General AUG12A, AUG12AGA, AOG12AGAL, AUG12RG, AUG12RGA Installation Manual

SPLIT TYPE ROOM AIR CONDITIONER

Cassette Type

INSTALLATION MANUAL

(PART NO. 9359992011-03)

For authorized service personnel only.

WARNING

1 For the room air conditioner to operate satisfactorily, install it as outlined in this installation manual.

2

Connect the indoor unit and outdoor unit with the room air conditioner piping and cords available from our standerd parts.

This installation manual describes the correct connections using the installation set available from our standard parts.

3 Installation work must be performed in accordance with national wiring standards by authorized personnel only.

4 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 shown in Table 1. If the units are further apart than this, correct operation cannot be
guaranteed.

STANDARD PARTS

The following installation parts are furnished. Use them as required.

INDOOR UNIT ACCESSORIES

Name and Shape Q’ty Application

Coupler
heat
insulation

Special nut A
(large flange)

Special nut B
(small flange)

Template For ceiling hole cutting

Remote
control unit

Battery (penlight)

Remote
control
unit holder

Tapping screw
(ø3 x 12)

For indoor side pipe joint

2

For installing indoor unit

4

For installing indoor unit

4

1

Use for air conditioner
operation

1

For remote control unit

4

For mounting the remote
control unit

1

For remote control unit
holder installation

3

OUTDOOR UNIT ACCESSORIES

Hexagon
wrench

Pipe(drain) For outdoor unit drain

Flexible tube For outdoor unit drain

Cap(drain) For outdoor unit drain

For air purge

1

piping work (Heat & Cool

1

model only)

piping work (Heat & Cool

1

model only)

piping work (Heat & Cool

2

model only)

GRILLE ACCESSORIES

Bolt

Washer For mounting grille

Spring washer For mounting grille

Blower cover insulation For discharged air

For mounting grille

4

4

4

2

SELECTING THE MOUNTING POSITION

Especially, the installation place is very important for the split type air
conditioner because it is very difficult to move from place after the
first installation.
Decide the mounting position together with the customer as follows:
The discharge direction can be selected as shown below.

Fig. 1

INDOOR UNIT

Install the indoor unit on a place having a sufficient strength so that

(1)

it withstands against the weight of the indoor unit.
The inlet and outlet ports should not be obstructed; the air should

(2)

be able to blow all over the room.
Leave the space required to service the air conditioner. (Fig. 2)

(3)

The ceiling rear height is 9-3/8” inches (250 mm) or more.

(4)

A place from where the air can be distributed evenly throughout the

(5)

room by the unit.
A place from where drainage can be extracted outdoors easily.

(6)

Fig. 2

Strong and durable ceiling

9-3/8” (250 mm)

or more

39” (1,000 mm)
or more

Obstruction

39” (1,000 mm)
or more

OUTDOOR UNIT

WARNING

1

Install the unit where it will not be tilted by more than 5°.

When installing the outdoor unit where it may

2

exposed to strong wind, fasten it securely.

If possible, do not install the unit where it will exposed to direct

(1)

sunlight. (If necessary, install a blind that does not interfere with the
air flow.)
Install the outdoor unit in a place where it will be free from being

(2)

dirty or getting wet by rain as much as possible.
Install the unit when connection to the indoor unit is easy.

(3)

Do not place animals and plants in the path of the warm air.

(4)

Take the air conditioner weight into account and select a place

(5)

where noise and vibration are small.
Select a place so that the warm air and noise from the air conditioner

(6)

do not disturb neighbors.
Provide the space shown in Fig. 3 so that the air flow is not blocked.

(7)

Also for efficient operation, leave open three of the four directions
front, rear, and both sides.
During heating operation, drain water flows from the outdoor unit.

(8)

Therefore, install the outdoor unit in a place where the drain water
flow will not be obstructed. (Reverse cycle model only)

Fig. 3

CONNECTION PIPE REQUIREMENT

Table 1

Diameter



Small

6.35 mm

  

(1/4 in)

•

Use 0.7 mm to 1.2 mm thick pipe.

•

Use pipe with water-resistant heat insulation.

•

Use pipe that can withstand a pressure of 3,040 kPa.



Large

12.7 mm
(1/2 in)

Maximum

length

20 m

(66 ft)

Maximum height

(between indoor

and outdoor)

ELECTRICAL PIPE REQUIREMENT

•

Electric wire size and fuse capacity;

Table 2

12,000/14,000 BTU/h class

POWER

CORD
(mm

Connection

cord

(mm

Fuse capacity (A)

Always use H07RN-F or equivalent as the connection cord.

•

Install the circuit breaker nearby the units. (Both indoor unit and

•

outdoor unit)

MAX

2

MIN

)

MAX

2

MIN

)

3.0

1.5

3.0

1.5

15

18,000 BTU/h class

3.0

2.5

3.0

2.5

20

INSTALLATION PROCEDURE

Install the room air conditioner as follows:

1

INDOOR UNIT INSTALLATION

1.

Position the ceiling hole and hanging bolts as shown in Fig. 4.

Fig. 4

23-27/32” (606 mm)

(Hanging bolt position)

2. Hanging preparations

Firmly fasten the hanging bolts as shown in Fig.5 or by another method.

Fig. 5

Fig. 6

(131 mm)

4-3/8” (111 mm)

5-5/32”

1-27/32” (46 mm)

3-3/8” (86 mm)

3. Body installation

Install special nut A, then special nut B onto the hanging bolt. (Fig. 7)

(1)

Raise the body and mount its hooks onto the hanging bolt between

(2)

the special nuts. (Fig. 7)
Turn special nut B to adjust the height of the body. (Fig. 7)

(3)

Leveling

(4)

Using a level, or vinyl hose filled with water, fine adjust so that the
body is level.

Perform final tightening by tightening the double nut
firmly.

Fig. 7

Special nut B

Hanging bolt

19/32” (15 mm)

Fig. 8

(□650 mm) (Grille measurement)

□25-15/32” (650 mm)

(Hanging bolt position)

15-3/4” (400 mm)

Hole-in anchor
Hole-in plug

1-27/32” (47 mm)

Concrete

Hanging bolt

M10

2-3/8” (60 mm)

Drain pipe (I. D. ø32 mm)

□23-5/8” (□600 mm)
(Ceiling opening measurement)

WARNING

Special nut A

Hook

2-19/32” (66 mm)

Insert

Length (H) = h-9-21/32”
(Shown in Fig. 6)

After installing the body,
tighten the nuts.

30 mm

or more

Ceiling

8 m

(26 ft)

17-5/16” (440 mm)

2-1/8” (54 mm)

9-27/32” (250 mm)

2

3

4

INSTALLING DRAIN PIPE

Note: Install the drain pipe.

Install the drain pipe with downward gradient (1/50 to 1/100) and so

•

there are no rises or traps in the pipe.
Use general hard polyvinyl chloride pipe (VP25) [outside diameter

•

1-1/4” (32 mm)] and connect it with adhesive (polyvinyl chloride) so
that there is no leakage.
When the pipe is long, install supporters.

•

Do not perform air bleeding.

•

Always heat insulate the indoor side of the drain pipe.

•

When desiring a high drain pipe height, raise it up to 15” (400 mm) or

•

less from the ceiling within a range of 6” (150 mm) from the body. A
rise dimension over this range will cause leakage.

Fig. 9

OUTDOOR UNIT INSTALLATION

When the outdoor unit will be exposed to strong wind, fasten it

(1)

with bolts at the places indicated by the arrows. (Fig. 10)
Since the drain water flows out of the outdoor unit during

(2)

heating operation, install the drain pipe and connect it to an
commercial 16 mm hose.
When installing the drain pipe, plug all the holes (

(3)

places) other than the drain pipe mounting hole in the bottom of
the outdoor unit with putty so there is no water leakage. (Fig.

10)

Fig. 10

NOTE:

Installation in cold regions. Do not use the accessory drain pipe.
(If the drain pipe is used, the drain water in the pipe may freeze in
extremely cold weather.)

holes at two

•

CONNECTING THE PIPING

1. Flare processing

(1)

Cut the connection pipe with pipe cutters so that the pipe is not
deformed.

(2)

Holding the pipe downward so that cuttings cannot enter the
pipe, remove the burrs.

(3)

Remove the flare nut from the indoor unit pipe and outdoor unit
and assemble as shown in (Table 3) and insert the flare nut onto
the pipe, and flare with a flaring tool.

(4)

Check if the flared part “L” (Fig. 11) is spread uniformly and that
there are no cracks.

Table 3

Pipe

Small pipe

Large pipe

Fig. 11

Small (width across flats 17 mm)

Large (width across flats 24 mm)

2. Bending pipes

The pipes are snapped by your hands. Be careful not to collapse them.

Fig. 12

Do not bend the pipes in an angle less than 90°.
When the pipes are bent and stretched repeatedly, the material will be
hardened, causing the pipes no longer be bent or stretched. Be sure to
limit number of bendings and stretchings to three times.

When bending the pipe, do not bend
it as is. The pipe will be collapsed. In
this case, cut the heat insulating pipe
with a sharp cutter as shown in Fig.
13, and bend it after exposing the
pipe. After bending the pipe as you
want, be sure to put the heat insulat­ing pipe back on the pipe, and secure
it with tape.

CAUTION

1

To prevent breaking of the pipe, avoid sharp bends.
Bend the pipe with a radius of curvature of 150 mm or
over.

2

If the pipe is bent repeatedly at the same place, it will
break.

Flare nut

Fig. 13

3. Connection pipes

(1) Indoor unit side

Fig. 14

Indoor unit

Small pipe

Large pipe

CAUTION

Be sure to apply the pipe against the port on the

1

indoor unit correctly. If the centering is improper, the
flare nut cannot be tightened smoothly. If the flare nut
is forced to turn, the threads will be damaged.

Do not remove the flare nut from the indoor unit pipe

2

unit immediately before connecting the connection
pipe.

When the flare nut is tightened properly by your hand, hold the body
side coupling with a separate spanner, then tighten with a torque
wrench. (Fig. 15)

Fig. 15

CAUTION

Hold the torque wrench at its grip, keeping it in the right
angle with the pipe as shown in Fig. 15, in order to tighten
the flare nut correctly.

Table 4 Flare nut tightening torque

Flare nut

Small pipe

6.35 mm dia.

Large pipe

12.7 mm dia.

Tightening torque

14.7 to 19.6 N • m

(150 to 200 kgf • cm)

49.0 to 53.9 N • m

(500 to 550 kgf • cm

CAUTION

Be sure to connect the large pipe after connecting the
small pipe completely.

(2) Outdoor unit side

Tighten the flare nut of the connection pipe at the outdoor unit
valve connector. The tightening method is the same as that as at
the indoor side.

Fig. 16

5

AIR PURGE

1. Air purge

Remove the cap, and connect the gauge manifold and the vacuum

(1)

pump to the charging valve by the service hoses.
Vacuum the indoor unit and the connecting pipes until the pressure

(2)

in them lowers to below 1.5 mmHg.
Disconnect the service hoses and fit the cap to the charging valve

(3)

(Tightening torque : 70 to 90 kgf • cm).
Remove the blank caps, and fully open the spindles of the 2-way and

(4)

3-way valves with a hexagon wrench (Torque : 2-way valve: 70 to 90
kgf • cm, 3-way valve: 100 to 120 kgf • cm).
Tighten the blank caps of the 2-way valve and 3-way valve to the

(5)

specified torque (200 to 250 kgf • cm).

Fig. 17

Additional
refrigerant

Cooling

Heat & Cool

(Reverse

6

7

2. Additional charge

Refrigerant suitable for a piping length of 5 m is charged in the outdoor
unit at the factory.
When the piping is longer than 5 m, additional charging is necessary.
For the additional amount, see the table below.

Table 5

model

model

cycle)

Pipe length

12,000 BTU/h

class

14,000 BTU/h

class

18,000 BTU/h

class

12,000 BTU/h

class

14,000 BTU/h

class

18,000 BTU/h

class

16 ft

(5 m)

None

None

None

None

23 ft

(7 m)

0.7 oz
(20 g)

1.1 oz
(30 g)

1.1 oz
(30 g)

2.1 oz
(60 g)

33 ft

(10 m)

1.8 oz
(50 g)

2.6 oz
(75 g)

2.6 oz
(75 g)

5.3 oz

(150 g)

49 ft

(15 m)

3.5 oz

(100 g)

5.3 oz

(150 g)

5.3 oz

(150 g)

10.6 oz
(300 g)

66 ft

(20 m)

5.3 oz

(150 g)

7.9 oz

(225 g)

7.9 oz

(225 g)

15.9 oz
(450 g)

oz / ft

(g / m)

0.35 oz/3.3 ft
(10 g/m)

0.53 oz/3.3 ft
(15 g/m)

0.53 oz/3.3 ft
(15 g/m)

1.06 oz/3.3 ft
(30 g/m)

CAUTION

1

When moving and installing the air conditioner, do not
mix gas other than the specified refrigerant (R22)
inside the refrigerant cycle.

2

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

3

The maximum length of the piping is 20 m. If the units
are further apart than this, correct operation can not
be guaranteed.

INSTALLING THE COUPLER
HEAT INSULATION

After checking for gas leaks, insulate by wrapping insulation around
the two parts (large and small) of the indoor unit coupling, using the
coupler heat insulation.

Fig. 18

CAUTION

Must fit tightly against body without any gap.

ELECTRICAL WIRING

HOW TO CONNECT WIRING TO THE TERMINALS

A. For solid core wiring (or F-cable)

Cut the wire end with a wire cutter or wire-cutting pliers,

(1)

then strip the insulation to about 15/16” (25 mm) of expose
the solid wire.
Using a screwdriver, remove the terminal screw(s) on the

(2)

terminal board.
Using pliers, bend the solid wire to form a loop suitable for

(3)

the terminal screw.
Shape the loop wire properly, place it on the terminal board

(4)

and tighten securely with the terminal screw using a screw
driver.

B. For strand wiring

Cut the wire and with a wire cutter or wire-cutting pliers,

(1)

then strip the insulation to about 3/8” (10 mm) of expose
the strand wiring.
Using a screwdriver, remove the terminal screw(s) on the

(2)

terminal board.
Using a round terminal fastener or pliers, securely clamp a

(3)

round terminal to each stripped wire end.
Position the round terminal wire, and replace and tighten

(4)

the terminal screw using a screwdriver.

Fig. 19

1. Indoor unit side

(1)

Remove the control box cover and install the connection cord.
(Fig. 20 and 21)

Fig. 20

Fig. 21

Heat and cool model
(Reverse cycle)

Connection cord

Power cord

Cord clamp Terminal board

Cooling model

Connection cord

Power cord

Cord clamp Terminal board

2. Outdoor unit side

(1)

Remove the terminal cover of the outdoor unit, and insert the
end of the connection cord and the power cord into the terminal
board.

(2)

Fasten the connection cord with the cord clamps, and install the
terminal cover.

Fig. 22

Fig. 23

4

3

2

1

N

L

Indoor
unit side
terminal

Cooling model

Connection cord

Green/Yellow

4

3

2

1

Outdoor
unit side
terminal

Power cord

Heat & Cool model
(Reverse cycle)

Connection cord

Green/Yellow

5

4

3

2

1

N

L

Indoor
unit side
terminal

Power cord

8

GRILLE INSTALLATION

1. Blower cover insulation

Install the blower cover insulation only when the outlet direction is
not specified.
Two blower cover insulations are packed with the grille assembly.
Install the blower cover insulation at the diffuser position shown in
Fig. 24. At the time, use the piping position as the criteria.

Fig. 24

2 direction example

Fit the blower cover insulation.

Blower cover
insulation

A-A Section view

5

4

23

1(N)

N

L

4

23

1(N)
N

L

5

4

3

2

1

Outdoor
unit side
terminal

CAUTION

Since 2-way outlet as shown below causes performance
problems, do not set it.

Vinyl hose

Control box cover

A

A

(Piping direction)

- Continued on back -

2. Installing grille assembly to body

Hang the grille assembly on the wires attached to the indoor unit as
shown in Fig. 25.

Fig. 25

2. Removing the intake grille

(1)

Slide the two grille stoppers inward, then open the
intake grille.

Fig. 31

Grille stopper

Remote control unit code switching.

Fig. 36

Indoor unit
Printed circuit board

OPERATION
LAMP

TIMER
LAMP

Table 7

Error display Error contents

0.5 sec 0.5 sec

ON

OFF

ON

OFF

0.1 sec

5 sec

0.1 sec

Two quick
flashes
repeated

0.1 sec ON/OFF
repeated

Room temperature
thermistor abnormal
temperature
detected

Wire

Motor cover assembly

Wire hook

Wire hook

Wire hook

Wire

Bolting the grille assembly to the body

Install the grille assembly to the body with the four bolts, spring
washers, and washers.

Fig. 26

Washer

Spring washer

Bolt

No gap between ceiling and
grille around entire periphery.

(2)

Remove the grille hook screws, then open the intake
grille.

Fig. 32

Grille hook

(3)

Open the intake grille so that it is at an angle of 20° to 40°,
then remove the grille.

Fig. 33

CAUTION

1

The louver angle cannot be changed if the power is
not on, (If moved by hand, it may be damaged.)

2

The grille assembly is directional relative to the air
conditioner body.

JM1

JM2

JM3

AUTORESTART
REMOCON 2
REMOCON 1

Remote control unit

ABCD

Remote control unit
signal selector switch

ABCD

ACL button

Confirm the remote control unit signal selector switch selection and
printed circuit board setting.
If these are not confirmed, the remote control unit cannot be operated
for the air conditioner.

Table 6

Jumper wire

JM 2

Connect

Connect

Disconnect

Disconnect

JM 3

Connect

Disconnect

Connect

Disconnect

Remote control unit

signal selector switch

A(Primary setting)

B

C

D

After setting the remote control unit signal selector
switch, press the ACL button.

OPERATION
LAMP

TIMER
LAMP

OPERATION
LAMP

TIMER
LAMP

ON

OFF

0.1 sec

ON

OFF

0.5 sec 0.5 sec

ON

OFF

0.1 sec

ON

OFF

0.5 sec

5 sec

0.1 sec

5 sec

0.1 sec

0.5 sec

Three quick
flashes
repeated

0.1 sec ON/OFF
repeated

Four quick
flashes
repeated

0.1 sec ON/OFF
repeated

Piping thermistor
abnormal
temperature
detected

Float switch ON for
3 minutes or longer

CHECK ITEMS

(1) INDOOR UNIT

Is operation of each button on the remote control unit

(1)

nomal?
Does each lamp light normally?

(2)

Do not air flow direction louvers operate normally?

(3)

Is the drain normal?

(4)

Is there any abnormal noise and vibration during operation?

(5)

(2) OUTDOOR UNIT

Is there any abnormal noise and vibration during operation?

(1)

Will noise, wind or drain water from the unit disturb the

(2)

neighbors?
Is there any gas leakage?

(3)

Do not operate the air conditioner in the test running state for a

•

long time.
For the operation method, refer to the operating manual and

•

perform operation check.

Wireless unit connection wire wiring

Connect the connector in accordance part A detail view.
Then clamp the lead wire with clamp so that it does not touch the
rotating parts.

Fig. 27

A

Fig. 28 Part A detail view

9

3

Install so that there is no gap between the grille
assembly and the air conditioner body.

REMOTE CONTROL UNIT
INSTALLATION

•

Install the remote control unit so that the front is facing the pho­tocell. (Fig. 34)

Fig. 34

Photocell

Remote control unit

10

TEST RUNNING

Press the remote control unit test run button while the air

•

conditioner is running.
At the end of test running, press the remote control unit start-

•

stop button. (Fig. 37)

Fig. 37

START/STOP button

START

STOP

ABCD

TEST RUN button

Display PCB wire
harness

Wire (Louver)

Display PCB wire harness

Joint wire (Louver)

INSTALLING/REMOVING THE INTAKE GRILLE

1. Installing the intake grille

Fully insert the intake grille hooks into the rectangular

(1)

holes in the panel.

Fig. 29

Close the intake grille, then slide the two grille stoppers

(2)

outward.

Fig. 30

Grille stopper

Panel

Rectangular hole

Grille hook

Intake grille

•

Install the remote control unit with a distance of 5 m between
the remote control unit and the grille photocell as the criteria.
However, when installing the remote control unit, check that it
operates positively.

•

Install the remote control unit holder to a wall, pillar, etc. with
the tapping screw (Fig.35).

Fig. 35

For use as Handy Type

Slide up

3

To remove the Remote
Control Unit (when use
at hand.)

Screws

1

Mount the Holder.

Insert

2

Set the Remote Control
Unit.

For use as Wall Fixing Type

Insert

Screws

Screws

•

Run the air conditioner in accordance with the operating manual.

SWING TIMER OPERATION

SWING LAMP

(Orange)

TIMER LAMP

(Green)

MANUAL

AUTO

OPERATION LAMP

(Red)

Operation can be checked by lighting and flashing of the grille
display section OPERATION and TIMER lamps.
Perform judgment in accordance with the following.

•

Test running

When the air conditioner is run by pressing the remote
control unit test run button, the OPERATION and TIMER
lamps flash slowly at the same time.

•

Error

The OPERATION and TIMER lamps operate as follows (Table 7)
according to the error contents.

1

Mount the Holder.

2

Set the Remote Control
Unit.

3

Attach the unit to the
holder as shown.

Slide

PART NO. 9359992011-03