Panasonic CU-4KE31NBU, CU-3KE19NBU, CU-4KE24NBU Installation Manual

APPENDIX A

INSTALLATION INSTRUCTIONS

CU-3KE19NBU CU-4KE24NBU CU-4KE31NBU

(852-6-4190-584-00-2)

A-1

For Outdoor Unit

INSTALLATION INSTRUCTIONS Split System Air Conditioner

This air conditioner uses the refrigerant R410A.

NOTE

External diameter of service port R410A: 5/16"

Contents

Page

IMPORTANT!

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

Model Combinations

Combine indoor and outdoor units only as listed below.

Model No.

Indoor Unit Outdoor Unit

CS-MKE7NKU CU-3KE19NBU

CS-MKE9NKU CU-4KE24NBU

CS-MKE12NKU CU-4KE31NBU

CS-MKE18NKU

CS-MKE24NKU

CS-MKE9NB4U

CS-MKE12NB4U

CS-KE18NB4UW

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

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. Connecting Indoor Units 2-3. Outdoor Unit 2-4. Baffle Plate for the Outdoor Unit 2-5. Outer Dimensions of Outdoor Unit 2-6. Diagram of Outdoor Unit Installation

3. INSTALLATION PROCESS .............................. 16

3-1. Embedding the Tubing and Wiring 3-2. Use of the Flaring Method 3-3. Flaring Procedure with a Flare Tool 3-4. Caution before Connecting Tubes Tightly 3-5. Tubing Connections 3-6. Insulation of Refrigerant Tubing 3-7. Taping the Tubes 3-8. Finishing the Installation

Combination example

Indoor unit B

Indoor unit A

Outdoor unit

Indoor unit D

Indoor unit C

4. AIR PURGING................................................... 19

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

5. WIRING INSTRUCTIONS ................................ 22

5-1. General Precautions on Wiring 5-2. Recommended Wire Length and Diameter 5-3. Wiring System Diagram 5-4. How to Connect Wiring to the Terminal 5-5. Wiring Instructions for the Outdoor Unit

6. TEST RUN......................................................... 26

7. CONNECTING A HOME AUTOMATION

DEVICE ............................................................. 27

8. INSTALLATION CHECK SHEET ...................... 27

85264190584002 2011 CV6233187853

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

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

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are completed or reconnected and checked.

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

death.

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heating at connection points and a possible fire hazard.

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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

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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

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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.

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cause fire.

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

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

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

When Servicing

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

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parts.

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

Others

CAUTION

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

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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.

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fins of the outdoor unit. You may get injured.

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accidentally.

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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. If the electric wiring diagram does not appear in this manual, please check for the diagram on the indoor unit.

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

6. Sabre saw or key hole saw

1-2. Accessories Supplied with Unit

Table 1

Parts Figure Q’ty Parts Figure Q’ty Parts Figure Q’ty

Labels for inter-unit cable and tube

Reducer (3/8" 1/2")

A B C D

CU-3KE19NBU

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

4 each

Cushion rubber 4

1

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

16. Vacuum pump (For R410A)

17. Manifold valve

Reducer (1/2" 3/8")

CU-4KE24NBU

CU-4KE31NBU

Packed in the outdoor unit.

1

2

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

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-MKE7NKU, CS-MKE9NKU, CS-MKE12NKU

CS-MKE18NKU

CS-MKE24NKU

CS-MKE9NB4U, CS-MKE12NB4U

CS-KE18NB4UW

Outer Dia. Thickness Outer Dia. Thickness

1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)

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

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

1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)

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

Narrow Tube Wide Tube

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 5. Wiring Instructions for details.

CAUTION

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

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

4

2. Installation Site Selection

2-1. Indoor Unit

To prevent abnormal heat generation

WARNING

AVOID:

 direct sunlight.

 nearby heat sources that may affect performance of the

unit.

 areas where leakage of flammable gas may be expected.

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

Drain hose

Outside drainage

Fig. 1

For wall-mounted units

 placing or allowing any obstructions near the air conditioner

inlet or outlet.

 installing in rooms that contain instant-on (rapid-start)

fluorescent lamps. (These may prevent the air conditioner from receiving signals.)

 places where large amounts of oil mist exist.

 installing in locations where there are devices that

generate high-frequency emissions.

DO:

 select an appropriate position from which every corner of

the room can be uniformly air-conditioned. (High on a wall is best for wall-mounted types.)

 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

unrestricted air flow around the unit. (Fig. 2a or 2b)

 install the unit within the maximum elevation difference

(H1, H2, H3, H4) above or below the outdoor unit and within a total tubing length (L1+L2+L3, L1+L2+L3+L4) from the outdoor unit as detailed in Table 3 and Fig. 3a.

INDOOR UNIT (1)

Elevation difference (H1)

H4

INDOOR UNIT (4)

Tubing length (L1)

OUTDOOR UNIT

L4

L2

L3

INDOOR UNIT (2)

INDOOR UNIT (3)

H2

H3

2" (5 cm)

min.

Front View

Fig. 2a

For ceiling-mounted cassette units

3.3 ft. (1m)

3.3 ft.

(1m)

Fig. 2b

CAUTION

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mounted cassette unit will be degraded if the distance from the floor to the ceiling is greater than 10 ft. (3 m).

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air conditioner, do not install wall-mounted units less than 5' (1.5 m) from floor level. (Fig. 3b)

6" (15 cm) min.

(1m)

3.3 ft. (1m)

Indoor unit

Minimum height from floor level

5' (1.5 m)

Floor level

2" (5 cm)

min.

3.3 ft.

3.3 ft. (1m)

Wall

Fig. 3a

Fig. 3b

5

 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.

 install in a sturdy manner to avoid increased operating

noise.

Table 3

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

Allowable Tubing Length Total Tubing Length Difference of Additional

Model Tubing Length at Shipment (L1+L2+L3) or (H1, H2, H3, H4) Refrigerant

Per Unit (L1+L2+L3) or (L1+L2+L3+L4) (ft.) (oz./ft.)*

(ft.) (L1+L2+L3+L4) (ft.)

(ft.)

CU-3KE19NBU 82 150 (L1+L2+L3) 150 (L1+L2+L3) 50 —

CU-4KE24NBU 82 150 (L1+L2+L3+L4) 200 (L1+L2+L3+L4) 50 0.22

CU-4KE31NBU 100 150 (L1+L2+L3+L4) 230 (L1+L2+L3+L4) 50 0.22

* If total tubing length becomes 150 to 200 ft. (Max.) or 150 to 230 ft. (Max.), charge additional refrigerant (R410A) by 0.22 oz./ft.

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

6

2-2. Connecting Indoor Units

Figures (4a) – (4k) show the different types of indoor unit connections, including the use of a reducer. To select the required indoor unit to be connected, refer to the Combination Table that was included in the outdoor unit package.

(1) Connecting indoor unit for CU-3KE19NBU

(A)

3/8"(9.52mm)

3/8"(9.52

mm

Outdoor unit Indoor unit

C

1/4"(6.35

B

)

A

)

1/4"(6.35

mm

)

3/8"(9.52

mm

)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

Fig. 4a

(B)

3/8"(9.52mm)

3/8"(9.52

mm

Flare 3/8"(9.52

A joint for connecting tubes of different sizes (3/8"(9.52mm) 1/2"(12.70mm)) Supplied Reducer

Outdoor unit Indoor unit

C

1/4"(6.35mm)

B

)

A

)

Union 1/2"(12.70mm)

mm

)

1/4"(6.35

mm

)

3/8"(9.52

1/2"(12.70

mm

)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

)

(CS-MKE18NKU) (CS-KE18NB4UW)

(2) Connecting indoor unit for CU-4KE24NBU

(A)

(1/2"(12.70

Outdoor unit Indoor unit

D

1/2"(12.70mm)

3/8"(9.52

mm

1/4"(6.35

C

)

B

)

A

)

1/4"(6.35

mm

Fig. 4b

mm

) 3/8"(9.52mm)) Supplied Reducer

Union 3/8"(9.52mm)Flare 1/2"(12.70mm)

mm

)

3/8"(9.52

mm

)

Fig. 4c

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

7

(B)

1/2"(12.70

3/8"(9.52

mm

(C)

1/2"(12.70mm)

3/8"(9.52mm)

3/8"(9.52

mm

Outdoor unit Indoor unit

D

)

C

)

B

)

A

)

1/4"(6.35

mm

)

1/2"(12.70

3/8"(9.52

mm

)

Fig. 4d

(1/2"(12.70mm) 5/8"(15.88mm)) Locally purchased

Union 5/8"(15.88mm)Flare 1/2"(12.70mm)

Outdoor unit Indoor unit

D

1/4"(6.35

C

1/4"(6.35

B

)

A

)

1/4"(6.35

mm

5/8"(15.88mm)

)

3/8"(9.52

)

3/8"(9.52

)

3/8"(9.52

)

mm

)

(CS-MKE18NKU) (CS-KE18NB4UW)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

(CS-MKE24NKU)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

(D)

1/2"(12.70

3/8"(9.52

Fig. 4e

(3/8"(9.52 Locally purchased

Outdoor unit Indoor unit

D

mm

)

C

mm

)

B

)

A

)

1/4"(6.35

mm

)

mm

)

mm

)

mm

) 1/2"(12.70mm))

Union 1/2"(12.70

1/2"(12.70

mm

)

1/2"(12.70mm)

3/8"(9.52

mm

)

)Flare 3/8"(9.52mm)

)

Fig. 4f

(CS-MKE18NKU) (CS-KE18NB4UW)

(CS-MKE7NKU,CS-MKE9NKU,CS-MKE12NKU) (CS-MKE9NB4U,CS-MKE12NB4U)

8