- 23 -
Installation
Read completely, then follow step by step.
1. Installation of Indoor, Outdoor unit
1) Select the best location
1. Indoor unit
■ Do not have any heat or steam near the unit.
■ Select a place where there are no obstacles in
front of the unit.
■ Make sure that condensation drainage can be
conveniently routed away.
■ Do not install near a doorway.
■ Ensure that the space around the left and right of
the unit is more than 5cm. The unit should be
installed as high on the wall as possible, allowing
a minimum of 5cm from ceiling.
■ Use a stud finder to locate studs to prevent
unnecessary damage to the wall.
2. Outdoor unit
■ If an awning is built over the unit to prevent direct
sunlight or rain exposure, make sure that heat
radiation from the condenser is not restricted.
■ Ensure that the space around the back and sides
is more than 10cm. The front of the unit should
have more than 70cm of space.
■ Do not place animals and plants in the path of the
warm air.
■ Take the air conditioner weight into account and
select a place where noise and vibration are minimum.
■ Select a place so that the warm air and noise
from the air conditioner do not disturb neighbors.
■ Rooftop Installations:
If the outdoor unit is installed on a roof structure,
be sure to level the unit. Ensure the roof structure
and anchoring method are adequate for the unit
location. Consult local codes regarding rooftop
mounting.
2) Piping length and elevation
More than 5cm
More than 5cm
More than 2.3m
More than 5cm
More than 10cm More than 10cm
More
than 60cm
More than 60cm
More than 70cm
In case more than 5m
• Capacity is based on standard length and maximum
allowance length is on the basis of reliability.
• Oil trap should be installed every 5~7 meters.
Outdoor unit
Indoor unit
A
B
A
Oil trap
Outdoor unit
Indoor unit
B
CAUTION
Install the indoor unit on the wall where the height
from the floors more than 2.3 meters.
CAUTION
18K(60Hz) 5/8" 1/4" 5 10 20 20
18K(50Hz) 1/2" 1/4" 5 15 30 30
24K(50Hz) 5/8" 3/8" 5 15 30 30
26K(50Hz) 5/8" 3/8" 5 15 30 30
Pipe Size
Capacity
(Btu/h)
GAS LIQUID
Max.
length
A (m)
Additional
Refrigerant
(g/m)
Max.
Elevation
B (m)
Standard
Length
(m)
- 24 -
3) How to fix installation plate
The wall you select should be strong and solid enough to prevent
vibration
1. Mount the installation plate on the wall with four
type A screws. If mounting the unit on a concrete
wall, use anchor bolts.
§ Mount the installation plate horizontally by align-
ing the centerline using a level.
2. Measure the wall and mark the centerline. It is also
important to use caution concerning the location
of the installation plate-routing of the wiring to
power outlets is through the walls typically.
Drilling the hole through the wall for piping connections must be done safely.
5-7mm
(0.2~0.3")
Indoor
WALL
Outdoor
Installation Plate
Marking-off line
Thread
Weight
Type "A" screw
"D" "C"
Right rear pipingLeft rear piping
Hole center
ø70mm
4) Drill a hole in the wall
■ Drill the piping hole with a ø70mm hole core drill.
Drill the piping hole at either the right or the left
with the hole slightly slanted to the outdoor side.
- 25 -
1) Flaring work
Main cause for gas leakage is due to defect in flaring work. Carry out correct flaring work in the following procedure.
1. Cut the pipes and the cable.
■ Use the piping kit accessory or the pipes purchased locally.
■ Measure the distance between the indoor and the
outdoor unit.
■ Cut the pipes a little longer than measured distance.
■ Cut the cable 1.5m longer than the pipe length.
2. Burrs removal
■ Completely remove all burrs from the cut cross
section of pipe/tube.
■ Put the end of the copper tube/pipe in a downward direction as you remove burrs in order to
avoid dropping burrs into the tubing.
3. Putting nut on
■ Remove flare nuts attached to indoor and outdoor
unit, then put them on pipe/tube having completed burr removal.
(not possible to put them on after flaring work)
Copper
pipe
90°
Slanted Uneven Rough
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
Pipe
Reamer
Point down
4. Flaring work
■ Carry out flaring work using flaring tool as shown
below.
Firmly hold copper pipe in a die in the dimension
shown in the table above.
5. Check
■ Compare the flared work with figure below.
■ If flare is noted to be defective, cut off the flared
section and do flaring work again.
Outside diameter A
mm inch mm
ø6.35 1/4 0 ~ 0.5
ø9.52 3/8 0 ~ 0.5
ø12.7 1/2 0 ~ 0.5
ø15.88 5/8 0 ~ 1.0
Flare nut
Copper tube
Inclined
Inside is shiny without scratches
Smooth all round
Even length
all round
Surface
damaged
Cracked Uneven
thickness
= Improper flaring =
2. Flaring Work and Connection of Piping
- 26 -
2) Connection of piping-Indoor
■ Preparing the indoor unit's piping and drain hose
for installation through the wall.
■ Remove the plastic tubing retainer(see illustration below) and pull the tubing and drain hose
away from chassis.
■ Replace the plastic tubing holder in the original
position.
1. Route the indoor tubing and the drain hose in the
direction of rear left.
2. Insert the connecting cable into the indoor unit
from the outdoor unit through the piping hole.
■ Do not connect the cable to the indoor unit.
■ Make a small loop with the cable for easy con-
nection later.
4. Indoor unit installation
■ Hook the indoor unit onto the upper portion of the
installation plate.(Engage the two hooks of the
rear top of the indoor unit with the upper edge of
the installation plate.) Ensure that the hooks are
properly seated on the installation plate by moving it left and right.
Press the lower left and right sides of the unit against the
installation plate until the hooks engage into their
slots(clicking sound).
3. Tape the tubing, drain hose and the connecting
cable. Be sure that the drain hose is located at the
lowest side of the bundle. Locating at the upper
side can cause drain pan to overflow inside the
unit.
5. Connecting the pipings to the indoor unit and
drain hose to drain pipe.
■ Align the center of the pipings and sufficiently
tighten the flare nut by hand.
NOTE:
If the drain hose is routed inside the room, insulate the
hose with an insulation material* so that dripping from
"sweating"(condensation) will not damage furniture or
floors.
*Foamed polyethylene or equivalent is recommended.
To remove the holder,
press the bottom of
chassis near the holder
upward and pull the tab
out of its hole.
Tubing holder
Pull
Press
2
1
Connecting
cable
Loop
Gas side
piping
Liquid side
piping
Drain hose
Drain hose
Connecting
cable
Drain hose
Indoor unit tubing Flare nut Pipings
For left rear piping
CAUTION
When install, make sure that
the remaining parts must be
removed clearly so as not to
damage the piping and drain
hose, especially power cord
and connecting cable.
- 27 -
6. Wrap the insulation material around the connecting portion.
■ Overlap the connection pipe insulation material
and the indoor unit pipe insulation material. Bind
them together with vinyl tape so that there is no
gap.
1. Route the indoor tubing and the drain hose to the
required piping hole position.
2. Insert the piping, drain hose and the connecting
cable into the piping hole.
Plastic bands
Insulation material
Drain pipe
Connecting cable
Vinyl tape(narrow)
Connection
pipe
Connecting cable
Vinyl tape
(wide)
Wrap with vinyl tape
Indoor
unit pipe
Pipe
Torque wrench
Indoor unit tubing
Spanner (fixed)
Connection pipe
Flare nut
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
■ When extending the drain hose at the indoor unit,
install the drain pipe.
■ Tighten the flare nut with a wrench.
18K, 24K, 26K
1/2"[5.5kg.m] 1/4"[1.8kg.m]
5/8"[6.6kg.m] 3/8"[4.2kg.m]
Pipe Size[Torque]
Capacity
(Btu/h)
GAS LIQUID
■ Wrap the area which accommodates the rear piping housing section with vinyl tape.
■ Bundle the piping and drain hose together by
wrapping them with vinyl tape over the range with-
in which they fit into the rear piping housing section.
For right rear piping
Wrap with vinyl tape
Pipe
Vinyl tape(wide)
Drain hose
- 28 -
3. Insert the connecting cable into the indoor unit.
■ Don't connect the cable to the indoor unit.
■ Make a small loop with the cable for easy con-
nection later.
4. Tape the drain hose and the connecting cable.
■ Connecting cable
5. Indoor unit installation
■ Hang the indoor unit from the hooks at the top of
the installation plate.
■ Insert the spacer etc. between the indoor unit and
the installation plate and separate the bottom of
the indoor unit from the wall.
Installation plate
Spacer
Indoor unit
8cm
6. Connecting the pipings to the indoor unit and the
drain hose to drain pipe.
■ Align the center of the pipings and sufficiently
tighten the flare nut by hand.
■ Tighten the flare nut with a wrench.
7. Wrap the insulation material around the connecting portion.
■ Overlap the connection pipe heat insulation and
the indoor unit pipe heat insulation material. Bind
them together with vinyl tape so that there is no
gap.
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection
pipe
Connecting cable
Indoor
unit piping
Pipe
Vinyl tape
(wide)
Wrap with vinyl tape
Indoor unit tubing Flare nut Pipings
Torque wrench
Indoor unit tubing
Spanner (fixed)
Connection pipe
Flare nut
Vinyl tape
Adhesive
Drain hose
Indoor unit drain hose
(narrow)
■ When extending the drain hose at the indoor unit,
install the drain pipe.
■
Wrap the area which accommodates the rear piping housing
section with vinyl tape.
18K, 24K, 26K
1/2"[5.5kg.m] 1/4"[1.8kg.m]
5/8"[6.6kg.m] 3/8"[4.2kg.m]
Pipe Size[Torque]
Capacity
(Btu/h)
GAS LIQUID
- 29 -
3) Connection of the pipes-Outdoor
1. Align the center of the pipings and sufficiently
tighten the flare nut by hand.
2. Finally, tighten the flare nut with torque wrench
until the wrench clicks.
■ When tightening the flare nut with torque wrench,
ensure the direction for tightening follows the
arrow on the wrench.
Outdoor unit
Liquid side piping
(Smaller diameter)
Gas side
piping
(Bigger
diameter)
Torque wrench
Outdoor unit
Gas side piping
(Bigger diameter)
Liquid side
piping
(Smaller
diameter)
Torque wrench
8. Reroute the pipings and the drain hose across the
back of the chassis.
9. Set the pipings and the drain hose to the back of
the chassis with the tubing holder.
■ Hook the edge of tubing holder to tap on chassis
and push the bottom of tubing holder to be
engaged at the bottom of chassis.
10. Indoor unit installation
■ Remove the spacer.
■ Ensure that the hooks are properly seated on the
installation plate by moving it left and right.
Drain hose
Connecting
cable
Piping for
passage through
piping hole
Tubing holder
Hook
1
Push
2
Drain hose
Vinyl tape(narrow)
Pipe
Wrap with
vinyl tape(wide)
■ 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.
Press the lower left and right sides of the unit against the
installation plate until the hooks engage into their
slots(clicking sound).
18K, 24K, 26K
1/2"[5.5kg.m] 1/4"[1.8kg.m]
5/8"[6.6kg.m] 3/8"[4.2kg.m]
Pipe Size[Torque]
Capacity
(Btu/h)
GAS LIQUID
- 30 -
1) Connect the cable to the Indoor unit.
■ Connect the cable to the indoor unit by connect-
ing the wires to the terminals on the control
board individually according to the outdoor unit
connection.
(Ensure that the color of the wires of the outdoor
unit and the terminal No. are the same as those
of the indoor unit.)
CAUTION
The power cord connected to the indoor unit should
be complied with the following specifications
(Type H05VV-F approved by HAR or SAA).
1(L)
Terminals on the outdoor unit
Terminals on the indoor unit
1(L)
2(N)
2(N)
BROWN BLUE
GREEN/YELLOW
BROWN BLUE
GREEN/YELLOW
Terminals on the outdoor unit
Terminals on the indoor unit
1(L)
1(L)
2(N)
2(N)
3 4
3
4
BROWN BLUE G/Y BLACK
RED
BROWN BLUE G/Y
RED
BROWN BLUE BLACK
BLACK
G/Y RED
REDG/Y
BLUE
BROWN
The power connecting cable connected to the indoor
and outdoor unit should be complied with the following
specifications
(Type H07RN-F approved by HAR or SAA).
The connecting cable connected to the indoor and
outdoor unit should be complied with the following
specifications
(Type H07RN-F approved by HAR or SAA).
• Cooling model
• Heat pump model
Color of Wires
Color of Wires
Color of Wires
Color of Wires
The length of the power supply cord should be over 1.8m
measured from the power supply cord entry of the cabinet
to the middle of the live pin of the plug.
Air
Conditioner
Main power source
If a power plug is not to be used, provide a circuit breaker between power source and
the unit as shown below.
Circuit Breaker
Use a circuit breaker or time delay
fuse.
CAUTION
Capacity
(Btu/h)
NORMAL CROSS
-SECTIONAL AREA
18K
24K
26K
1.5mm
2
2.5mm
2
Capacity
(Btu/h)
NORMAL CROSS
-SECTIONAL AREA
18K
24K
26K
1.5mm
2
2.5mm
2
3. Connecting the Cable Between Indoor Unit and Outdoor Unit
NORMAL
CROSS-SECTIONAL
AREA 0.75mm
2
- 31 -
2) Connect the cable to the outdoor unit
1. Remove the control cover from the unit by
loosening the screw.
Connect the wires to the terminals on the
control board individually.
2. Secure the cable onto the control board with
the cord clamp.
3. Refix the control cover to the original position
with the screw.
4. Use a recognized circuit breaker 20A (18K),
25A (24K, 26K) between the power source and
the unit. A disconnecting device to adequately disconnect all supply lines must be fitted.
Terminal block
Over 5mm
Cover control
Connecting cable
Connecting cable
After the confirmation of the above conditions, prepare the wiring as follows:
1) Never fail to have an individual power circuit specifically for the air conditioner. As for the method of
wiring, be guided by the circuit diagram posted on the inside of control cover.
2) The screw which fasten the wiring in the casing of electrical fittings are liable to come loose from vibrations to which the unit is subjected during the course of transportation. Check them and make sure that
they are all tightly fastened. (If they are loose, it could cause burn-out of the wires.)
3) Specification of power source.
4) Confirm that electrical capacity is sufficient.
5) See to that the starting voltage is maintained at more than 90 percent of the rated voltage marked on the
name plate.
6) Confirm that the cable thickness is as specified in the power source specification.
(Particularly note the relation between cable length and thickness.
7) Always install an earth leakage circuit breaker in a wet or moist area.
8) The following would be caused by voltage drop.
• Vibration of a magnetic switch, which will damage the contact point, fuse breaking, disturbance of the nor-
mal function of the overload.
9) The means for disconnection from a power supply shall be incorporated in the fixed wiring and have an
air gap contact separation of at least 3mm in each active(phase) conductors.
Outdoor Unit
CAUTION
- 32 -
2) Form the piping
1. Form the piping by wrapping the connecting portion of the indoor unit with insulation material and
secure it with two kinds of vinyl tapes.
§ If you want to connect an additional drain hose,
the end of the drain outlet should be routed
above the ground. Secure the drain hose appropriately.
2. In cases where the outdoor unit is installed below
the indoor unit perform the following.
§ Tape the piping, drain
hose and connecting
cable from down to up.
§ Secure the tapped
piping along the
exterior wall using
saddle or equivalent.
Taping
Drain
hose
Pipings
Connecting
cable
Trap is required to prevent water
from entering into electrical parts.
Seal small openings
around pipings with a
gum type sealer.
3. In cases where the Outdoor unit is installed above
the Indoor unit perform the following.
§ Tape the piping and connecting cable from down
to up.
§ Secure the taped piping along the exterior wall.
Form a trap to prevent water entering the room.
§ Fix the piping onto the wall by saddle or equiva-
lent.
Seal a small opening
around the pipings
with gum type sealer.
Trap
Trap
1) Checking the drainage
1. To remove the front panel from the indoor unit,
remove the front panel from the indoor unit cabinet.
§ Set the air direction louvers up-and-down to the
position(horizontally) by hand.
§ Remove the securing screws that retain the front
panel. Pull the lower left and right sides of the
grille toward you and lift it off.
Pull the right and
the left side.
Screw
2. To check the drainage.
§ Pour a glass of water
on the evaporator.
§ Ensure the water flows
through the drain hose
of the indoor unit without any leakage and
goes out the drain exit.
3. Drain piping
§ The drain hose should point downward for easy
drain flow.
§ Do not make drain piping.
Downward slope
Do not raise
Accumulated
drain water
Tip of drain hose
dipped in water
Air
Waving
Water
leakage
Water
leakage
Ditch
Less than
50mm gap
Water
leakage
4. Checking the Drainage and Forming the Pipings
- 33 -
1) Air purging
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below.
■ Pressure in the system rises.
■ Operating current rises.
■ Cooling(or heating) efficiency drops.
■ Moisture in the refrigerant circuit may freeze and
block capillary tubing.
■ Water may lead to corrosion of parts in the refrigeration system.
Therefore, the indoor unit and tubing between the
indoor and outdoor unit must be leak tested and
evacuated to remove any noncondensables and
moisture from the system.
2) Air purging with vacuum pump
1. Preparation
■
Check that each tube(both liquid and gas side tubes)
between the indoor and outdoor units have been properly
connected and all wiring for the test run has been completed. Remove the service valve caps from both the gas
and the liquid side on the outdoor unit. Note that both the
liquid and the gas side service valves on the outdoor unit
are kept closed at this stage.
2. Leak test
■ Connect the manifold valve(with pressure
gauges) and dry nitrogen gas cylinder to this service port with charge hoses.
■ Pressurize the system to no more than 150
P.S.I.G. with dry nitrogen gas and close the cylinder valve when the gauge reading reached 150
P.S.I.G. Next, test for leaks with liquid soap.
Lo Hi
Indoor unit
Outdoor unit
Manifold valve
Charge hose
Nitrogen gas
cylinder(in vertical
standing position)
Pressure
gauge
■ Do a leak test of all joints of the tubing(both
indoor and outdoor) and both gas and liquid side
service valves.
Bubbles indicate a leak. Be sure to wipe off the
soap with a clean cloth.
■ After the system is found to be free of leaks,
relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
Be sure to use a manifold valve for air purging.
If it is not available, use a stop valve for this purpose.
The "Hi" knob of the manifold valve must always be
kept close.
To avoid nitrogen entering the refrigerant system in
a liquid state, the top of the cylinder must be higher
than its bottom when you pressurize the system.
Usually, the cylinder is used in a vertical standing
position.
CAUTION
CAUTION
5. Air Purging
- 34 -
3. Evacuation
■ Connect the charge hose end described in the
preceding steps to the vacuum pump to evacuate
the tubing and indoor unit.
Confirm the "Lo" knob of the manifold valve is
open. Then, run the vacuum pump.
The operation time for evacuation varies with tubing length and capacity of the pump.
The following table shows the time required for
evacuation.
■ When the desired vacuum is reached, close the
"Lo" knob of the manifold valve and stop the vacuum pump.
4. Finishing the job
■ With a service valve wrench, turn the valve stem
of liquid side valve counter-clockwise to fully
open the valve.
■ Turn the valve stem of gas side valve
counter-clockwise to fully open the valve.
■ Loosen the charge hose connected to the gas
side service port slightly to release the pressure,
then remove the hose.
■ Replace the flare nut and its bonnet on the gas
side service port and fasten the flare nut securely
with an adjustable wrench. This process is very
important to prevent leakage from the system.
■ Replace the valve caps at both gas and liquid
side service valves and fasten them tight.
This completes air purging with a vacuum pump.
The air conditioner is now ready to test run.
(1) Remove the caps from the 2-way and 3-way valves.
(2) Remove the service-port cap from the 3-way valve.
(3) To open the 2-way valve turn the valve stem counter-
clockwise approximately 90°, wait for about 2~3 sec,
and close it.
(4) Apply a soap water or a liquid neutral detergent on the
indoor unit connection or outdoor unit connections by a
soft brush to check for leakage of the connecting points
of the piping.
(5) If bubbles come out, the pipes have leakage.
Soap water method
Gas side
Liquid side
Cap
Hexagonal wrench
2-way valve
(Open)
3-way valve
(Close)
Required time for evacuation
when 30 gal/h vacuum pump is used
10 min. or more 15 min. or more
If tubing length is less
than 10m (33 ft)
If tubing length is longer
than 10m (33 ft)
Indoor unit
Outdoor unit
Lo Hi
Manifold valve
Vacuum pump
Pressure
gauge
Open
Close
- 35 -
1. Check that all tubing and wiring have been prop-
erly connected.
2. Check that the gas and liquid side service valves
are fully open.
1. Prepare remote control
Remove the battery cover
by pulling it according to the
arrow direction.
Insert new batteries making
sure that the (+) and (–) of
battery are installed correctly.
Reattach the cover by
pushing it back into position.
NOTE:
• Use 2 AAA(1.5volt) batteries. Do not use
rechargeable batteries.
• Remove the batteries from the remote control if
the system is not going to be used for a long time.
2. Settlement of outdoor unit
■ Anchor the outdoor unit with a bolt and
nut(ø10mm) tightly and horizontally on a concrete
or rigid mount.
■ When installing on the wall, roof or rooftop,
anchor the mounting base securely with a nail or
wire assuming the influence of wind and earthquake.
■ In the case when the vibration of the unit is con-
veyed to the hose, secure the unit with an
anti-vibration rubber.
3. Evaluation of the performance
Operate unit for 15~20 minutes, then check the system refrigerant charge:
1. Measure the pressure of the gas side service
valve.
2. Measure the temperature of the intake and discharge of air.
NOTE:
If the actual pressure are higher than shown,
the system is most likely over-charged, and
charge should be removed. If the actual pressure are lower than shown, the system is most
likely undercharged, and charge should be
added.
The air conditioner is now ready for use.
Bolt
Tubing connection
Outside ambient TEMP
The pressure of the gas side service valve
35°C(95°F)
4.5~5.5kg/cm2G(63.9~78.1 P.S.I.G.)
This is performed when the unit is to be relocated
or the refrigerant circuit is serviced.
Pump Down means collecting all refrigerant in the outdoor unit without loss in refrigerant gas.
CAUTION:
Be sure to perform Pump Down procedure with the
unit cooling mode.
Pump Down Procedure
1. Connect a low-pressure gauge manifold hose to the
charge port on the gas side service valve.
2. Open the gas side service valve halfway and purge the
air from the manifold hose using the refrigerant gas.
3. Close the liquid side service valve(all the way in).
4. Turn on the unit's operating switch and start the cooling operation.
5. When the low-pressure gauge reading becomes 1 to
0.5kg/cm2 G(14.2 to 7.1 P.S.I.G.), fully close the gas
side valve stem and then quickly turn off the unit. At
that time, Pump Down has been completed and all
refrigerant gas will have been collected in the outdoor
unit.
PUMP DOWN
3. Ensure the difference between the intake temperature and the discharge is more than 8°C
(Cooling) or reversely (Heating).
4. For reference; the gas side pressure of optimum
condition is as below.(Cooling)
Discharge
temperature
Discharge air
Intake temperature
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