General ASH14L, ASH14LSBCW, AOH14LFBC, ASH18L, ASH18LSBCW Installation Manual

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SPLIT TYPE ROOM AIR CONDITIONER

INSTALLATION MANUAL

(PART NO. 9313802028-01)

This air conditioner uses new refrigerant HFC (R410A).

The basic installation work procedures are the same as conventional refrigerant (R22) models.

However, pay careful attention to the following points:

(1) 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 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 the R410A piping and flare nuts.

(2) Models that use refrigerant R410A have a different charging port thread diameter to prevent

erroneous charging with conventional refrigerant (R22) and for safety. Therefore, check beforehand.[The charging port thread diameter for R410A is 1/2 threads per inch.]

(3) Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with refrigerant

(R22) models. Also, when storing the piping ,securely seal the opening by pinching ,taping, etc.

(4) When charging the refrigerant, take into account the slight change in the composition of the

gas and liquid phases, and always charge from the liquid phase side whose composition is stable.

For authorized service personnel only.

WARNING

(1) For the room air conditioner to operate satisfactory, install it as outlined in this installation manual. (2) Connect the indoor unit and outdoor unit with the air conditioner piping and cords available standards parts. This

installation manual describes the correct connections using the standard accessories and the parts specified in

this installation manual. (3) Have installation work done by authorized service personnel only. (4) Never cut the power cord, lengthen or shorten the cord, or change the plug. (5) Also do not use an extension cord. (6) Plug in the power cord plug firmly. If the receptacle is loose, repair it before using the room air conditioner.

(7) Do not turn on the power until all installation work is complete.

● Be careful not to scratch the air conditioner when handling it.

● After installation, explain correct operation to the customer, using the operating manual.

● Let the customer keep this installation manual because it is used when the air conditioner is serviced or moved.

● The maximum length of the piping is 20 m. The maximum height difference of the piping is 10 m,

if the units are further apart than these, correct operation can not be guaranteed.

STANDARD ACCESSORIES

The following installation accessories are supplied. Use them as required.

One set of following parts are necessary in istallation of this product.

Special tools for R410A

Tool name

Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous

Gauge manifold

Charge hose

Vacuum pump

Gas leakage detector

Copper pipes

It is necessary to use seamless copper pipes and it is desirable that the amount of residual oil is less than 40 mg/10m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface). Otherwise, the expansion value or capillary tube may become blocked with contaminants. As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials. Thicknesses of copper pipes used with R410A are as shown in Table1.Never us copper pipes thinner than 0.8mm even when it is available on the market.

mixing of other refrigerants, the diameter of each port has been changed. It is recommended the gauge with seals-0.1 to 5.3 MPa (-1 to 53 bar) for high pressure.

-0.1 to 3.8 MPa (-1 to 38 bar) for low pressure. To increase pressure resistance, the hose material and base size were changed. A conventional vacuum pump can be used by installing a vacuum pump adapter. Special gas leakage detector for HFC refrigerant R410A.

Contents of change

Table 1 Thicknesses of Annealed Copper Pipes

Nominal diameter

1/4

1/2

Outer diameter

(mm)

6.35

12.7

Thickness (mm)

R410A

0.80

[ref.] R22

0.80

Name and Shape Q’ty Name and Shape Q’ty

Wall hook bracket

Remote control unit

Cloth tape

Tapping screw (big)

Tapping screw (small)

Battery

Air cleaning filter

Remote control unit holder

Air cleaning filter frame

Name

Connection pipe assembly

Connection cord

Wall pipe

Decorative tape

Vinyl tape

Wall cap

Saddle

Drain hose

Tapping screws

Sealant

ELECTRICAL REQUIREMENT

Always make the air conditioner power supply a special branch circuit and provide a special switch and receptacle. Do not extend the power cord.

WARNING

(1) Do not use the existing (for R22) piping and flare nuts.

• If the existing materials are used, the pressure inside the refrigerant cycle will rise and cause breakage, injury, etc.(Use the special R410A materials.)

(2) 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.

SELECTING THE MOUNTING POSITION

Decide the mounting position with the customer as follows:

1. INDOOR UNIT

(1) Install the indoor unit level on a strong wall which is not subject to

vibration.

(2) The inlet and outlet ports should not be obstructed : the air should

be able to blow all over the room. (3) Install the unit near an electric outlet or special branch circuit. (4) Do not install the unit where it will be exposed to direct sunlight. (5) Install the unit where connection to the outdoor unit is easy. (6) Install the unit where the drain pipe can be easily installed. (7) Take servicing, etc. into consideration and leave the spaces shown

in (Fig. 2). Also install the unit where the filter can be removed.

INSTALLATION DIAGRAM OF INDOOR AND OUTDOOR UNITS

Fig. 2

[INDOOR UNIT]

Wall hook bracket

5 cm or over

6 cm or over

9 cm or over

2. OUTDOOR UNIT

(1) If possible, do not install the unit where it will be exposed to direct

sunlight. (If necessary, install a blind that does not interfere with

the air flow.) (2) Do not install the unit where a strong wind blows or where it is very

dusty. (3) Do not install the unit where people pass. (4) Take you neighbors into consideration so that they are not disturbed

by air blowing into their windows or by noise. (5) Provide the space shown in Fig. 2 so that the air flow is not blocked.

Also for efficient operation, leave open three of the four directions

front, rear, and both sides.

WARNING

Install at a place that can withstand the weight of the indoor and outdoor units and install positively so that the units will not topple or fall.

[OUTDOOR UNIT]

150 cm or over

230 cm or over

Remote

control unit

Connection Cord

Conform to Type245 IEC57

60 cm or over

(Wall cap)

Remote

control unit

holder

Tapping

screw

(small)

10 cm or over

CAUTION

(1) Do not install where there is the danger of com-

bustible gas leakage. (2) Do not install near heat sources. (3) If children under 10 years old may approach the

unit, take preventive measures so that they can-

not reach the unit. (4) Install the indoor unit on the wall where the height

from the floors more than 230 cm.

10 cm or over

30 cm or over

[Indoor unit piping direction]

The piping can be connected in the five directions indicated by 1, 2, 3, 4, and 5 in (Fig. 1). When the piping is connected in

direction 2 or 5, cut along the piping groove in the side of the front cover with a hacksaw. When connecting the piping in direction 3, cut a notch in the thin wall at the front bottom of the front cover.

Fig. 1

(Rear)

2 Right

outlet

3 Bottom outlet

1 Rear outlet

4 Left rear

outlet

5 Left

outlet

Fig. 3

Drain hose

54 cm

Outdoor unit bottom

32 cm

Drain pipe

Seal A

FRONT PANEL REMOVAL AND INSTALLATION

THE INTAKE GRILLE REMOVAL

(1) Open the intake grille. (2) Pull down the knob. (3) Lift the intake grille upward, until the axle at the top of the in-

take grille is removed.

THE INTAKE GRILLE INSTALLATION

(1) The fixing axle of the intake grille is installed on the Panel. (2) Lay down the intake grille.

THE FRONT PANEL REMOVAL

(1) Remove intake grille (Reference the intake grille removal.) (2) Remove four screws. (3) The thumb is hung on the lower part as shown in the figure,

and it pulls to the front, pushing [-] mark , and bottom hooks (two position) is removed from wall hook bracket.

(4) The front panel bottom is pulled to the front, and bottom hooks

is removed indoor unit.

(5) The front panel is pulled to the front, raising the upper surface,

and a front panel is removed.

THE FRONT PANEL INSTALLATION

(1) Firstly, fit the lower part of the front panel, and insert top and

bottom hooks. (Three top sides, six bottom sides) (2) Four screws is attached. (3) The intake grille is attached.

Indoor unit

Bottom hole

(six position)

CAUTION

Install the front panel and INTAKE GRILLE securely. If installation is imperfect, the front panel or INTAKE GRILLE may fall off and cause injury.

Be sure that the top hole of the front panel is hooked securely to the hook of the base.

CUSTOMER GUIDANCE

Explain the following to the customer in accordance with the operating manual: (1) Starting and stopping method, opera-

tion switching, temperature adjustment, timer, air flow switching, and other remote control unit operations.

(2) Air filter removal and cleaning, and how

to use the air louvers.

(3) Give the operating and installation

manuals to the customer.

Bottom hooks

(six position)

Front panel

TEST RUNNING

● Perform test operation and check items 1 and 2 below.

● For the test operation method, refer to the operating manual.

● The outdoor unit, may not operate, depending on the room temperature. In this case, press

the test run button on the remote control unit while the air conditioner is running, (Point the transmitter section of the remote control unit toward the air conditioner and press the test run button with the tip of a ball-point pen, etc.)

● To end test operation, press the remote control unit START/STOP button. (When the air conditioner is run by pressing the test run button, the OPERATION indicator lamp and TIMER indicator lamp will simultaneously flash slowly.)

1. INDOOR UNIT

(1) Is operation of each button on the remote control unit normal? (2) Does each lamp light normally? (3) Do the air flow-direction louver operate normally? (4) Is the drain normal?

2. OUTDOOR UNIT

(1) Is there any abnormal noise and vibration during operation? (2) Will noise, wind, or drain water from the unit disturb the

neighbors?

(3) Is there any gas leakage?

POWER

WARNING

(1) The rated voltage of this product is 230 V AC 50 Hz. (2) Before turning on the power, check if the voltage is within

the 220 V -10 % to 240 V +10 % range.

(3) Always use a special branch circuit and install a special

receptacle to supply power to the room air conditioner.

(4) Use a circuit breaker and receptacle matched to the ca-

pacity of the air conditioner. (5) Do not extend the power cord. (6) Perform wiring work in accordance with standards so that

the air conditioner can be operated safely and positively. (7) Install a leakage circuit breaker in accordance with the

related laws and regulations and electric company

standards.

(1) The power source capacity must be the sum of the air conditioner

(2) When the voltage is low and the air conditioner is difficult to start,

Fig. 4

Push

[-] mark

Top holes (two sides)

Top hole (center)

Indoor unit

Intake grille

Mounting shaft

Bearing

Front panel

Push

Wall hook bracket

Screws

(4 position)

Front panel

Top hook (center)

Top hooks

(two sides)

Transmitter section

Test run button

Intake grille

Knob

Front panel

Fig. 5

CAUTION

current and the current of other electrical appliances. When the current contracted capacity is insufficient, change the contracted capacity.

contact the power company the voltage raised.

Installation instruction on the back.

INDOOR UNIT

CUTTING THE HOLE IN THE WALL FOR THE CONNECTING PIPING

(1) Cut a 65 mm diameter hole in the wall at the position shown in (Fig.

6).

(2) When cutting the wall hole at the inside of the installation frame, cut

the hole within the range of the left and right center marks 40 mm below the installation frame. When cutting the wall hole at the outside of the installation frame, cut the hole at least 10 mm below over.

(3) Cut the hole so that the outside end is lower (5 to 10 mm) than the

inside end.

(4) Always align the center of the wall hole. If misaligned, water leakage

will occur.

(5) Cut the wall pipe to match the wall thickness, stick it into the wall cap,

fasten the cap with vinyl tape, and stick the pipe through the hole. (The connection pipe is supplied in the installation set.) (Fig. 6)

(6) For left piping and right piping, cut the hole a little lower so that drain

water will flow freely. (Fig. 6)

INSTALLING THE WALL HOOK BRACKET

(1) Install the wall hook bracket so that it is correctly positioned horizon-

tally and vertically. If the wall hook bracket is tiled, water will drip to the floor.

(2) Install the wall hook bracket so that it is strong enough to withstand

the weight of an adult.

● Fasten the wall hook bracket to the wall with 6 or more screws through

the holes near the outer edge of the bracket.

● Check that there is no rattle at the wall hook bracket.

WARNING

If the wall pipe is not used, the cord interconnecting the indoor and outdoor units may touch metal and cause electric leakage.

CAUTION

Install the wall hook bracket horizontally and perpendicularly.

FORMING THE DRAIN HOSE AND PIPE

[Rear piping, Right piping, Bottom piping]

● Install the indoor unit piping in the direction of the wall hole and bind

the drain hose and pipe together with vinyl tape. (Fig. 8)

● Install the piping so that the drain hose is at the bottom.

● Wrap the pipes of the indoor unit that are visible from the outside

with decorative tape.

[For Left rear piping, Left piping]

Interchange the drain cap and the drain hose.

CAUTION

After removing the drain hose, do not forget to install the drain cap.

Indoor unit drain hose

Drain cap

Insert the drain cap and drain hose until it butts against the drain port.

Fig. 6

Fasten with vinyl tape

(Wall cap)

Fig. 7

Wall hook bracket

Fig. 8

Right piping

Lower

65 mm dia. hole

(Wall pipe)

(Inside)

Tapping screw

Bottom

piping

Indoor unit drain hose

Wall (Outside)

Center mark

5 to 10 mm low

65 mm dia. hole

Center notch

Wall hook bracket

Bind with vinyl tape

Pipe (top) Rear piping

Indoor unit drain hose (bottom)

For left outlet piping, cut off the piping outlet cutting groove with a hacksaw.

Drain cap

Lower

10 mm or over

Hook

String

Remove the drain cap by pulling at the projection at the end of the cap with pliers, etc.

● For left piping and left rear piping, align the marks on the wall hook

bracket and shape the connection pipe.

● Bend the connection piping at the bend radius of 70 mm or more and

install no more than 35 mm from the wall.

● After passing the indoor piping and drain hose through the wall hole,

hang the indoor unit on the hooks at the top and bottom of the wall hook bracket.

[Installing the indoor unit]

● Hang the indoor unit from the hooks at the top of the wall hook bracket.

● Insert the spacer, etc. between the indoor unit and the wall hook

bracket and separate the bottom of the indoor unit from the wall.

Indoor unit

(Spacer)

Wall hook bracket

CONNECTING THE PIPING

CONNECTION

(1) Install the outdoor unit wall cap (supplied with the optional installation set

or procured at the site) to the wall pipe. (2) Connect the outdoor unit and indoor unit piping. (3) After matching the center of the flare surface and tightening the nut hand

tight, tighten the nut to the specified tightening torque with a torque wrench.

(Table 2)

FLARING

(1) Cut the connection pipe to the necessary

length with a pipe cutter. (2) Hold the pipe downward so that cuttings

will not enter the pipe and remove the

burrs. (3) Insert the flare nut onto the pipe and flare

the pipe with a flaring tool.

Insert the flare nut (always use the flare nut attached to the indoor and outdoor units 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. When using the conventional flare tool, always use an allowance adjustment gauge and secure the A dimension shown in table 3 .

Check if [L] is flared uniformly and is not cracked or scratched.

Die

Pipe

INDOOR UNIT WIRING

(1) Remove the cord clamp. (2) Bend the end of the connection cord as shown in the figure.

Fig. 11

Right bottom of indoor unit

Cord clamp

(There is a

terminal block

inside.)

Screw

(1) Match the terminal block numbers and connection

cord colors with those of the outdoor unit. Erroneous wiring may cause burning of the electric parts.

(2) Connect the connection cords firmly to the terminal

block. Imperfect installation may cause a fire.

Connection cord

CAUTION

Fig. 9

Connection pipe (6.35 mm dia.)

Bend (R70) with a pipe bender

Connection pipe (12.7 mm dia.)

Indoor unit

After hooking the indoor unit to the top hook, hook the fittings of the indoor unit to the two bottom hooks while lowering the unit and pushing it against the wall.

Fig. 10

Indoor unit pipe

(Fitting)

Tighten with two wrenches.

Wrench (fixed)

Torque wrench

Flare nut

Connection pipe

Align the marks.

Top hooks

Wall hook

Bottom hooks

To prevent gas leakage, coat the flare surface with refrigerator oil.

bracket

Table 2 Flare nut tightening torque

Flare nut

6.35 mm dia.

12.7 mm dia.

Tightening torque

15.7 to 17.6 N•m

(160 to 180 kgf•cm)

49.0 to 53.9 N•m

(500 to 550 kgf•cm)

Tightening torque standard

(using a 20 cm wrench)

Wrist strength

Arm strength

Table 3 Pipe outside diameter

Pipe outside

diameter

ø 6.35 mm (1/4”) ø 12.7 mm (3/8”)

Flash tool for

R410A, clutch type

0 to 0.5 0 to 0.5

A (mm)

Conventional (R22) flare tool

Clutch type

1.0 to 1.5

Wing nut type

1.5 to 2.0

(3) Connect the end of the connection cord fully into the terminal block. (4) Fasten the connection cord with a cord clamp.

Cord clamp

5 mm

12 mm

50 mm

5 mm

12 mm

40 mm

Ta b

Square hole

Screw

Insert the tab into the square hole of the indoor unit and fasten with a screw.

(3) Always fasten the outside covering of the connec-

tion cord with the cord clamp. (If the insulator is

chafed, electric leakage may occur.) (4) Securely earth the power cord plug. (5) Do not use the earth screw for an external connector.

Only use for interconnection between two units.

OUTDOOR UNIT

OUTDOOR UNIT INSTALLATION

● Set the unit on a strong stand, such as one made of concrete blocks

to minimize shock and vibration.

● Do not set the unit directly on the ground because it will cause trou-

ble.

Connector cover removal

● Remove the tapping screws.

Installing the connector cover

(1) After inserting the two front hooks, then insert the rear hook. (2) Tighten the tapping screws.

AIR PURGE

Always use a vacuum pump to purge the air. Refrigerant for purging the air is not charged in the outdoor unit at the factory.

Close the high pressure side valve of the gauge manifold fully and do not operate it during the following work.

WARNING

(1) Install the unit where it will not be tilted by more

than 5°.

(2) When installing the outdoor unit where it may ex-

posed to strong wind, fasten it securely.

Fig. 12

Tapping screw

Front hooks

Rear hooks

Connector cover

CAUTION

(1) Refrigerant must not be discharged into

atmosphere.

(2) After connecting the piping , check the joints for

gas leakage with gas leak detector.

Additional charge

Refrigerant suitable for a piping length of 15 m is charged in the outdoor unit at the factory. When the piping is longer than 15 m, additional charging is necessary. For the additional amount, see the table below.

Table 5

Pipe length

Additional refrigerant

15 m

None

20 m

100 g

OUTDOOR UNIT WIRING

(1) Remove the outdoor unit connector cover. (2) Bend the end of the cord as shown in the figure. (3) Connect the end of the connection cord fully into the terminal block. (4) Fasten the sheath with a cord clamp. (5) Install the connector cover.

Fig. 14

Control box

Cord clamp

Connector cord

CAUTION

(1)

When adding refrigerant, add the refrigerant from the charging port at the completion of work.

(2) The maximum length of the piping is 20 m. If

the units are further apart than this, correct operation can not be guaranteed.

Between 15 m and 20 m, when using a connection pipe other than that in the table, charge additional refrigerant with 20g/1 m as the criteria.

5mm

30mm

12mm

Earth screw

Cord clamp

Earth screw

Fig. 15

Sheath

Connection cord

12mm

25mm

Outdoor unit terminal blockIndoor unit terminal block

5mm

1. Check if the piping connections are secure.

2. Check that the stems of 2-way valve and 3-way valve are closed fully.

3. Connect the gauge manifold charge hose to the charging port of the 3-way valve (side with the projection for pushing in the valve core).

4. Open the low pressure side valve of the gauge manifold fully.

5. Operate the vacuum pump and start pump down.

6. Slowly loosen the flare nut of the 3-way valve and check if air enters, then retighten the flare nut. (When the flare nut is loosened the operating sound of the vacuum pump changes and the reading of the compound pressure gauge goes from minus to zero.)

7. Pump down the system for at least 15 minutes, then check if the compound pressure gauge reads -0.1 MPa (-76 cmHg, -1 bar).

8. At the end of pump down, close the low pressure side gauge of the gauge manifold fully and stop the vacuum pump.

9. Slowly loosen the valve stem of the 3-way valve. When the compound pressure gauge reading reaches 0.1-0.2 MPa, retighten the valve stem and disconnect the charge hose from the 3-way valve charging port. (If the stem of the 3-way valve is opened fully before the charge hose is disconnected, it may be difficult to disconnect the charge hose.)

10. Fully open the valve stems of the 2-way valve and 3-way valve using a hexagon wrench. (After the valve stem begins to turn, turn it with a torque of less than 2.9 N•m (30 kgf•cm) until it stops turning.)

11. Firmly tighten the 2-way valve and 3-way valve blank cap and the charging port cap.

Fig. 13

Gauge manifold

-0.1 MPa (-76 cmHg

-1 bar)

Low pressure side valve

Charge hose

Pressure gauge

High pressure side valve (closed)

Charge hose

Vacuum pump

3-way valve

Charging port cap

Compound pressure gauge

2-way valve

Flare nut

Valve stem

Blank cap

Charging port

Table 4

Tightening torque

Blank cap (2-way valve) 19.6 to 24.5 N•m (200 to 250 kgf•cm)

Blank cap (3-way valve) 27.4 to 31.4 N•m (280 to 320 kgf•cm)

Charging port cap 12.3 to 15.7 N•m (125 to 160 kgf•cm)

Connection cord wiring

Run the connection cord to the rear of the outdoor unit within the A range of the arrows shown in the figure. (The connector cover becomes difficult to install.)

CAUTION

(1) Match the terminal block numbers and connection

cord colors with those of the indoor unit. Erroneous wiring may cause burning of the electric parts.

(2) Connect the connection cords firmly to the terminal

block. Imperfect installation may cause a fire.

(3) Always fasten the outside covering of the connec-

(4) Securely earth the power cord plug. (5) Do not use the earth screw for an external connector.

FINISHING

(1) Insulate between pipes.

● For rear, right, and bottom piping, overlap the connection pipe heat insulation and indoor unit pipe heat insulation and bind them with vinyl tape so that there is no gap.

● For left and left rear piping, butt the connection pipe heat insulation and indoor unit pipe heat insulation together and bind them with and vinyl tape so that there is no gap.

● For left and left rear piping, wrap the area which accommodates the rear piping housing section with cloth tape.

● For left and left rear piping, bind the connection cord to the top of the pipe with vinyl tape.

● For left and left rear piping, bundle the piping and drain hose together by wrapping them with cloth tape over the range within which they fit into the rear piping housing section.

(2) Temporarily fasten the connection cord along the connection pipe with vinyl tape. (Wrap

to about 1/3 the width of the tape from the bottom of the pipe so that water does not enter.)

(3) Fasten the connection pipe to the outside wall with saddles, etc. (4) Fill the gap between the outside wall pipe hole and the pipe with sealer so that rain

water and wind cannot blow in.

(5) Fasten the drain hose to the outside wall, etc.

Wall

(Outside wall cap)

(Sealer putty)

(Outdoors)

Fig. 16

(Saddle)

Pipe

Connector cord

tion cord with the cord clamp. (If the insulator is chafed, electric leakage may occur.)

Only use for interconnection between two units.

Fig. 17

Connection pipe (heat insulation)

Bind the pipes together so that there is no gap.

Left piping

Connection cord

Pipe

Check the following:

GOOD

Drain hose

Overlap the insulation

Pipe

Drain hose

Saddle

Indoor unit pipe (heat insullation)

Vinyl tape

Wrap with cloth tape

Cloth tape

For connection from the left rear

Wall pipe

Drain hose

BAD

Lifted up

Connection cord

Connection pipe

BAD BAD

Wave End in water

P/N 9313802028-01