Mitsubishi PCA-A36GA1, PCA-A42GA, PCA-A42GA1, PCA-A24GA1, PCA-A30GA Installation Guide

MITSUBISHI

,mrlELECTRIC

Air-Con i

PCA-A.GA

=r. Llllm

m

|oners

INSTALLATION MANUAL i FO_iNS_ _ i

For safe and correct use, read this manual and the outdoor unit installation manual thoroughly before installing
the air-conditioner unit.

MANUAL DE INSTALACION

Para un uso correcto y seguro, lea detalladamente este manual y el manual de instalaci6n de la unidad exterior
antes de instalar la unidad de aire acondicionado.

Contents

1. Safety precautions ................................................................................... 2 5. Drainage piping work ............................................................................... 6

2. Installation location .................................................................................. 3 6. Electricalwork .......................................................................................... 6

3. Installing the indoor unit ........................................................................... 3 7. Test run .................................................................................................. 13

4. Installing the refrigerant piping ................................................................. 5 8. Easy maintenance function .................................................................... 16

1. Safety precautions

Before installing the unit, make sure you read all the "Safety precau-
tions".

Please report to your supply authority or obtain their consent before
connecting this equipment to the power supply system.

Warning:

Describes precautions that must be observed to prevent danger of injury or
death to the user.

z_ Caution:
Describes precautions that must be observed to prevent damage to the unit.

Z_ Warning:
= Ask a dealer or an authorized technician to install the unit.

= For installation work, follow the instructions in the Installation Manual and

use tools and pipe components specifically made for use with refrigerant
specified in the outdoor unit installation manual.

• The unit must be installed according to the instructions in order to minimize
the risk of damage from earthquakes, typhoons, or strong winds. An incor-

rectly installed unit may fall down and cause damage or injuries.
= The unit must be securely installed on a structure that can sustain its weight.
= if the air conditioner is installed in a small room, measures must be taken to

prevent the refrigerant concentration in the room from exceeding the safety

limit in the event of refrigerant leakage. Should the refrigerant leak and cause

the concentration limit to be exceeded, hazards due to lack of oxygen in the

room may result.

1.1. Before installation (Environment)

Caution:

• Do not use the unit in an unusual environment, if the air conditioner is in-

stalled in areas exposed to steam, volatile oil (including machine oil), or sulfuric

gas, areas exposed to high salt content such as the seaside, the performance

can be significantly reduced and the internal parts can be damaged.
= Do not install the unit where combustible gases may leak, be produced, flow,

or accumulate, if combustible gas accumulates around the unit, fire or explo-

sion may result.
= Do not keep food, plants, caged pets, artwork, or precision instruments in the

direct airflow of the indoor unit or too close to the unit, as these items can be

damaged by temperature changes or dripping water.

1.2. Before installation or relocation

Z_ Caution:

• Be extremely careful when transporting the units.Two or more persons are

needed to handle the unit, as it weighs 20 kg, 44 Ibs or more. Do not grasp

the packaging bands. Wear protective gloves as you can injure your hands

on the fins or other parts.

• Be sure to safely dispose of the packaging materials. Packaging materials,

such as nails and other metal or wooden parts may cause stabs or other

injuries.

1.3. Before electric work

Caution:
= Be sure to install circuit breakers, if not installed, electric shock may result.
= For the power lines, use standard cables of sufficient capacity. Otherwise, a

short circuit, overheating, or fire may result.

= When installing the power lines, do not apply tension to the cables.

After installation work has been completed, explain the 'Safety Precautions," use,
and maintenance of the unit to the customer according to the information in the Op-
eration Manual and perform the test run to ensure normal operation. Both the Instal-

lation Manual and Operation Manual must be given to the user for keeping. These
manuals must be passed on to subsequent users.

a

(_: Indicates which must be

part grounded.

Z_ Warning:
Carefully read the labels affixed to the main unit,

• Ventilate the room if refrigerant leaks during operation, if refrigerant comes
into contact with a flame, poisonous gases will be released.

• All electric work must be performed by a qualified technician according to
local regulations and the instructions given in this manual.

• Use only specified cables for wiring.

• The terminal block cover panel of the unit must be firmly attached.

• Use only accessories authorized by Mitsubishi Electric and ask a dealer or

an authorized technician to install them.

• The user should never attempt to repair the unit or transfer it to another loca-

tion.

• After installation has been completed, check for refrigerant leaks, if refriger-

ant leaks into the room and comes into contact with the flame of a heater or

portable cooking range, poisonous gases will be released.

• When the room humidity exceeds 80% or when the drainpipe is clogged, wa-

ter may drip from the indoor unit. Do not install the indoor unit where such
dripping can cause damage.

• When installing the unit in a hospital or communications office, be prepared

for noise and electronic interference, inverters, home appliances, high-fre-
quency medical equipment, and radio communications equipment can cause

the air conditioner to malfunction or breakdown.The air conditioner may also
affect medical equipment, disturbing medical care, and communications equip-

ment, harming the screen display quality.

• Thermal insulation of the refrigerant pipe is necessary to prevent condensa-

tion. if the refrigerant pipe is not properly insulated, condensation will be formed.

• Place thermal insulation on the pipes to prevent condensation, if the drain-
pipe is installed incorrectly, water leakage and damage to the ceiling, floor,

furniture, or other possessions may result.

• Do not clean the air conditioner unit with water. Electric shock may result.

• Tighten all flare nuts to specification using a torque wrench, if tightened too

much, the flare nut can break after an extended period.

• Be sure to ground the unit. if the unit is not properly grounded, electric shock
may result.

= Use circuit breakers (ground fault interrupter, isolating switch (+B fuse), and

molded case circuit breaker) with the specified capacity, if the circuit breaker

capacity is larger than the specified capacity, breakdown or fire may result.

1.4. Before starting the test run

Z_ Caution:
= Turn on the main power switch more than 12 hours before starting operation.

Starting operation just after turning on the power switch can severely dam-
age the internal parts.

• Before starting operation, check that all panels, guards and other protective
parts are correctly installed. Rotating, hot, or high voltage parts can cause

injuries.

2

= Do not operate the air conditioner without the air filter set in place, if the air

filter is not installed, dust may accumulate and breakdown may result.

= Do not touch any switch with wet hands. Electric shock may result.
= Do not touch the refrigerant pipes with bare hands during operation.

= After stopping operation, be sure to wait at least five minutes before turning off

the main power switch. Otherwise, water leakage or breakdown may result.

2. Installation location

w

Fig. 2=1

3. Installing the indoor unit

Z_ Caution:
Install the indoor unit at least 2.4 m, 8 ft above floor or grade level.

®

®

@ i®

2.1. Outline dimensions (Indoor unit) (Fig. 2=1)

Select a proper position allowing the following clearances for installation and mainte-
nance. (mm)

Models W D m _ ® @ ®

A24, A30 61-9/16 26-7/32 8-9/32 Min,10-5/8 Min,11-13/1(Min,19-11/1( Max,9-13/16

A36, A42 51-9/16 26-7/32 10-5/8 Min,10-5/8 Min,11-13/1(Min,19-11/1( Max,9-13/16

1310 680 221 Min. 270 Min. 300 Min. 500 Max. 250

1310 680 281 Min. 270 Min. 300 Min. 500 Max. 250

2.2. Outline dimensions (Outdoor unit)

Refer to the outdoor unit installation manual.(rnrn)

3.1. Check the indoor unit accessories (Fig. 3=1)

The indoor unit should be supplied with the following accessories (contained in the

inside of the intake grille).

® Washer 4 pcs
® Pipe cover 1 pc Large size (For gas tubing)

(_) Band 4 pcs
® Joint socket 1 pc Marked with 'UNIT"

® Socket cover 1 pc
_7_ Drain tubing cover 1 pc

® Wired remote controller 1 pc

Accessory name Q'ty

Pipe cover 1 pc Small size (For liquid tubing)

(inch)

6-11/16(9-1/16)]_ Q

3-5/32

Fig. 3=1

Fig. 3=2

(inch)

3.2.

Preparation for installation (Fig. 3=2)

3.2.1

c

. Suspension bolt installing spacing

Models A B C

A24, A30 1240, 48-13/16 1310, 61-9/16 221,8-9/32
A36, A42 1240, 48-13/16 1310, 51-9/16 281,10-5/8

(mm, inch)

3.2.2. Refrigerant and drain tubing location

(mm)

Models D

A24, A30 5-5/32

A36, A42 7-9/16

Front side outlet

®
®

®

Left side outlet

®

Right side outlet

®

Independent piece (Removable)

3.2,3. Fresh air intake hole
At the time of installation, use the duct holes (knock out) located at the positions

shown in following diagram, as and when required.

Models G H J K

A24, A30

(inch)

A36, A42 13 7-7/8 2-3/16 6/7/8

3.2.4. Selection of suspension bolts and tubing positions (Fig. 3-3)

®

_ ]_(8-5/16)

Using the pattern paper provided for installation, select proper positions for suspen-
sion bolts and tubing and prepare relative holes.

_A_Pattern paper
® Suspension bolt hole

(07Indoor unit width

Secure the suspension bolts or use angle stock braces or square timbers for bolt
installation.

_A_Use inserts of 100 kg to 150 kg, 220 to 230 Ibseach.
® Use suspension bolts of W3/8 orM10 in size

131

191

Fresh air intake hole (knock out hole)

300 100 67 64

11-13/16 3-16/16 2-1/4 2-1/8

330 200 65 160

E F

175 178

6-7/8 7-3/32

235 238

9-9/32 9-3/8

® Right drain tubing
(_) Left drain tubing

Gas tubing
Liquid tubing

(inch)

(mm, inch)

Fig. 3=3

3

3. Installing the indoor unit

Fig. 3=4

Fig. 3=5

Fig. 3=6

®

I

3.2.5. indoor unit preparation (Fig. 3-4)

1. Install the suspending bolts. (Procure the W3/8 or M 10 bolts locally.)
Predetermine the length from the ceiling ((j) within 100 ram, 3-59/64 inch).

(A) Ceiling surface
_) Suspending bolt

© Suspending bracket

2. Remove the intake grille.
Slide the intake grille holding knobs (at two locations) backward to open the intake

(inch)

I

grille.

3. Remove the side panel.
Remove the side panel holding screws (one in each side, right and left) then slide the

side panel forward for removal.

3.3. installing the indoor unit

Use a proper suspending method depending on the presence or absence of ceiling
materials as follows. (Fig. 3-5)

In the absence of ceiling materials

Cb)Suspending bracket
@ Unit

1) Directly suspending the unit (Fig. 3-6)
Installing procedures

1. Install the washer 1_ (supplied with the unit) and the nut (to be locally procured).

2. Set (hook) the unit through the suspending bolts.

3. Tighten the nuts.
Check the unit installing condition.

• Check that the unit is horizontal between the right and left sides.

• Check that the unit slopes continuously downward from the front to the rear.

When embedding pipes, into the wall

2) Installing the suspending bracket first onto the ceiling (Fig. 3-7)
Installing procedures

1. Remove the suspending brackets, U-shaped washers, and suspending bracket
holding screws from the unit.

2. Adjust the suspending bracket holding bolts on the unit.

3. Attach the suspending brackets to the suspending bolts.

4. Set (hook) the unit to the suspending brackets.

_: Be sure to install the U-shaped washers.

(A) Bolt (ram, inch)
(_ Unit CbblA24 - A42 11207-1212, 47-1/2 to 47-23/32 I

© Washer
@ Suspending bracket holding screw

(E_Bolt
(F) Washer (1)

@ Double nuts

Fig. 3=7

4

4. Installing the refrigerant piping

2,

_° Fig. 4-1

(_ Flare cutting dimensions

Copper pipe O.D. Flare dimensions

(mm, inch) sA dimensions (mm, inch)
e6.35, 1/4" 8.7- 9.1, 11/32-23/64
e9.52, 3/8" 12.8 - 13.2, 1/2-33/64

o12.7, 1/2" 16.2 - 16.6, 41/64-21/32

e15.88, 5/8" 19.3 - 19.7, 49/64-25/32

(inch)

4.1. Precautions

4.1.1. For devices that use R410A refrigerant

• Use ester oil, ether oil, alkylbenzene oil (small amount) as the refrigeration oil
applied to the flared sections.

• Use Cl 220 copper phosphorus, for copper and copper alloy seamless pipes,
to connect the refrigerant pipes. Use refrigerant pipes with the thicknesses
specified in the table to the below. Make sure the insides of the pipes are

clean and do not contain any harmful contaminants such as sulfuric com-
pounds, oxidants, debris, or dust.

Z_ Warning:

When installing or moving the air conditioner, use only the specified refriger-

ant (R410A) to charge the refrigerant lines. Do not mix it with any other refriger-
ant and do not allow air to remain in the lines. Air enclosed in the lines can

cause pressure peaks resulting in a rupture and other hazards.

Liquid pipe 09.52 mm, 3/8 inch thickness 0.8 mm, 1/32 inch

I A24, A30, A36, A42

Gas pipe o15.88 mm, 5/8 inch thickness 1.0 mm, 3/64 inch

= Do not use pipes thinner than those specified above.

4.2. Connecting pipes (Fig. 4-1)

+ When commercially available copper pipes are used, wrap liquid and gas pipes

with commercially available insulation materials (heat-resistant to 100 °C, 212 °F or
more, thickness of 12 mm 1/2 inch or more).

+ The indoor parts of the drain pipe should be wrapped with polyethylene foam insu-

®

lation materials (specific gravity of 0.03, thickness of 9 mm, 23/64 inch or more).

+ Apply thin layer of refrigerant oil to pipe and joint seating surface before tightening

flare nut.

+ Use two wrenches to tighten piping connections.
+ Use refrigerant piping insulation provided to insulate indoor unit connections. Insu-

late carefully.

(_) Flare nut tightening torque

Copper pipe O.D.

(mm, inch)
e6.35, 1/4"

e9.52, 3/8"
o12.7, 1/2"

o15.88, 5/8"

(c) Apply refrigerating machine oil over the entire flare seat surface.
_@Use correct flare nuts meeting the pipe size of the outdoor unit.

Available pipe size

Flare nut O.D. Tightening torque

(mm, inch) (N.m, ft.lbs)

17, 43/64 14- 18, 10-13

22, 7/8 34 - 42, 25-30

26, 1-3/64 49 - 61,35-44
29, 1-9/64 68 - 82, 49-59

L_ipL<

A24, A30, A36, A42

Liquid side 09.52

Gas side e15.88

O : Factory flare nut attachment to the heat-exchanger.

(2

®

4.3. insulating pipes (Fig. 4=2)

1. Slide the supplied pipe cover (2_ over the gas tubing until it is pressed against the
sheet metal inside the unit.

2. Slide the provided pipe cover 3_ over the liquid tubing until it is pressed against
the sheet metal inside the unit.

3. Tighten the pipe covers (2_and _ at the both ends (15 - 20 mm, 5/8-3/4 inch) with
the supplied bands (_).

_A_Gas tubing _E_ Pipe cover (_
(B_Liquid tubing (_) Press the pipe cover against the sheet metal.

(C) Band @ @ Refrigerant tubing heat insulating material
_@Pipe cover (_)

+I+

Fig. 4-2

5