General ASH9UB, ASH9USBCW, AOH9UGBC Installation Manual

SPLIT TYPE ROOM AIR CONDITIONER
INSTALLATION MANUAL
(PART NO. 9312365012-01)
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.
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.
(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.
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
WARNING
1/4
3/8
Outer diameter
(mm)
6.35
9.52
Thickness (mm)
R410A
0.80
0.80
[ref.] R22
0.80
0.80
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.
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.
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.
[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)
5 Left
outlet
2 Right
outlet
3 Bottom outlet
1 Rear outlet
4 Left rear
outlet
INSTALLATION DIAGRAM OF INDOOR AND OUTDOOR UNITS
Fig. 2
[INDOOR UNIT]
Wall hook bracket
9 cm or over
Wall cap
5 cm or over
25 cm or over
26.5 cm
6 cm or over
150 cm or over
Connection Cord
Conform to Type245 IEC57
[OUTDOOR UNIT]
60 cm or over
10 cm or over
60 cm or over
Fig. 3
Remote
control unit
Drain hose
5 cm or over
230 cm or over
Outdoor unit bottom
50 cm
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.
4).
(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. 4)
(6) For left piping and right piping, cut the hole a little lower so that drain
water will flow freely. (Fig. 4)
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. 6)
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. 4
Fasten with vinyl tape
(Wall cap)
Fig. 5
Wall hook bracket
Fig. 6
Right piping
Under cover
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
Remove the drain cap by pulling at the projection at the end of the cap with pliers, etc.
Lower
10 mm or over
Hook
String
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)
Indoor unit
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
A
Pipe
INDOOR UNIT WIRING
(1) Remove the cord clamp. (2) Bend the end of the connection cord as shown in the figure.
Fig. 9
Right bottom of indoor unit
Cord clamp
Connection
cord
Screw
Connection cord
(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.
5 mm
12 mm
50 mm
CAUTION
Fig. 7
Connection pipe (6.35 mm dia.)
Bend (R70) with a pipe bender
Connection pipe (9.52 mm dia.)
(Fitting)
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. 8
Table 2 Flare nut tightening torque
Flare nut
6.35 mm dia.
9.52 mm dia.
Table 3 Pipe outside diameter
Pipe outside
diameter
ø 6.35 mm (1/4”) ø 9.52 mm (3/8”)
(3) Connect the end of the connection cord fully into the terminal block. (4) Fasten the connection cord with a cord clamp.
Tighten with two wrenches.
Torque wrench
Indoor unit pipe
Tightening torque
15.7 to 17.6 N•m
(160 to 180 kgf•cm)
29.4 to 41.1 N•m
(300 to 420 kgf•cm)
Flash tool for
R410A, clutch type
5 mm
12 mm
40 mm
Wrench (fixed)
Flare nut
Connection pipe
0 to 0.5 0 to 0.5
Cord clamp
Tab
Screw
Insert the tab into the square hole of the indoor unit and fasten with a screw.
Align the marks.
Top hooks
Bottom hooks
To prevent gas leakage, coat the flare surface with refrigerator oil.
Tightening torque standard
(using a 20 cm wrench)
Wrist strength
A (mm)
Conventional (R22) flare tool
Clutch type
1.0 to 1.5
1.0 to 1.5
Square hole
Wall hook bracket
Arm strength
Wing nut type
1.5 to 2.0
1.5 to 2.0
(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.
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 15 m. The maximum height difference of the piping is 8 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.
Name and Shape Q’ty Name and Shape Q’ty
Wall hook bracket
Drain pipe
1
Remote control unit
Cloth tape
1
1
1
One set of following parts are necessary in istallation of this product.
Name
Connection pipe assembly
Connection cord (3-conductor)
Connection cord (2-conductor)
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.
Battery Tapping screw
28
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 two mounting screws.
Put your hand on the back side ( mark) and take out the connector
cover forwards.
Installing the connector cover
(1) After inserting the three front hooks, then insert the rear hook. (2) Tighten the two mounting 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.
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.)
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. 10
ø5 mm tapping screw (special)
(Rear hook)
Connector cover
ø4 mm skirted screw
Front hook
Always use the screws as shown above. Do not select the top and bottom screws incorrectly.
CAUTION
(1) Refrigerant must not be discharged into
atmosphere.
(2) After connecting the piping , check the joints for
gas leakage with gas leak detector.
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. 11
Outdoor unit
2-way valve
Valve stem
Charging port cap
Charging port
Charge hose
(For a description of how to use the gauge manifold, refer to the gauge manifold operation manual.)
Table 4
Blank cap 19.6 to 24.5 N•m (200 to 250 kgf•cm)
Charging port cap 12.3 to 15.7 N•m (125 to 160 kgf•cm)
Flare nut
Blank cap
3-way valve
Compound pressure gauge
-0.1 MPa (-76 cmHg
-1 bar)
Low pressure side valve
Vacuum pump adapter
Tightening torque
Gauge manifold
Pressure gauge
High pressure side valve (closed)
Charge hose
Vacuum pump
ADDITIONAL CHARGE
Refrigerant suitable for a piping length of 7.5 m is charged in the outdoor unit at the factory. When the piping is longer than 7.5 m, additional charging is necessary. For the additional amount, see the table below.
Table 5
Pipe length
Additional refrigerant
Between 7.5 m and 15 m, when using a connection pipe other than that in the table, charge additional refrigerant with 20g/1 m as the criteria.
7.5 m
None
10 m
50 g
15 m
150 g
OUTDOOR UNIT WIRING
(1) Remove the outdoor unit connector cover. (2) Remove the control box cover-B. (3) Bend the end of the cord as shown in the figure. (4) Connect the end of the connection cord fully into the terminal block.
Fig. 12
Terminal block
Connection cord wiring
Run the connection cord to the rear of the outdoor unit within the range of the arrows shown in the figure. (The connector cover becomes difficult to install.)
(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.
Earth screw
Control box cover-B
Cord clamp
After installed the control box cover-B
CAUTION
CAUTION
(1) When adding refrigerant, add the refrigerant from
the charging port at the completion of work.
(2) The maximum length of the piping is 15 m. If the
units are further apart than this, correct operation can not be guaranteed.
(5) Fasten the sheath with a cord clamp. (6) Install the control box cover-B. (7) Install the connector cover.
Earth screw
12mm
Cord clamp
23mm
(Sheath)
Connection cord
Earth screw
(Insulator)
Outdoor unit terminal blockIndoor unit terminal block
Connection cord
Fig. 13
Outdoor unit
(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.
Sheath
Earth screw
Connection cord
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. 15
(Saddle)
Pipe
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 intake 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, operation
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?
Top holes (two sides)
Indoor unit
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 capacity 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 current and the current
of other electrical appliances. When the current contracted capacity is insufficient, change the contracted capacity.
(2) When the voltage is low and the air conditioner is difficult to start, contact the power
company the voltage raised.
NOTE: These equipment shall be connected to a suitable mains network with a main
impedance less than the following: 0. 424 The product is intended for use only in premises having a service current capacity 100A per phase,supplied from a distribution network having a nominal voltage of 230 V, and instruct the user to determine in consulation with the supply authority, if necessary, that the service current capacity at the interface point is sufficient for the equipment.
Fig. 14
Connection pipe (heat insulation)
Bind the pipes together so that there is no gap.
Left piping
Connection cord
Pipe
Check the following:
GOOD
Fig. 16
Intake grille
Mounting shaft
Bearing
Font panel
Push
[-] mark
Top hole (center)
Overlap the insulation
Pipe
Drain hose
Drain hose
Drain hose
Saddle
Screws
(4 position)
Push
Wall hook bracket
Top hooks
(two sides)
CAUTION
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
Front panel
Top hook (center)
Front panel
Connection cord
Connection pipe
BAD BAD
Wave End in water
Intake grille
Knob
Front panel
Fig. 17
Transmitter section
Test run button
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