Panasonic cs-ke18nku, cs-ke24nku operating instructions

APPENDIX B

CS-KE18NKU + CU-KE24NKU
CS-KE24NKU + CU-KE24NKU

INSTALLATION INSTRUCTIONS

(852-6-4190-579-00-1)

A-2

INSTALLATION INSTRUCTIONS
Split System Air Conditioner

This air conditioner uses the refrigerant R410A.

NOTE

External diameter of service port R410A: 5/16"

Model Combinations

Combine indoor and outdoor units only as listed
below.

Model No.

Indoor Unit Outdoor Unit

CS-KE18NKU CU-KE18NKU

CS-KE24NKU CU-KE24NKU

Power Source:
60 Hz, single-phase, 230/208 V

Contents

Page

IMPORTANT!

Please Read Before Starting .................................. 2

1. GENERAL .......................................................... 4

1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation

2. INSTALLATION SITE SELECTION ................... 5

2-1. Indoor Unit
2-2. Outdoor Unit

3. HOW TO INSTALL THE INDOOR UNIT ............. 7

3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Remove the Grille to Install the Indoor Unit
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Drain Hose

4. HOW TO INSTALL THE OUTDOOR UNIT ....... 17

4-1. Wiring Instructions for the Outdoor Unit

5. REFRIGERANT TUBING .................................. 18

5-1. Use of the Flaring Method
5-2. Flaring Procedure with a Flare Tool
5-3. Caution before Connecting Tubes Tightly
5-4. Connecting Tubing between Indoor and

Outdoor Units
5-5. Insulation of Refrigerant Tubing
5-6. Taping the Tubes
5-7. Finishing the Installation

6. AIR PURGING................................................... 20

 Air Purging with a Vacuum Pump (for Test Run)
 Basic Functions of the Service Valves
 Pump Down
 Service Valve Connections

7. REMOTE CONTROLLER INSTALLATION

POSITION ......................................................... 24

7-1. Mounting on a Wall

8. ADDRESS SWITCH .......................................... 25

8-1. Address Setting of the Remote Controller

85264190579001 2011

CV6233187211

IMPORTANT!
Please Read Before Starting

This air conditioning system meets strict safety and operating
standards. As the installer or service person, it is an important
part of your job to install or service the system so it operates
safely and efficiently.

When Transporting

Be careful when picking up and moving the indoor and out­door units. Get a partner to help, and bend your knees when
lifting to reduce strain on your back. Sharp edges or thin alu­minum fins on the air conditioner can cut your fingers.

When Installing…

For safe installation and trouble-free operation, you
must:



Carefully read this instruction booklet before beginning.



Follow each installation or repair step exactly as shown.



Observe all local, state, and national electrical codes.



Pay close attention to all warning and caution notices
given in this manual.

This symbol refers to a hazard

WARNING

CAUTION

or unsafe practice which can
result in severe personal injury
or death.

This symbol refers to a hazard
or unsafe practice which can
result in personal injury or prod­uct or property damage.

If Necessary, Get Help

These instructions are all you need for most installation
sites and maintenance conditions. If you require help for a
special problem, contact our sales/service outlet or your
certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for improp­er installation or maintenance service, including failure to
follow the instructions in this document.

SPECIAL PRECAUTIONS

Select an installation location which is rigid and strong
enough to support or hold the unit, and select a location for
easy maintenance.

…In a Ceiling or Wall

Make sure the ceiling/wall is strong enough to hold the
unit’s weight. It may be necessary to construct a strong
wood or metal frame to provide added support.

…In a Room

Properly insulate any tubing run inside a room to prevent
“sweating” that can cause dripping and water damage to
walls and floors.

Keep the fire alarm and the air

CAUTION

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a
solid, level foundation for the outdoor unit. This prevents
water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a
metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is higher
than drifting snow. Provide snow vents.

outlet at least 1.5 m away from
the unit.

WARNING

 'RQRWVXSSO\SRZHUWRWKHXQLWXQWLODOOZLULQJDQGWXELQJ

are completed or reconnected and checked.

 +LJKO\GDQJHURXVHOHFWULFDOYROWDJHVDUHXVHGLQWKLV

system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and
inadequate grounding can cause accidental injury or

death.

 *URXQGWKHXQLW following local electrical codes.

 &RQQHFWDOOZLULQJWLJKWO\/RRVHZLULQJPD\FDXVHRYHU

heating at connection points and a possible fire hazard.

 7RSUHYHQWSRVVLEOHKD]DUGVIURPLQVXODWLRQIDLOXUH

the unit must be grounded.

When Wiring

ELECTRICAL SHOCK CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH. ONLY A
QUALIFIED, EXPERIENCED ELECTRICIAN
SHOULD ATTEMPT TO WIRE THIS SYSTEM.

When Connecting Refrigerant Tubing

 :KHQSHUIRUPLQJpiping work

do not mix air except for speci­fied refrigerant (R410A) in
refrigeration cycle. It causes
capacity down, and risk of
explosion and injury due to
high tension inside the refrige-

WARNING

 9HQWLODWHWKHURRPZHOOLQWKHHYHQWWKDWUHIULJHUDQW

gas leaks during the installation. Be careful not to allow
contact of the refrigerant gas with a flame as this will
cause the generation of poisonous gas.

2

rant cycle.

 5HIULJHUDQWJDVOHDNDJHPD\

cause fire.

 'RQRWDGGRUUHSODFHUHIULJHUDQW

other than specified type.
It may cause product damage,
burst and injury etc.

 8VHWKHIODUHPHWKRGIRUFRQQHFWLQJWXELQJ

 $SSO\UHIULJHUDQWOXEULFDQWWRWKHPDWFKLQJVXUIDFHVRI

the flare and union tubes before connecting them,
then tighten the nut with a torque wrench for a leak­free connection.

 &KHFNFDUHIXOO\IRUOHDNVEHIRUHVWDUWLQJWKHWHVWUXQ

 'RQRWOHDNUHIULJHUDQWZKLOHSLSLQJZRUNIRUDQLQVWDOODWLRQ

or re-installation, and while repairing refrigeration parts.
Handle liquid refrigerant carefully as it may cause frost­bite.

When Servicing

 7XUQWKHSRZHU2)) DWWKHPDLQSRZHUER[PDLQV

before opening the unit to check or repair electrical
parts and wiring.

 .HHS\RXUILQJHUVDQGFORWKLQJDZD\IURPDQ\PRYLQJ

parts.

 &OHDQXSWKHVLWHDIWHU\RXILQLVKUHPHPEHULQJWRFKHFN

that no metal scraps or bits of wiring have been left inside
the unit being serviced.

Others

CAUTION

 9HQWLODWHDQ\HQFORVHGDUHDVZKHQLQVWDOOLQJRUWHVWLQJ

the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously
toxic gas.

 &RQILUPXSRQFRPSOHWLQJLQVWDOODWLRQWKDWQRUHIULJHUDQW

gas is leaking. If escaped gas comes in contact with a
stove, gas water heater, electric room heater or other heat
source, it can produce dangerously toxic gas.

 'RQRWWRXFKWKHDLULQOHWRUWKHVKDUSDOXPLQXP

fins of the outdoor unit. You may get injured.

 'RQRWVLWRUVWHSRQWKHXQLW\RXPD\IDOOGRZQ

accidentally.

 'RQRWVWLFNDQ\REMHFWLQWRWKH)$1&$6(

You may be injured and the unit may be damaged.

NOTE

The illustrations are based on the typical appearance of
a standard model. Consequently, the shape may differ
from that of the air conditioner that you are installing.

3

1. General

This booklet briefly outlines where and how to install the
air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and make
sure all accessory parts listed are with the system before
beginning.

1-1. Tools Required for Installation (not supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Carpenter’s level

1-2. Accessories Supplied with Unit

Table 1

Parts Figure Q’ty Parts Figure Q’ty

Remote
controller

Remote control
holder

Tapping screw

1

1

Rawl plug

Truss-head
Phillips

5

/32 x5/8" (4x16 mm)

6. Sabre saw or key hole saw

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

Parts Figure Q’ty

10

Clamp

8

Cushion
rubber*

1

4

AAA alkaline
battery

1-3. Optional Copper Tubing Kit

Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or air conditioning workshop.

1-4. Type of Copper Tube and Insulation Material

2

Drain hose

adapter

1

2. Foamed polyethylene insulation for the specified
copper tubes as required to precise length of tubing.
Wall thickness of the insulation should be not less
than 5/16" (8 mm).

3. Use insulated copper wire for field wiring. Wire size
varies with the total length of wiring. Refer to 3-6.
Wiring Instructions for details.

If you wish to purchase these materials separately from
a local source, you will need:

1. Deoxidized annealed copper tube for refrigerant tub­ing as detailed in Table 2.

Cut each tube to the appropriate lengths 1' to 1'4"
(30 cm to 40 cm) to dampen vibration between units.

Table 2

Model

CS-KE18NKU 1/4" (6.35 mm) 0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)

CS-KE24NKU 1/4" (6.35 mm) 0.0314" (0.8 mm) 5/8" (15.88 mm) 0.0393" (1.0 mm)

Outer Dia. Thickness Outer Dia. Thickness

Narrow Tube Wide Tube

CAUTION

*Packed in the outdoor unit.

Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.

4

1-5. Additional Materials Required for Installation

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire
(See local codes.)

3. Putty

4. Refrigeration lubricant

5. Clamps or saddles to secure refrigerant tubing

2. Installation Site Selection

2-1. Indoor Unit

WARNING

AVOID:

To prevent abnormal heat genera­tion and the possibility of fire, do
not place obstacles, enclosures
and grilles in front of or surround­ing the air conditioner in a way
that may block air flow.

Indoor unit

2" (5 cm)

min.

Outside drainage

Fig. 1

6" (15 cm)
min.

Drain hose

2" (5 cm)

min.

 direct sunlight.

 nearby heat sources that may affect performance of the unit.

 areas where leakage of flammable gas may be expected.

 places where large amounts of oil mist exist.

DO:

 select an appropriate position from which every corner of

the room can be uniformly cooled. (High on a wall is best.)

 select a location that will hold the weight of the unit.

 select a location where tubing and drain hose have the

shortest run to the outside. (Fig. 1)

 allow room for operation and maintenance as well as unre-

stricted air flow around the unit. (Fig. 2)

 install the unit within the maximum elevation difference (H)

above or below the outdoor unit and within a total tubing length
(L) from the outdoor unit as detailed in Table 3 and Fig. 3a.

 install the indoor unit more than 3.3' (1 m) away from any

antenna or power lines or connecting wires used for television,
radio, telephone, security system, or intercom. Electrical noise
from any of these sources may affect operation.

Front View

Fig. 2

INDOOR
UNIT

Elevation
difference (H)

Fig. 3a

CAUTION

For stable operation of the
air conditioner, do not
install wall-mounted type
indoor units less than 5'
(1.5 m) from floor level.

Tubing length (L)

OUTDOOR
UNIT

Indoor unit

Minimum height
from floor level

5' (1.5 m)

Floor level

Wall

Fig. 3b

Table 3

Max. Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of

Model Length at Shipment Length (L) Difference (H) Additional Refrigerant

CS-KE18NKU 25 100 50 0.27

CS-KE24NKU 33 100 50 0.27

* If total tubing length becomes 25 to 100 ft. (Max.) or 33 to 100 ft. (Max.), charge additional refrigerant (R410A) by 0.27 oz./ft.

No additional charge of compressor oil is necessary. For more detailed charging information, refer to the Technical & Service Manual.

(ft.) (ft.) (ft.) (oz./ft.)*

5

2-2. Outdoor Unit

AVOID:

 heat sources, exhaust fans, etc. (Fig. 4)
 damp, humid or uneven locations.

NO

Hot air

Exhaust fan

Heat source

DO:

 choose a place as cool as possible.
 choose a place that is well ventilated.
 allow enough room around the unit for air intake/

exhaust and possible maintenance. (Fig. 5a or 5b)

 provide a solid base (level concrete pad, concrete block,

4"  1'4" (10  40 cm) or 6"  1'4" (15  40 cm) beams
or equal), a minimum of 4" (10 cm) or 6" (15 cm) above
ground level to reduce humidity and protect the unit
against possible water damage and decreased service
life. (Figs. 5c and 5d or 5e)

CAUTION

 install cushion rubber under unit’s feet to reduce

A solid base must not cover
the hole of the bottom plate.

vibration and noise. (Fig. 5f)

 use lug bolts or equal to bolt down unit, reducing

vibration and noise.

 install in a location where no antenna of a television

or radio exists within 10' (3 m).

(CU-KE18NKU)

Air intake

Concrete
or equal

About 1'4" (40 cm)

About 4" (10 cm)

Anchor bolts
(4 pcs.)

Min. 4" (10 cm)

Outdoor unit

(CU-KE18NKU)

Air intake Min. 4" (10 cm)

Min.

2" (5 cm)

Air discharge

(CU-KE24NKU)

Air intake Min. 6" (15 cm)

Min.

4" (10 cm)

Air discharge

Drain holes

Fig. 4

Valve
side
Min. 10"
(25 cm)

Min.
1'4" (40 cm)

Fig. 5a

Valve
side
Min. 10"
(25 cm)

Min.
1'8" (50 cm)

Fig. 5b

Obstacle above

Min.

7' (2 m)

Air discharge

Ground

Obstacle above

Min.

7' (2 m)

Air discharge

Ground

Min. 6" (15 cm)

Air intake

Min.

7' (2 m)

Obstacle

Min. 4" (10 cm)

Air intake

Min.

7' (2 m)

Obstacle

(CU-KE24NKU)

Air intake

Concrete
or equal

About 1'4" (40 cm)

Fig. 5d

Fig. 5e

Anchor bolts
(4 pcs.)

Min. 6" (15 cm)

About 6" (15 cm)

Fig. 5c

Cushion rubber

Fig. 5f

6

3. How to Install the Indoor Unit

3-1. Remove the Rear Panel from the Unit

(1) Remove and discard the set screw on the rear

panel. (Fig. 6)

(2) Press the 2 

marks on the frame cover and disen-

gage the stationary tabs from the frame. (Fig. 7)

(3) Remove the rear panel.

NOTE

Tubing can be extended in 5 directions as shown in Fig.

8. Select the direction you need providing the shortest

run to the outside unit.

 When left tubing is to be done, switch the drain hose

and drain cap. (For details, refer to “Switching drain
hose and drain cap” on page 15.)

3-2. Make a Hole

(1) Place the rear panel from the indoor unit on the wall

at the location selected. Make sure the panel is hori­zontal, using a carpenter’s level or tape measure to
measure down from the ceiling. Wait until after cut­ting the hole before attaching the rear panel to the
wall.

(2) Determine which side of the unit you should make

the hole for tubing and wiring. (Fig. 9)

NOTE

Left
tubing

Set screw only for transportation

Fig. 6

Rear panel

Fig. 7

Left-rear
tubing

marks

Right-rear
tubing
(recommended)

Right tubing

In the case of left-rear tubing, use the measurement
points 2-3/8" (60 mm) from the edge of the rear panel for
precise placement of the hose outlet. (Fig. 9)

(3) Before making the hole, check carefully that no

studs or pipes are directly run behind the spot to be
cut.

CAUTION

Also avoid areas where elec­trical wiring or conduits are
located.

The above precautions are also applicable if tubing
goes through the wall in any other location.

Downward tubing

Fig. 8

2-3/8" (60 mm)

Fig. 9

7

g

(4) Using a sabre saw, key hole saw or hole-cutting drill

attachment, cut a hole in the wall. See Table 4 and
Fig. 10.

Table 4

Hole Dia.

3-5/32" (80 mm)

(5) Measure the thickness of the wall from the inside

edge to the outside edge and cut PVC pipe at a
slight angle 1/4" (6 mm) shorter than the thickness of
the wall. (Fig. 11)

(6) Place the plastic cover over the end of the pipe (for

indoor side only) and insert the pipe in the wall. (Fig.

12)

3-3. Install the Rear Panel on the Wall

Be sure to confirm that the wall is strong enough to sus­pend the unit.

See either Item a) or b) below depending on the wall type.

a) If Wooden Wall

(1) Attach the rear panel to the wall with the 8 screws

provided. (Fig. 13)

NOTE

Hole should be made at a slight downward slant to the
outdoor side.

Indoor
side

Outdoor
side

Fig. 10

PVC pipe (Locally purchased)

Cut at sli

ht angle

Fig. 11

INSIDE OUTSIDE

Wall

Plastic cover

(Locally purchased)

PVC pipe

Slight
angle

If you are not able to line up the holes in the rear
panel with the beam locations marked on the wall,
use rawl plugs or toggle bolts to go through the
holes on the panel or drill 3/16" (5 mm) dia. holes in
the panel over the stud locations and then mount the
rear panel.

(2) Double check with a carpenter’s level or tape mea-

sure that the panel is level. This is important to
install the unit properly. (Fig. 14)

(3) Make sure the panel is flush against the wall. Any

space between the wall and unit will cause noise
and vibration.

b) If Block, Brick, Concrete or Similar Type Wall

Make 3/16" (4.8 mm) dia. holes in the wall. Insert rawl
plugs for appropriate mounting screws. (Fig. 15)

Fig. 12

Fig. 13

Fig. 14

3/16"
(4.8 mm) dia. hole

Rawl plug

Fig. 15

8

3-4. Remove the Grille to Install the Indoor Unit

Basically, these models can be installed and wired with­out removing the grille. If access to any internal part is
needed, follow the steps as given below.

How to remove the grille

Air intake grille

Grille

(1) Grasp both ends of the air intake grille, and remove

it by opening towards the front and pulling towards
you. (Fig. 16a)

(2) Remove the 3 screws. (Fig. 16b)

(3) Remove the screw on the right side cover plate and

open the cover. (Fig. 17a)

(4) Take out the thermistor from the grille. (Fig. 17b)

(5) Press the 3 tabs at the top of the grille and the 3

tabs on the front face to separate the grille from the
frame. (Fig. 18a)

(6) Pull the grill toward you to remove it.

How to replace the grille

(1) When installing the grille, place the bottom of the

grille into the frame first. (Fig. 18b)
Then insert the tabs on the top of the grille and on
the front face into the frame.

(2) Make sure that the grille and frame are firmly fitted

together by engaging the tabs.

(3) Attach the thermistor on the grille. (Fig. 17a)

Thermistor

Fig. 17a

Fig. 16a

Fig. 16b

Cover

Thermistor

Fig. 17b

Ta b

(4) Close the cover and replace the screw. (Fig. 17a)

(5) Affix the grille with the 3 previously removed screws.

(Fig. 16b)

(6) Install the air intake grille.

(a) Allow the edge of the air intake grille to slide into the

top of the indoor unit, and then insert it all the way
inside. (Fig. 19a)

(b) Press the bottom right and left corners and center of

the air intake grille to attach it to the indoor unit.
(Fig. 19b)

NOTE

Attach so that the round pins at the top right and left cor­ners of the air intake grille are inserted into the grooves
at the top right and left of the indoor unit.

Ta b

Fig. 18a

Fig. 18b

Groove

Pin

Fig. 19b

Fig. 19a

9

3-5. Shape the Indoor Side Tubing

(1) Arrangement of tubing by direction

a) Right or left tubing

Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)

b) Right-rear or left-rear tubing

In this case, the corner of the frame need not be
cut.

(2) To mount the indoor unit on the rear panel:

Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)

3-6. Wiring Instructions

General precautions on wiring

(1) Before wiring, confirm the rated voltage of the unit as

shown on its nameplate, then carry out the wiring
closely following the wiring diagram.

(2) Provide a power outlet to be used exclusively for

each unit, with a power supply disconnect and cir­cuit breaker for overcurrent protection provided in
the exclusive line.

Frame

Left tubing
outlet

Fig. 20

Frame

Right tubing
outlet

Fig. 21

(3) To prevent possible hazards due to insulation failure,

the unit must be grounded.

(4) Each wiring connection must be done tightly and in

accordance with the wiring system diagram. Wrong
wiring may cause the unit to misoperate or become
damaged.

(5) Do not allow wiring to touch the refrigerant tubing,

compressor, or any moving parts of the fan.

(6) Unauthorized changes in the internal wiring can be

very dangerous. The manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.

Fig. 22

10

3-7. Recommended Wire Length and Diameter

Regulations on wiring diameter differ from locality to locality. For field wiring
requirements, please refer to your local electrical codes. Carefully observe these
regulations when carrying out the installation.
Table 5 lists recommended wire lengths and diameters for power supply systems.

NOTE

Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in
Table 5.

Refer to your local codes or in the absence of local codes see the National Elec­tric Code: ANSI/NFPA70.

Table 5

(A)+(B) (A) Power Supply Wiring Length (ft) (C) Control

(B) Power Line Length (ft) Line Length (ft)

Model (#14) (#12) (#14)

CU-KE18NKU 131 (Max.) 230 (Max.) 100 (Max.) 15A

CU-KE24NKU 131 (Max.) 230 (Max.) 100 (Max.) 20A

# ... AWG (American Wire Gauge)

Fuse or Circuit AWG

Breaker Capacity

WARNING

 Be sure to comply with local codes on running the wire

from the indoor unit to the outdoor unit (size of wire and
wiring method, etc.).

 Each wire must be firmly connected.
 No wire should be allowed to touch refrigerant tubing, the

compressor, or any moving part.

WARNING

 To avoid the risk of electric shock, each air conditioner

unit must be grounded.

 For the installation of a grounding device, please

observe local electrical codes.

 Grounding is necessary, especially for units using

inverter circuits, in order to release charged electricity
and electrical noise caused by high tension.
Otherwise, electrical shock may occur.

 Place a dedicated ground more than 7' (2 m) away from

other grounds and do not have it shared with other elec­tric appliances.

WIRING SYSTEM DIAGRAM

INDOOR

UNIT

Terminal Terminal

1

2

3

Disconnect

*

switch
Field supply

(C)

Grounding line

230/208V

230/208V

230/208V

(B)

(B)

OUTDOOR

UNIT

1

2

3

4

5

6

Fig. 23

NOTE

*

Disconnect switch may be required by
national or local codes.

CAUTION

Always comply with national and local code
requirements.

Power supply

Single phase 230/208V 60HZ

(A)

L

1

L

2

Grounding
line

CAUTION

 Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram.

The indoor unit draws its power from the outdoor unit.

 Do not run wiring for antenna, signal, or power lines of television, radio, stereo, telephone,

security system, or intercom any closer than 3'4" (1 m) from the power cable and wires
between the indoor and outdoor units. Electrical noise may affect the operation.

11

3-8. Wiring Instructions for Inter-unit Connections

(1) Insert the inter-unit wiring (according to local codes)

into the through-the-wall PVC pipe. Run the wiring
toward the indoor side allowing approx. 10" (25 cm)
to extend from the wall face. (Fig. 24)

Rear
panel

Wall

Plastic
cover

(2) Grasp both ends of the air intake grille, and remove

it by opening towards the front and pulling towards
you.

(3) Remove the screw on the right side cover plate and

open the cover. (Fig. 25)

(4) Route the inter-unit wiring from the back of the

indoor unit and pull it toward the front for connec­tion. (Fig. 26a, 26b)

(5) Connect the inter-unit wiring to the corresponding

terminals on the terminal plate (Fig. 26a, 26b) while
referring to the wiring diagram.

(6) Be sure to secure the wiring with the provided

clamp.

NOTE

When closing the air intake grille, press the bottom right
and left corners and center. (Fig. 27)

Please refer to “How to replace the grille” on page 9 for
installing the air intake grille.

Wiring

10"
(25 cm)

Fig. 24

Cover

Fig. 25

Terminal
plate

Fig. 27

Fig. 26a

Inter-unit
wiring

Earth
plate

Lock nut

Top of conduit
connector

Fig. 26b

12

WARNING

Loose wiring may cause the
terminal to overheat or result
in unit malfunction. A fire
hazard may also exist. There­fore, be sure all wiring is
tightly connected.

When connecting each power wire to the corresponding
terminal, follow the instructions “How to connect wiring
to the terminal” and fasten the wire securely tight with
the fixing screw of the terminal plate.

How to connect wiring to the terminal

a) For Indoor Unit

(1) Cut the wire end with a cutting pliers, then strip the

insulation to expose the wire about 9/32" (7 mm).
See the label (Fig. 28) near the terminal plate.

(2) Using a screwdriver, loosen the terminal screw on

the terminal plate.

(3) Insert the wire and tighten the terminal screw com-

pletely using a screwdriver.

b) For Outdoor Unit

 For solid core wiring (or F-cable)

(1) Cut the wire end with a cutting pliers, then strip the

insulation to expose the solid wire about 15/16" (25
mm). (Fig. 29)

(2) Using a screwdriver, remove the terminal screw(s)

on the terminal plate.

9/32"

STRIP
SIZE

(7 mm)

Fig. 28

Solid wire

Strip 15/16" (25 mm)

Insulation

Fig. 29

Stranded wire

Strip 3/8" (10 mm)

(ACTUAL

SIZE)

Loop

Ring
connector

(3) Using the pliers, bend the solid wire to form a loop

suitable for the terminal screw.

(4) Shape the loop wire properly, place it on the termi-

nal plate and fix it securely with the removed termi­nal screw using a screwdriver.

 For stranded wiring

(1) Cut the wire end with a cutting pliers, then strip the

insulation to expose the stranded wiring about 3/8"
(10 mm) and tightly twist the wire ends. (Figs. 30
and 31)

(2) Using a screwdriver, remove the terminal screw(s)

on the terminal plate.

(3) Using a ring connector fastener or pliers, securely

clamp each stripped wire end with a ring connector.
(Fig. 30)

(4) Place the ring connector wire, and replace and

tighten the removed terminal screw using a screw­driver. (Fig. 32)

Wire

Special
washer

Fig. 30

Twist wire ends

Fig. 31

Screw

Ring connector

Terminal plate

Fig. 32

Screw and
special washer

Ring
connector

Wire

13

3-9. Mounting

(1) To install the indoor unit, mount the indoor unit onto

the 2 tabs on the upper part of the rear plate.

(2) Hold down the air discharge outlet and press the

lower part of the indoor unit until it clicks to securely
fasten to the 2 tabs on the lower part of the rear
plate. (Fig. 33)

NOTE

For tubing, choose either the right or left tubing direction
and follow the steps below. This work can be made easi­er by placing padding material (such as styrofoam) at the
rear right side of the indoor unit. (Fig. 34)

 Right-side tubing

(1) Shape the refrigerant tubing so that it can easily go

into the wall hole. (Fig. 35)

Push

Fig. 33

(2) Push the wiring, refrigerant tubing, and drain hose

through the hole in the wall. Adjust the indoor unit so
it is securely seated on the rear panel. (Fig. 36)

(3) Carefully bend the tubing (if necessary) to run along

the wall in the direction of the outdoor unit and then
tape as far as the fittings. (See Caution on page

19.) The drain hose should come straight down the
wall to a point where water runoff won’t stain the
wall.

(4) Connect the refrigerant tubing to the outdoor unit.

(After performing a leak test on the connecting part,
insulate it with the tubing insulation. (Fig. 37a)) Also,
refer to Section 5-4. Connecting Tubing between
Indoor and Outdoor Units.

(5) Assemble the refrigerant tubing, drain hose, and

conduit (including inter-unit wiring) as shown in
Fig. 37b.

Refrigerant tubing

Padding material

Fig. 34

Rear panel

Cover

Refrigerant
tubing

Inter-unit
wiring

Drain hose

Fig. 35

Fig. 37a

Insulation

Conduit

Inter-unit wiring

Fig. 37b

Drain hose

14

Fig. 36

 Left-side tubing

(1) Lead the tubing and drain hose through the wall,

allowing sufficient length for connection. Then bend
the tubing using a tube bender to make the attach­ment. (Fig. 38)

(2) Switch the drain hose and drain cap.

Hole in wall

Bent part

Rear panel

Wide tube

Narrow tube

Switching drain hose and drain cap

(a) Locate the drain hose and the drain cap. (Fig.

39)

(b) Remove the screw fastening the drain hose on

the right side, and pull out the drain hose to
remove it. (Fig. 39)

(c) Apply moderate force to pull off the drain cap

on the left side. (If you cannot pull it off by
hand, use a long-nose pliers.)

(d) Reattach the drain hose to the left side and the

drain cap to the right side. (Fig. 40a)

Drain hose

Slide the drain hose fully onto the drain pan outlet
until the drain hose edge is pushed into the insula­tion. Check that the screw holes in the drain bracket
and the drain pan outlet are aligned and securely in
contact, then fasten them with the screw. (After
attaching the drain hose, check that it is attached
securely.) (Fig. 40c)

Fig. 38

Drain cap

Drain hose

Fig. 39

Drain hose

Clamp

Drain cap

Drain cap

Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)

(3) Install the indoor unit on the rear panel.

(4) Connect the tubing and wiring led inside from out-

doors.

(5) After completing a leak test, bundle the tubing

together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Figs. 40a and 41)

Insulation

Drain bracket

Drain hose

Fig. 40c

Fig. 40a

Screw hole

Drain bracket

Conduit

Drain pan outlet

Drain hose

Screw

Fig. 40b

Refrigerant tubing

Inter-unit wiring

15

Fig. 41

To unmount indoor unit

Press the 2 

marks on the lower part of the indoor unit
and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)

3-10. Drain Hose

a) The drain hose should be slanted downward to the

outdoors. (Fig. 43)

b) Never form a trap in the course of the hose.

c) If the drain hose will run in the room, insulate the

hose with insulation* so that chilled condensation
will not damage furniture or floors. (Fig. 44)

* Foamed polyethylene or its equivalent is recom-

mended.

WARNING

Do not supply power to the
unit or operate it until all
tubing and wiring to the out­side unit are completed.

Risk of Electric Shock

Indoor
unit

Push

Fig. 42

Slant

Drain
hose

Insulation material
(Locally purchased)
must be used.

Fig. 43

Condensation

Fig. 44

16

4. How to Install the Outdoor Unit

First refer to Section 2. Installation Site Selection.

4-1. Wiring Instructions for the Outdoor Unit

Regulations on wire size differ from locality to locality. For
field wiring requirements, please refer to your local elec­trical codes. Make sure that the installation fully complies
with all local and national regulations.

(1) Remove access panel “C”. (Fig. 46)

(2) Connect the inter-unit and power supply line accord-

ing to the drawing on the panel side.

(3) Be sure to size each wire allowing approx. 4"

(10 cm) longer than the required length for wiring.
Store excess wiring inside the cabinet.

(4) When connections are completed, check that all

connections are correct as shown in the wiring sys­tem diagram on panel side.

Lock nut

Cabinet

Terminal
block

Conduit
plate

Access panel C

(5) Be sure to ground the unit according to your local

codes.

Plug

Inter unit
(Conduit)

Power supply
(Conduit)

Fig. 46

17

5. Refrigerant Tubing

5-1. Use of the Flaring Method

Many of the conventional split system air conditioners
employ the flaring method to connect refrigerant tubes
which run between indoor and outdoor units. In this
method, the copper tubes are flared at each end and
connected with flare nuts.

5-2. Flaring Procedure with a Flare Tool

Before

Deburring

After

(1) Cut the copper tube to the required length with a

tube cutter. It is recommended to cut approx. 12" to
20" (30 to 50 cm) longer than the tubing length you
estimate.

(2) Remove burrs at the end of the copper tube with a

tube reamer or file. This process is important and
should be done carefully to make a good flare.
(Fig. 47)

NOTE

When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)

(3) Remove the flare nut from the unit and be sure to

mount it on the copper tube.

(4) Make a flare at the end of copper tube with a flare

tool.* (Figs. 49a and 49b)

(*Use “RIDGID” or equivalent.)

NOTE

A good flare should have the following characteristics:

 inside surface is glossy and smooth.

 edge is smooth.

 tapered sides are of uniform length.

If the special R410A
flare tool is used:

0 to 0.0196"
(0 to 0.5 mm)

Fig. 47

Copper
tubing

Reamer

Fig. 48

If the previous flare tool
(clutch-type) is used:

0.0472" (1.2 mm)

Adjust so that the amount of tube
protrusion is as shown in the figure.

Fig. 49a

Flare nut

Copper
tubing

5-3. Caution before Connecting Tubes Tightly

a) Be sure to apply a sealing cap or water-proof tape

to prevent dust or water from getting into the tubes
before they are used.

b) Be sure to apply refrigerant lubricant to the match-

ing surfaces of the flare and union before connect­ing them together. This is effective for reducing gas
leaks. (Fig. 50)

c) For proper connection, align the union tube and

flare tube straight with each other, then screw in the
flare nut lightly at first to obtain a smooth match.
(Fig. 51)

18

Flare tool

Fig. 49b

Apply refrigerant
lubricant here and here

Fig. 50

Union

Flare nut

Fig. 51

5-4. Connecting Tubing between Indoor and

Outdoor Units

a) Tightly connect the indoor side refrigerant tubing exten-

ded from the wall with the outdoor side tubing. (Fig. 52)

b) To fasten the flare nuts, apply specified torque as:

Torque wrench

Spanner

Indoor unit

Table 6

Tube Dia. Nut Tightening Torque

1/4" (6.35 mm) 21/32" (17 mm) Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)

3/8" (9.52 mm) 7/8" (22 mm) Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)

1/2" (12.70 mm) 1-1/32" (26 mm) Approx. 430 – 480 lbs·in (490 – 550 kgf·cm)

5/8" (15.88 mm) 1-5/32" (29 mm) Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)

5-5. Insulation of Refrigerant Tubing

IMPORTANT

To prevent heat loss and wet floors due to dripping of con­densation, both tubes must be well insulated with a
proper insulation material. (Fig. 53)
The thickness of the insulation should be a minimum 5/16"
(8 mm). (Fig. 54)

5-6. Taping the Tubes

CAUTION

After a tube has been insulat­ed, never try to bend it into a
narrow curve, as this may
cause the tube to break or
crack.

Min.
5/16"
(8 mm)

Outdoor unit

Fig. 52

Insulation

Fig. 53

Insulation

Thickness:
min. 5/16"
(8 mm)

Fig. 54

(1) At this time, the 2 refrigerant tubes (and electrical wire

if local codes permit) should be taped together with
armoring tape. The drain hose may also be included
and taped together as 1 bundle with the tubing.

(2) Wrap the armoring tape from the bottom of the outdoor

unit to the top of the tubing where it enters the wall. As
you wrap the tubing, overlap half of each previous tape
turn. (Fig. 55)

(3) Clamp the tubing bundle to wall, using 1 clamp approx.

every 47" (120 cm).

NOTE

Do not wind the armoring tape too tightly, since this will
decrease the heat insulation effect. Also, be sure the con­densation drain hose splits away from the bundle and drips
clear of the unit and the tubing.

5-7. Finishing the Installation

After finishing insulating and taping over the tubing, use
sealing putty to seal off the hole in the wall to prevent rain
and draft from entering. (Fig. 56)

Clamp

Insulated tubes

Fig. 55

Apply putty here

Tubing

Fig. 56

19

6. Air Purging

Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below. Therefore,
they must be purged completely.

 pressure in the system rises

 operating current rises

 cooling (or heating) efficiency drops

 moisture in the air may freeze and block capillary tubing

 water may lead to corrosion of parts in the refrigerant

system

 Air Purging with a Vacuum Pump (for Test Run)

(1) Check that each tube (both narrow and wide tubes)

between the indoor and outdoor units have been
properly connected and all wiring for the test run
has been completed. Note that both narrow and
wide tube service valves on the outdoor unit are
kept closed at this stage.

Indoor unit

Outdoor unit

(2) Using an adjustable wrench or box wrench, remove

the valve caps from the service valve on both nar­row and wide tubes.

(3) Connect a vacuum pump and a manifold valve (with

pressure gauges) to the service port on the wide
tube service valve. (Fig. 57)

CAUTION

The service port on the wide tube
service valve uses a Schrader core
valve to access the refrigerant sys­tem. The valve core is similar to
those used in automobile tires.
Therefore, be sure to use a vacuum
hose connector which has a push­pin inside.

CAUTION

Be sure to use a manifold valve
for air purging. If it is not avail­able, use a stop valve (field sup­ply) for this purpose. The “Hi”
knob of the manifold valve must
always be kept closed.

(4) With the “Lo” knob of the manifold valve open, run

the vacuum pump. The operation time for the vacu­um pump varies with tubing length and the capacity
of the pump. The following table shows the amount
of time for evacuation:

Manifold valve
(Exclusively for R410A)

Pressure
gauge

Vacuum pump

HiLo

Charging hose
(Exclusively for R410A)

Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)

Fig. 57

NOTE

To prevent other refrigerants from being mistakenly
charged to units which use R410A, the size of the
charge port on the service valve is different from the
one for other refrigerant types. For servicing such as
recharging, the specified charging hose, manifold and
vacuum pump adapter (with reverse flow prevention)
for R410A must be used.

Table 7

Required time for evacuation when

100 liter/h vacuum pump is used

If tubing length is If tubing length is

less than 33 ft. (10 m) more than 33 ft. (10 m)

10 min. or more 15 min. or more

NOTE

The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.

20

(5) With the vacuum pump still running, close the “Lo”

knob of the manifold valve. Then stop the vacuum
pump.

(6) With the hex wrench, turn the valve stem on the

narrow tube service valve counter-clockwise by
90 degrees (1/4 turn) for 10 seconds, and then turn
the stem clockwise to close it again. (Fig. 58)

90 (1/4 turn)

Narrow tube

Hex wrench

Wide tube

CAUTION

Be sure to completely insert
the hex wrench before
attempting to turn the valve.

(7) Leak test all joints at the tubing (both indoor and out-

doors) with soapy water. Bubbles indicate a leak. Tight­en the joint more when leaks, then check if there is no
leak. Be sure to wipe off the soap with a clean cloth.

(8) With the hex wrench, turn the wide tube service

valve stem counter-clockwise to fully open the valve.

(9) Turn the narrow tube service valve stem counter-

clockwise to fully open the valve.

(10) Loosen the vacuum hose connected to the wide

tube service port slightly to release the pressure.
Then, remove the hose.

CAUTION

This may cause the refriger­ant gas to leak. In order to
avoid this, take off the hose
quickly.

Valve cap

Vacuum hose to manifold valve

Fig. 58

(11) Fasten the valve cap on the wide tube service port

securely with an adjustable wrench or box wrench.
Next, mount the valve cap on the service valve and
tighten it to 170 lbs·in (200 kgf·cm) with a torque
wrench. This process is very important to prevent
gas from leaking from the system.

(12) Test run the air conditioner. (See next page.)

(13) While the air conditioner is running, apply liquid

soap to check for any gas leaks around the service
valves or caps.

(14) If there is no leakage, stop the air conditioner.

(15) Wipe off the soap on the tubing.

This completes air purging with a vacuum pump and the
air conditioner is ready for actual operation.

21

How to Test Run the Air Conditioner

After turning on the power of the air conditioner, use the
remote controller and follow the steps below to conduct the
test run.

(1) Set the remote controller in Test Run mode.

(Fig. 59a)

a)Press and hold the QUIET button and the 1HR.

TIMER button.

b)Then press and hold the ACL (Reset) button with a

pointed object such as the tip of a pen. After 5 sec­onds, release the ACL button first.

c) Then release the QUIET and 1HR. TIMER buttons.

d) appears and “oP-1” blinking in the remote con-

troller clock display area. (Fig. 59b)

(2) Start Cooling mode test run by pressing the ON/OFF

operation button of the remote controller. (Fig. 59a)

 7KLVVWDUWVWKHIDQSURGXFLQJXQFRROHGIRUFHGDLUZLWK

the 3 indicator lamps (OPERATION lamp, TIMER
lamp and QUIET lamp) on the main unit blinking.
(Fig. 59c)

 $IWHUPLQXWHVWKHV\VWHPVKLIWVLQWRFRROLQJRSHUD

tion, and cool air will start to be felt. Cooling mode test
run is unaffected by the room temperature.

(3) Press the ON/OFF operation button of the remote con-

troller again to stop the test run. (Fig. 59a)

(4) Finally press the ACL (Reset) button of the remote con-

troller to release it from Test Run mode to return to nor­mal mode. (Fig. 59a)

 ´ µDQG´R3µZLOOGLVDSSHDUIURPWKHUHPRWHFRQ

troller clock display area.

QUIET

button

A

Fig. 59a

ON/OFF
operation

button

1HR.
TIMER

button

ACL
(Reset)

button

NOTE

Troubleshooting:
In the event that the green “OPERATION lamp” is blinking
upon powering up the system, an error condition exists. In
this case, refer to the self-diagnostics procedure on the
inside of the front cover.

IMPORTANT

After the test run is completed, be sure to press the
ACL (Reset) button to return to normal mode. The
air conditioner will not operate correctly if this is not
done.

Fig. 59b

OPERATION lamp
TIMER lamp

QUIET lamp

Fig. 59c

22

 Basic Functions of the Service Valves

Close

Hex
wrench

Open

The basic functions of the service valves are given in Table 8 below.

Table 8

Action

Shipping

Operating and

test running

the air conditioner

Measuring pressure

and gas charging

Air purging with

a vacuum pump

Narrow Tube Service

Valve (2-Way)

CLOSED

Fully OPEN

Fully OPEN

CLOSED

Wide Tube Service

Valve (3-Way)

O-ring

*

*

Valve cap

Stem

* The service port on the wide tube ser-

vice valve uses a Schrader core valve
to access the refrigerant system.
Therefore, be sure to use a hose con­nector which has a push-pin inside.
(Fig. 60a)

CAUTION

When opening or closing
the service valve stem,
use the hex wrench.
Be sure to fully seat the
wrench before turning

Fig. 60b

the valve.

 Pump Down

Pump down means collecting all refrigerant gas in the
system back into the outdoor unit without losing any of
the gas. Pump down is used when the unit is to be
moved or before servicing the refrigerant circuit.

Pump Down Procedure

Be sure to carry out pump down with the unit in
cooling mode.

(1) Connect the Lo side charging hose of the manifold

valve to the service port on the wide tube service
valve.

Service valve

Hose with push-pin

PUSH

NOTE

External diameter of service port
R410A: 5/16"

Fig. 60a

(2) Using a hex wrench, turn the narrow tube service

valve clockwise all the way to close the service
valve. (Be sure to confirm that the wide tube service
valve is fully open.)

(3) Press the operation button and start cooling oper-

ation.

(4) When the low pressure gauge reading falls to 14.2 to

7.1 psi (1 to 0.5 kg/cm

2

), fully close the wide tube

valve stem. Then quickly stop the unit.

(5) Disconnect all gauges and hoses, and replace the

valve caps as they were before.

23

 Service Valve Connections

a) Temporary connection:

Screw in 3 – 5 turns by hand. (Fig. 60c)

b) To fasten the flare nuts, apply specified torque

as Table 9 and Fig. 60d.

Table 9

Tube Dia. Nut Tightening Torque

1/4" (6.35 mm) 21/32" (17 mm) Approx. 120 – 160 lbs·in (140 – 180 kgf·cm)

3/8" (9.52 mm) 7/8" (22 mm) Approx. 300 – 360 lbs·in (340 – 420 kgf·cm)

1/2" (12.70 mm) 1-1/32" (26 mm) Approx. 430 – 480 lbs·in (490 – 550 kgf·cm)

5/8" (15.88 mm) 1-5/32" (29 mm) Approx. 590 – 710 lbs·in (680 – 820 kgf·cm)

7. Remote Controller Installation Position

The remote controller can be operated from either a non-fixed posi­tion or a wall-mounted position.

To ensure that the air conditioner operates correctly, do not install
the remote controller in the following places:

 In direct sunlight

 Behind a curtain or other place where it is covered

 More than 26' (8 m) away from the air conditioner

 In the path of the air conditioner’s airstream

 Where it may become extremely hot or cold

 Where it may be subject to electrical or magnetic interference

 Where there is an obstacle between the remote controller and

the air conditioner (since a check signal is sent from the remote
controller every 5 minutes)

Torque wrench

Fig. 60c Fig. 60d

Be sure to tighten the

CAUTION

flare nut using the
prescribed torque.
If the nut is over­tightened, refrigerant
leakage may occur.

7-1. Mounting on a Wall

Before mounting the remote controller, press the ON/OFF
operation button at the mounting location to make sure that the air
conditioner operates from that location. The indoor unit should
make a beeping sound to indicate that it has received the signal.

Remote control holder

Press

Set in
place

Mounting screws

5/32 x 5/8" (4 x 16 mm)

(Included)

To take out the remote controller, pull it forward.

Rear side

Hole

To prevent loss of the remote
controller, you can connect the
remote controller to the holder by
passing a string through the remote
controller and attachment hole.

Fig. 61

24

8. Address Switch

8-1. Address Setting of the Remote Controller

The address can be set in order to prevent interference
between remote controllers when 2 indoor units are
installed near each other. The address is normally set to
“A.” To set a different address, it is necessary to change
the address on the second remote controller.

Ta b

NOTE

Once changed, you cannot restore the original address
setting of the air conditioner.

(1) Switch on the power source.

(2) Break the address-setting tab marked “A” on the

second remote controller to change the address
(Fig. 62). When the tab is removed, the address is
automatically set to B (Fig. 63).

(3) Press and hold the remote controller QUIET button

and 1HR. TIMER button. Then, press and hold the
ACL (Reset) button with a pointed object such as
the tip of a pen. After 5 seconds, release the ACL
button first, then release the QUIET and 1HR.
TIMER buttons. “oP-1” (Test Run) appears, blinking
in the remote controller clock display area.

(4) Each time the 1HR. TIMER button is pressed, the

display changes as shown below. Press this button
2 times to change the display to “oP-7” (Address
setting). (Fig. 64)

Fig. 62

ACL button

Fig. 63

Test run mode

Selfdiagnostic mode

Address setting mode

(5) “oP-7” has now been selected for address setting.

(6) Press the ON/OFF operation button on the remote

controller. (Fig. 64) Check that the “beep”signal­received sound is heard from the second indoor unit
(approximately 5 times). The sound you hear is the
signal that the remote controller address has been
changed.

(7) Finally press the remote controller ACL (Reset) but-

ton to cancel the blinking “oP-7” display.
(Fig. 64)

Changing of the second remote controller address is
now completed.

QUIET

button

A

Fig. 64

ON/OFF
operation

button

1HR.
TIMER

button

ACL
(Reset)

button

25

DC1111-0