contact with a flame, it produces
lines. Excess pressure can cause a rupture. a toxic gas.

During installation, make sure that the refrigerant pipe is attached firmly before you
run the compressor. Do not operate the compressor under the condition of refrigerant
piping not attached properly with 3-way valve open. This may cause abnormal pressure
in the refrigeration cycle that leads to rupture and even injury.
When installing or relocating the air conditioner, do not mix gases other than the
specified refrigerant (R410A) to enter the refrigerant cycle.
If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to
an abnormally high value and cause rupture, injury, etc.
For the air conditioner to work appropriately, install it as written in this manual.
To connect the indoor unit and outdoor unit, use air conditioner piping and cables
available locally as standard parts. This manual describes proper connections using
such installation set.

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WARNING 3. INSTALLATION WORK
The basic installation work procedures are the same as conventional refrigerant models.
However, pay careful attention to the following points: Make sure to obtain the customer’s approval for selecting and installing the outdoor unit.

• Since the working pressure is 1.6 times higher than that of conventional refrigerant
(R22) models, some of the piping and installation and service tools are special. (See 3.1. Selecting an installation location
the table below.)
Especially, when replacing a conventional refrigerant (R22) model with a new
refrigerant R410A model, always replace the conventional piping and flare nuts with WARNING
the R410A piping and flare nuts.
Securely install the outdoor unit at a location that can withstand the weight of the unit.
• Models that use refrigerant R410A have a different charging port thread diameter Otherwise, the outdoor unit may fall and cause injury.
to prevent erroneous charging with conventional refrigerant (R22) and for safety.
Be sure to install the outdoor unit as prescribed, so that it can withstand earthquakes
Therefore, check beforehand. [The charging port thread diameter for R410A is and typhoons or other strong winds. Improper installation can cause the unit to topple or
1/2-20 UNF.] fall, or other accidents.
• Be careful that foreign matter (oil, water, etc.) does not enter the piping than with
Do not install the outdoor unit near the edge of a balcony. Otherwise, children may climb
refrigerant models. Also, when storing the piping, securely seal the openings by onto the outdoor unit and fall off of the balcony.
pinching, taping, etc.
• When charging the refrigerant, take into account the slight change in the composition
of the gas and liquid phases. And always charge from the liquid phase where
CAUTION
refrigerant composition is stable. Do not install the outdoor unit in the following areas:
• Area with high salt content, such as at the seaside. It will deteriorate metal parts,
causing the parts to fail or the unit to leak water.
• Area filled with mineral oil or containing a large amount of splashed oil or steam, such as
2.2. Special tools for R410A refrigerant a kitchen. It will deteriorate plastic parts, causing the parts to fail or the unit to leak water.
• Area that generates substances that adversely affect the equipment, such as
sulphuric gas, chlorine gas, acid, or alkali. It will cause the copper pipes and brazed
WARNING joints to corrode, which can cause refrigerant leakage.
To install a unit that uses R410A refrigerant, use dedicated tools and piping materials • Area containing equipment that generates electromagnetic interference. It will cause
the control system to malfunction, preventing the unit from operating normally.
that have been manufactured specifically for R410A use. Because the pressure of
• Area that can cause combustible gas to leak, contains suspended carbon fibres or
R410A refrigerant is approximately 1.6 times higher than R22, failure to use dedicated
flammable dust, or volatile inflammables such as paint thinner or gasoline. If gas
piping material or improper installation can cause rupture or injury. Furthermore, it can leaks and settles around the unit, it can cause a fire.
cause serious accidents such as water leakage, electric shock, or fire. • Area where small animals may live. It may cause failure, smoke or fire if small
animals enter and touch internal electrical parts.
• Area where animals may urinate on the unit or ammonia may be generated.
Tool name Changes Do not tilt the outdoor unit more than 3 degrees. However, do not install the unit with it
Gauge manifold Pressure is high and cannot be measured with a conventional tilted towards the side containing the compressor.
gauge. To prevent erroneous mixing of other refrigerants, the Install the outdoor unit in a well-ventilated location away from rain or direct sunlight.
diameter of each port has been changed. If the outdoor unit must be installed in an area within easy reach of the general public,
It is recommended the gauge with seals –0.1 to 5.3 MPa (-1 to install as necessary a protective fence or the like to prevent their access.
53 bar) for high pressure. –0.1 to 3.8 MPa (-1 to 38 bar) for low
pressure. Install the outdoor unit in a location that would not inconvenience your neighbours, as
they could be affected by the airflow coming out from the outlet, noise, or vibration. If it
must be installed in proximity to your neighbours, be sure to obtain their approval.
Charging hose To increase pressure resistance, the hose material and base
size were changed. If the outdoor unit is installed in a cold region that is affected by snow accumulation,
snow fall, or freezing, take appropriate measures to protect it from those elements.
Vacuum pump A conventional vacuum pump can be used by installing a To ensure a stable operation, install inlet and outlet ducts.
vacuum pump adapter. Install the outdoor unit in a location that is away from exhaust or the vent ports that
discharge vapour, soot, dust, or debris.
Gas leakage detector Special gas leakage detector for HFC refrigerant R410A.
Install the indoor unit, outdoor unit, power supply cable, connection cable, and remote
Copper pipes controller cable at least 1 m away from a television or radio receivers. The purpose of
It is necessary to use seamless copper pipes and it is desirable that the amount of residual this is to prevent TV reception interference or radio noise. (Even if they are installed
oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or more than 1 m apart, you could still receive noise under some signal conditions.)
discoloured portion (especially on the interior surface). Otherwise, the expansion valve or Branch switch and
capillary tube may become blocked with contaminants. circuit breaker
As an air conditioner using R410A incurs pressure higher than when using conventional 1 m or more
refrigerant, it is necessary to choose adequate materials.
Thicknesses of copper pipes used with R410A are as shown in the table. Never use 1 m or more
copper pipes thinner than that in the table even when it is available on the market.
Thicknesses of Annealed Copper Pipes (R410A) Branch switch and
circuit breaker
Pipe outside diameter [mm (in.)] Thickness [mm]
6.35 (1/4) 0.80
9.52 (3/8) 0.80
12.70 (1/2) 0.80
If children under 10 years old may approach the unit, take preventive measures so that
15.88 (5/8) 1.00
they cannot reach the unit.
Keep the length of the piping of the indoor and outdoor units within the allowable range.
2.3. Accessories Consider the transportation route, installation space, maintenance space, and access,
and install the unit in a location with sufficient space for the refrigerant piping.
For maintenance purposes, do not bury the piping.
WARNING
For installation purposes, be sure to use the parts supplied by the manufacturer or other (1) Install the outdoor unit in a location which can withstand the weight of the unit and
prescribed parts. The use of non-prescribed parts can cause serious accidents such as vibration, and which can install horizontally.
the unit falling, water leakage, electric shock, or fire. (2) Provide the indicated space to ensure good airflow.
(3) If possible, do not install the unit where it will be exposed to direct sunlight.
Keep this manual in a safe place, and do not discard any other accessories until the (If necessary, install a blind that does not interfere with the airflow.)
installation work has been completed. (4) Do not install the unit near a source of heat, steam, or flammable gas.
(5) During heating operation, drain water flows from the outdoor unit.
Therefore, install the outdoor unit in a place where the drain water flow will not be
obstructed. (Reverse cycle model only)
(6) Do not install the unit where strong wind blows or where it is very dusty.
(7) Do not install the unit where people pass.
(8) Install the outdoor unit in a place where it will be free from being dirty or getting wet by
rain as much as possible.
(9) Install the unit where connection to the indoor unit is easy.

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When there are obstacles at the back side when installing more than one unit
3.2. Installation dimensions

If the space is larger than that is stated, the condition will be the same as that there are
no obstacles.
• Do not install it directly on the ground, otherwise it will cause failure.

AIR

30
mo cm
re or
30 cm
mo cm 30 more
re or r
o

3.3. Placing the unit

5 cm or more WARNING
Do not touch the fins.
When the upward area is open Otherwise, personal injury could result.

CAUTION
When carrying the unit, hold the handles on the right and left sides and be careful.
If the outdoor unit is carried from the bottom, hands or fingers may be pinched.

• Be sure to hold the handles on the sides of the unit. Otherwise, the suction grilles on
the sides of the unit may be deformed.
• When there are
obstacles at the
back side.
AIR
3.4. Secure the unit

cm e WARNING
30 mor
or When installing the outdoor unit where it may exposed to strong wind, fasten it securely.

(Unit : mm)

AIR 2 - Ø 12 hole

• When there are


obstacles at the
back and front

343
sides. AIR
cm
30 ore
m
or
cm
60 ore
r m 603
o

• Install 4 anchor bolts at the locations indicated with arrows in the above figure.
When an obstruction is present also in the upward area • To reduce vibration, do not install the unit directly on the ground. Install it on a secure
base (such as concrete blocks).
• The foundation shall support the legs of the unit and have a width of 50 mm or more.
• Depending on the installation conditions, the outdoor unit may spread its vibration
60-100 cm

during operation, which may cause noise and vibration. Therefore, attach damping
materials (such as damping pads) to the outdoor unit during installation.
• Install the foundation, making sure that there is enough space for installing the
connection pipes.
• Secure the unit to a solid block using foundation bolts.
(Use 4 sets of commercially available M10 bolts, nuts, and washers.)
• The bolts should protrude 20 mm.
• When there are (Refer to the figure below.)
obstacles at the • If overturning prevention is required, purchase the necessary commercially available
back, side(s), and items.
top Bolt
30 AIR Nut
or c
mo m
20 mm

re cm Block
30 ore
30 m
(S cm or
erv or
ice mo
sp re
ac
e)

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4. PIPE INSTALLATION 4.3. Brazing

CAUTION CAUTION
Do not use mineral oil on flared part. Prevent mineral oil from getting into the system as If air or another type of refrigerant enters the refrigeration cycle, the internal pressure in
this would reduce the lifetime of the units. the refrigeration cycle will become abnormally high and prevent the unit from exerting
its full performance.
While welding the pipes, be sure to blow dry nitrogen gas through them.
Apply nitrogen gas while brazing the pipes. If a pipe is Pressure regulating valve
The maximum lengths of this product are shown in the table. If the units are further
brazed without applying nitrogen gas, an oxidation film Cap
apart than this, correct operation cannot be guaranteed.
will be created.
This can degrade performance or damage the parts in
the unit (such as the compressor or valves). Nitrogen gas
4.1. Selecting the pipe material Nitrogen gas pressure: 0.02 MPa
(= pressure felt sufficiently on the back of the hand) Brazing area

For brazing material, use phosphor copper that does not require flux. Do not use flux to
CAUTION braze pipes. If the flux is the chlorine type, it will cause the pipes to corrode.
Do not use existing pipes. Furthermore, if the flux contains fluoride, it will adversely affect the refrigerant pipe
system such as by degrading the refrigerant.
Use pipes that have clean external and internal sides without any contamination which If fluoride is contained, quality of refrigerant deteriorates and affects the refrigerant
may cause trouble during use, such as sulphur, oxide, dust, cutting waste, oil, or water. piping system.
It is necessary to use seamless copper pipes.
Material: Phosphor deoxidized seamless copper pipes.
It is desirable that the amount of residual oil is less than 40 mg/10 m.
4.4. Pipe connection
Do not use copper pipes that have a collapsed, deformed, or discoloured portion
(especially on the interior surface). Otherwise, the expansion valve or capillary tube may
become blocked with contaminants. 4.4.1. Protection of pipes
Improper pipe selection will degrade performance. As an air conditioner using R410A Protect the pipes to prevent the entry of moisture and dust.
incurs pressure higher than when using conventional refrigerant, it is necessary to Especially, pay attention when passing the pipes through a hole or connecting the end of
choose adequate materials. a pipe to the outdoor unit.

Thicknesses of copper pipes used with R410A are as shown in the table. Location Working period Protection method
Never use copper pipes thinner than those indicated in the table even if they are available 1 month or more Pinch pipes
on the market. Outdoor
Less than 1 month Pinch or tape pipes
Thicknesses of Annealed Copper Pipes (R410A) Indoor - Pinch or tape pipes

Pipe outside diameter


Thickness [mm] 4.4.2. Flaring
[mm (in.)]
6.35 (1/4) (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.
9.52 (3/8) 0.8 (3) Insert the flare nut (always use the flare nut attached to the indoor and outdoor units
12.70 (1/2) respectively) onto the pipe and perform the flare processing with a flare tool.
Use the special R410A flare tool, or the conventional (for R22) flare tool.
15.88 (5/8) 1.0
When using the conventional flare tool, always use an allowance adjustment gauge
and secure the A dimension shown in the following table.

4.2. Pipe requirements Check if [L] is flared uniformly


and is not cracked or scratched.

CAUTION
Keep the piping length between the indoor unit and outdoor unit within the allowable
tolerance. Die

A
Pipe diameter <Liquid/Gas> L
(Standard) 6.35 (1/4) / 15.88 (5/8)
[mm (in.)] Pipe

Max. piping length


20
[m] Pipe outside diameter
Min. piping length
5 A (mm)
[m]
Pipe outside
Max. height difference Flare tool for R410A, Conventional (R22) flare tool
diameter
<Indoor unit to outdoor unit> 8 clutch type Clutch type Wing nut type
[m]
6.35 mm (1/4 in.) 0 to 0.5 1.0 to 1.5 1.5 to 2.0
• Use pipe with water-resistant heat insulation. 15.88 mm (5/8 in.) 0 to 0.5 1.0 to 1.5 2.0 to 2.5
CAUTION
Install heat insulation around both the gas and liquid pipes. Failure to do so may cause 4.4.3. Bending pipes
water leaks.
The pipes are shaped by your hands. Be careful not to collapse them.
Use heat insulation with heat resistance above 120 °C. (Reverse cycle model only)
Do not bend the pipes in an angle more than 90°.
In addition, if the humidity level at the installation location of the refrigerant piping is
When pipes are repeatedly bent or stretched, the material will harden, making it difficult to
expected to exceed 70 %, install heat insulation around the refrigerant piping.
bend or stretch them any more.
If the expected humidity level is 70-80 %, use heat insulation that is 15 mm or thicker
Do not bend or stretch the pipes more than three times.
and if the expected humidity exceeds 80 %, use heat insulation that is 20 mm or thicker.
If heat insulation is used that is not as thick as specified, condensation may form on the Pipe
• When bending the pipe, do not bend it
surface of the insulation.
as is. The pipe will be collapsed. In this
In addition, use heat insulation with heat conductivity of 0.045 W/(m·K) or less (at 20 °C). Insulating
case, cut the insulating pipe with a sharp
Pipe
cutter as shown on the right, and bend it
after exposing the pipe. After bending the Cutter
pipe as you want, be sure to put the heat
insulating pipe back on the pipe, and
secure it with tape.

Cut line

CAUTION
To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150 mm or over.
If the pipe is bent repeatedly at the same place, it will break.

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4.4.4. Connecting pipes
4.6. Vacuum process
CAUTION
Be sure to install the pipe against the port on the indoor unit and the outdoor unit
correctly. If the centring is improper, the flare nut cannot be tightened smoothly. If the CAUTION
flare nut is forced to turn, the threads will be damaged. Perform a refrigerant leakage test (air tightness test) to check for leaks using nitrogen
Do not remove the flare nut from the outdoor unit pipe until immediately before gas while all valves in the outdoor unit are closed. (Use the test pressure indicated on
connecting the connection pipe. the nameplate.)
After installing the piping, make sure that the connection pipes do not touch the Be sure to evacuate the refrigerant system using a vacuum pump.
compressor or outer panel. If the pipes touch the compressor or outer panel, they will The refrigerant pressure may sometimes not rise when a closed valve is opened after
vibrate and produce noise. the system is evacuated using a vacuum pump. This is caused by the closure of the
refrigerant system of the outdoor unit by the electronic expansion valve. This will not
(1) Install the outdoor unit wall cap (supplied with the optional installation set or procured
affect the operation of the unit.
in the field) to the wall hole pipe.
(2) Connect the outdoor unit and indoor unit piping. If the system is not evacuated sufficiently, its performance will drop.
(3) After matching the centre of the flare surface and tightening the nut hand tight, Use a clean gauge manifold and charging hose that were designed specifically for use
tighten the nut to the specified tightening torque with a torque wrench. with R410A. Using the same vacuum equipment for different refrigerants may damage
the vacuum pump or the unit.
Do not purge the air with refrigerants, but use a vacuum pump to evacuate the system.

Connection pipe (1) Check that the valves are closed by removing the blank caps from the gas and liquid
pipes.
(2) Remove the charging port cap, and connect the gauge manifold and the vacuum
Flare nut pump to the charging valve with the service hoses.
(3) Vacuum the indoor unit and the connecting pipes until the pressure gauge indicates
90° –0.1 MPa (–76 cmHg).
(4) When –0.1 MPa (–76 cmHg) is reached, operate the vacuum pump for at least
Torque wrench 60 minutes.
(5) Disconnect the service hoses and fit the charging port cap to the charging valve to the
specified torque. (Refer to below table)
(6) Remove the blank caps, and fully open the 3-way valves with a hexagon wrench
[Torque: 6 to 7 N·m (60 to 70 kgf·cm)].
(7) Tighten the blank caps of the 3-way valve to the specified torque.

Pipe outside diameter Tightening torque


6.35 mm (1/4 in.) 20 to 25 N·m (200 to 250 kgf·cm)
9.52 mm (3/8 in.) 20 to 25 N·m (200 to 250 kgf·cm)
Blank cap
12.70 mm (1/2 in.) 28 to 32 N·m (280 to 320 kgf·cm)
To prevent gas leakage, coat the flare 15.88 mm (5/8 in.) 30 to 35 N·m (300 to 350 kgf·cm)
surface with alkylbenzene oil (HAB). Charging port cap 12.5 to 16 N·m (125 to 160 kgf·cm)
Do not use mineral oil.

Flare nut tightening torque Connecting pipe

Flare nut Tightening torque Blank cap


6.35 mm (1/4 in.) dia. 16 to 18 N · m (160 to 180 kgf · cm)
Hexagon wrench
9.52 mm (3/8 in.) dia. 32 to 42 N · m (320 to 420 kgf · cm) Outdoor unit
12.70 mm (1/2 in.) dia. 49 to 61 N · m (490 to 610 kgf · cm) Use a 4 mm
Service hose hexagon wrench.
15.88 mm (5/8 in.) dia. 63 to 75 N · m (630 to 750 kgf · cm) with valve core 3-way valve

Do not remove the cap from the connection pipe before connecting the pipe. Charging port

4.5. Sealing test


Cap
WARNING
Before operating the compressor, install the pipes and securely connect them.
Otherwise, if the pipes are not installed and if the valves are open when the compressor CAUTION
operates, air could enter the refrigeration cycle. If this happens, the pressure in the
refrigeration cycle will become abnormally high and cause damage or injury. Use a clean gauge manifold
After the installation, make sure there is no refrigerant leakage. If the refrigerant leaks and charging hose for R410A
into the room and becomes exposed to a source of fire such as a fan heater, stove, or exclusively.
burner, it produces a toxic gas.
Do not subject the pipes to strong shocks during the sealing test. It can rupture the
pipes and cause serious injury.

CAUTION
Do not block the walls and the ceiling until the sealing test and the charging of the
refrigerant gas have been completed. Gauge manifold
For maintenance purposes, do not bury the piping of the outdoor unit.

• After connecting the pipes, perform a sealing test.


• Make sure that the 3-way valves are closed before performing a sealing test.
• Pressurize nitrogen gas to 4.15 MPa to perform the sealing test.
• Add nitrogen gas to both the liquid pipes and the gas pipes. Vacuum pump
• Check all flare connections and welds. Then, check that the pressure has not
decreased.
• Compare the pressures after pressurizing and letting it stand for 24 hours, and check
that the pressure has not decreased.
* When the outdoor air temperature changes 5 °C, the test pressure changes Service hose
0.05 MPa. If the pressure has dropped, the pipe joints may be leaking.
• If a leak is found, immediately repair it and perform the sealing test again.
• After completing the sealing test, release the nitrogen gas from both valves.
• Release the nitrogen gas slowly.

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4.7. Additional charging 5. ELECTRICAL WIRING

WARNING 5.1. Notes for electrical wiring


When moving and installing the air conditioner, do not mix gas other than the specified
refrigerant R410A inside the refrigerant cycle.
If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to an WARNING
abnormally high value and cause breakage, injury, etc.
Wiring connections must be performed by a qualified person in accordance with the
specifications. The voltage rating for this product is 220-240 V at 50 Hz. It should be
CAUTION operated within the range of 198 to 264 V.
After vacuuming the system, add refrigerant. Before connecting the wires, make sure the power supply is OFF.
Do not reuse recovered refrigerant. Use a dedicated power supply circuit. Insufficient power capacity in the electrical circuit
When charging the refrigerant R410A, always use an electronic scales for refrigerant or improper wiring may cause electric shock or fire.
charging (to measure the refrigerant by weight). Adding more refrigerant than the
Install a breaker at the power supply for each outdoor unit. Improper breaker selection
specified amount will cause a malfunction.
can cause electric shock or fire.
When charging the refrigerant, take into account the slight change in the composition
Install a leakage circuit breaker in accordance with the related laws and regulations.
of the gas and liquid phases, and always charge from the liquid phase side whose
An improperly installed electrical box cover can cause serious accidents such as electric
composition is stable. Adding refrigerant through the gas pipe will cause a malfunction.
shock or fire through exposure to dust or water.
Check if the steel cylinder has a siphon installed or not before filling. (There is an
indication “with siphon for filling liquid” on the steel cylinder.) A circuit breaker is installed in the permanent wiring. Always use a circuit that can trip
all the poles of the wiring and has an isolation distance of at least 3 mm between the
Filling method for cylinder with siphon contacts of each pole.
R410A Use designated cables and power cables. Improper use may cause electric shock or fire
Set the cylinder vertical and fill with the liquid. by poor connection, insufficient insulation, or over current.
Gas
(Liquid can be filled without turning bottom up with the
siphon inside.) Do not modify power cable, use extension cable or branch wiring. Improper use may
Liquid cause electric shock or fire by poor connection, insufficient insulation or over current.
Filling method for other cylinders Connect the connector cable securely to the terminal. Check no mechanical force bears
on the cables connected to the terminals. Faulty installation can cause a fire.
R410A
Gas Use ring terminals and tighten the terminal screws to the specified torques, otherwise,
Turn bottom up and fill with liquid.
abnormal overheating may be produced and possibly cause serious damage inside the
(Be careful to avoid turning over the cylinder.)
unit.
Liquid
Make sure to secure the insulation portion of the connector cable with the cable clamp.
Be sure to use the special tools for R410A for pressure resistance and to avoid mixing Damaged insulation can cause a short circuit.
of impure substances.
Fix cables so that cables do not make contact with the pipes (especially on high
If the units are further apart than the maximum pipe length, correct operation can not be pressure side). Do not make power supply cable and transmission cable come in
guaranteed. contact with valves (Gas).
Make sure to back closing valve after refrigerant charging. Otherwise, the compressor Never install a power factor improvement condenser. Instead of improving the power
may fail. factor, the condenser may overheat.
Minimize refrigerant release to the air. Excessive release is prohibited under the Freon
Be sure to perform the earthing (grounding) work.
Collection and Destruction Law.
Do not connect earthing (grounding) wires to a gas pipe, water pipe, lightning rod or
Additional charging amount earthing (grounding) wire for a telephone.
Refrigerant suitable for a piping length of 7.5 m is charged in the outdoor unit at the • Connection to a gas pipe may cause a fire or explosion if gas leaks.
factory. • Connection to a water pipe is not an effective earthing (grounding) method if PVC
When the piping is longer than 7.5 m, additional charging is necessary. pipe is used.
For the additional amount, see the table below. • Connection to the earthing (grounding) wire of a telephone or to a lightning rod may
cause a dangerously abnormal rise in the electrical potential if lightning strikes.
Less than Improper earthing (grounding) work can cause electric shocks.
Pipe length 10 m 20 m g/m
7.5 m
Securely install the electrical box cover on the unit. An improperly installed service panel
can cause serious accidents such as electric shock or fire through exposure to dust or
water.
Additional charge amount None 50 g 250 g 20 g/m

CAUTION
The primary power supply capacity is for the air conditioner itself, and does not include
the concurrent use of other devices.
4.8. Gas leakage inspection Do not start operation until the refrigerant is charged completely. The compressor will
fail if it is operated before the refrigerant piping charging is complete.

CAUTION Transmission cable between indoor unit and outdoor unit is 220-240 V.
After connecting the piping, check the joints for gas leakage with gas leak detector. Be sure not to remove thermistor sensor etc. from power wiring and connection wiring.
Compressor may fail if operated while removed.
Start wiring work after closing branch switch and over current breaker.
WARNING
Use an earth leakage breaker that is capable of handling high frequencies. Because the
During installation, make sure that the refrigerant pipe is attached firmly before
you run the compressor. outdoor unit is inverter controlled, a high-frequency earth leakage breaker is necessary
Do not operate the compressor under the condition of refrigerant piping not attached to prevent a malfunction of the breaker itself.
properly with 2-way or 3-way valve open. This may cause abnormal pressure in the When using an earth leakage breaker that has been designed solely for earth (ground)
refrigeration cycle that leads to breakage and even injury. fault protection, be sure to install a fuse-equipped switch or circuit breaker.
During the pump-down operation, make sure that the compressor is turned off Do not connect the AC power supply to the transmission line terminal board. Improper
before you remove the refrigerant piping. wiring can damage the entire system.
Do not remove the connection pipe while the compressor is in operation with 2-way or
3-way valve open. Do not use crossover power supply wiring for the outdoor unit.
This may cause abnormal pressure in the refrigeration cycle that leads to breakage and
If the temperature surrounding the breaker is too high, the amperage at which the
even injury.
breaker cuts out may decrease.
When installing and relocating the air conditioner, do not mix gases other than
the specified refrigerant (R410A) to enter the refrigerant cycle.
If air or other gas enters the refrigerant cycle, the pressure inside the cycle will rise to an
abnormally high value and cause breakage, injury, etc.

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How to connect wiring to the terminal
Caution when wiring cable 5.3. Wiring method
When stripping off the coating of a lead wire, always use a special tool such as a wire
stripper. If there is no special tool available, carefully strip the coating with a knife etc. (1) Remove the terminal cover and cable clamp.
(1) Use ring terminals with insulating sleeves as shown in the figure below to connect
to the terminal block.
(2) Securely clamp the ring terminals to the wires using an appropriate tool so that the
wires do not come loose.

Strip : 10 mm
Ring terminal Terminal cover
Control box

Sleeve Cable clamp

(3) Use the specified wires, connect them securely, and fasten them so that there is no
stress placed on the terminals.
(4) Use an appropriate screwdriver to tighten the terminal screws. Do not use a
screwdriver that is too small, otherwise, the screw heads may be damaged and
prevent the screws from being properly tightened.
(5) Do not tighten the terminal screws too much, otherwise, the screws may break.
Screw with special washer Screw with
special washer
Ring terminal
Wire

Ring terminal

Terminal blocks
Wire (2) Connect the power supply cable and the connection cable to terminal.

(6) See the table below for the terminal screw tightening torques. L N 1(L)2(N) 3
Terminal
Tightening torque [N·m (kgf·cm)] block
M4 screw 1.2 to 1.8 (12 to 18) Control box
M5 screw 2.0 to 3.0 (20 to 30)

5.2. Selecting circuit breaker and wiring


Cable clamp

CAUTION
Power supply
Be sure to install a breaker with specified capacity. Connection cable
cable
Before the electrical working, confirm electrical standards and regulations in each
country, region, or installing place. Then select appropriate cables and breakers that
comply with them.

Voltage rating 1 Φ 220-240 V (50 Hz)


Operating range 198 to 264 V
15~20 mm
30 mm

15~30 mm
40 mm

Cable Conductor size [mm2]*1 Type Remarks


Power Supply 2 Cable + Earth (Ground)
2.5 ~ 3.0 Type 60245 IEC66
Cable 1 Φ 220-240 V
3 Cable + Earth (Ground)
Connection Cable 1.5 ~ 2.5 Type 60245 IEC57
1 Φ 220-240 V

*1 Selected sample: Select the correct cable type and size according to the country or
region’s regulations.
Max. wire length: Set a length so that the voltage drop is less than 2%. Increase the wire
diameter when the wire length is long.

Breaker Specification*2
. 0   
Circuit breaker (over current) Current : 20 (A)
Earth leakage breaker Leakage current : 30mA 0.1 sec or less*3

*2 Select the appropriate breaker of the described specification according to the national
Earth Earth
or regional standards. (Ground) (Ground)
*3 Select the breaker that enough load current can pass through it.
• Before starting work check that power is not being supplied to all poles of the indoor Power line
unit and outdoor unit.
• Install all electrical works in accordance to standard. Power Connection
supply cable
• Install the disconnect device with a contact gap of at least 3mm in all poles nearby the
cable (To indoor unit)
units. (Both indoor unit and outdoor unit)
• Wiring size must comply with the applicable local and national code.

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(3) Put the cable clamp and terminal cover back after completion of the work.

Terminal cover
Control box

Cable clamp

6. TEST RUN
Perform test run as described in the installation manual of the indoor unit.

7. CHECK LIST
Check items during test operation.

Is the outdoor unit making any abnormal noise or vibrating significantly?


Is the cold air or hot air blowing from indoor unit according to the operation
mode?
Operate the unit according to the operating manual provided with the indoor unit,
and check that it is operating normally.

8. PUMP DOWN OPERATION (FORCED COOLING


OPERATION)

WARNING
During the pump-down operation, make sure that the compressor is turned off before
you remove the refrigerant piping. Do not remove the connection pipe while the
compressor is in operation with 2 or 3 way valve open. This may cause abnormal
pressure in the refrigeration cycle that may lead to breakage or injury.

To avoid discharging refrigerant into the atmosphere at the time of relocation or disposal,
recover refrigerant by doing the cooling operation or forced cooling operation according
to the following procedure. (When the cooling operation cannot start in winter, and so on,
start the forced cooling operation.)

(1) Do the air purging of the charge hose by connecting the charging hose of gauge
manifold to the charging port of 3-way valve (large) and opening the low-pressure
valve slightly.
(2) Close the valve stem of 2-way valve (small) completely.
(3) Start the cooling operation or forced cooling operation as described in the installation
manual of the indoor unit.
(4) Close the valve stem of 3-way valve (large) when the reading on the compound
pressure gauge becomes 0.05~0 MPa (0.5 ~ 0 kg/cm²).
(5) Stop the operation as described in the installation manual of the indoor unit.

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