Sanyo CH2672R, CH3072R, CH3672R, CH4872R, C2672R Installation Instructions Manual

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Page 1

INSTALLATION INSTRUCTIONS

– Split System Heat Pump Air Conditioner –

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Units and Outdoor Units

Indoor Unit Type 26 30 36 48 Remarks

4-Way Air Discharge Semi-Concealed

Wall-Mounted

Ceiling-Mounted

Concealed-Duct UH2672R UH3672RU

Outdoor Units

Wired Remote

Controller

(WD)

Wireless Remote

Controller

(WL)

Timer Remote Controller

System Controller SHA-KC64UG (Optional part)SC

XH2672R XH3672R XH4872RX

KH2672R

KHH2672R Unit with Back-up heater

TH2672R TH3672R

THH2672R THH3672R

CH2672R CH3072R CH3672R CH4872R

C2672R C3072R C3672R C4872R

RCS-SH80UG (Optional part)

Built-in type: RCS-SH80UA.WL (Optional part) External type: RCS-BH80UA.WL (Optional part) Built-in type: RCS-SH1UA (Optional part)

RCS-TM80BGTRC

KH3072R KH3672R

TH4872R

Unit with Back-up heater

H/P

S/C

(WD)

(WL)

85464359863001 ©SANYO 2006

OPERATING LIMITS

 Maximum Conditions Cooling / Heating

Outdoor temperature : 109°F DB / 65°F WB Room temperature : 71°F WB / 80°F DB

 Minimum Conditions

Outdoor temperature : 0°F* DB / 5°F WB Room temperature : 57°F WB / 59°F DB

* When air discharge chamber is installed.

Units should be installed by licensed contractor according to local code requirements.

SANYO FISHER COMPANY In Canada A DIVISION OF SANYO NORTH SANYO Canada Inc. AMERICA CORPORATION 300 Applewood Crescent 21605 Plummer Street Concord, Ontario Chatsworth, CA 91311 U.S.A. L4K 5C7, Canada

TRC

Page 2

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.

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 or

WARNING

CAUTION

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

WARNING

• Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked.

• Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.

• Ground the unit following local electrical codes.

• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.

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 Wiring

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

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.

When Installing…

…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.

…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.

When Connecting Refrigerant Tubing

• Ventilate the room well, in the event that is refrigerant 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.

• Keep all tubing runs as short as possible.

• Use the flare method for connecting tubing.

• Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leak-free connection.

• Check carefully for leaks before starting the test run.

When Servicing

• Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring.

• Keep your fingers and clothing away from any moving parts.

• Clean up the site after you finish, remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced.

CAUTION

• Ventilate any enclosed areas when installing or testing the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas.

• Confirm after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas water heater, electric room heater or other heat source, it can cause the generation of poisonous gas.

Page 3

Check of Density Limit

The room in which the air conditioner is to be installed requires a design that in the event of refrigerant gas leaking out, its density will not exceed a set limit.

The refrigerant (R410A), which is used in the air conditioner, is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws imposed to protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its density should rise excessively. Suffocation from leakage of refrigerant is almost non-existent. With the recent increase in the number of high density buildings, however, the installation of multi air conditioner systems is on the increase because of the need for effective use of floor space, individual control, energy conservation by curtailing heat and carrying power, etc. Most importantly, the multi air conditioner system is able to replenish a large amount of refrigerant compared to conventional individual air conditioners. If a single unit of the multi air conditioner system is to be installed in a small room, select a suitable model and installation procedure so that if the refrigerant accidentally leaks out, its density does not reach the limit (and in the event of an emergency, measures can be made before injury can occur). In a room where the density may exceed the limit, create an opening with adjacent rooms, or install mechanical ventilation combined with a gas leak detection device. The density is as given below.

2. The standards for minimum room volume are as follows.

(1) No partition (shaded portion)

(2) When there is an effective opening with the adja-

cent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15% or larger than the respective floor spaces at the top or bottom of the door).

Outdoor unit

Refrigerant tubing

Indoor unit

(3) If an indoor unit is installed in each partitioned

room and the refrigerant tubing is interconnected, the smallest room of course becomes the object. But when mechanical ventilation is installed interlocked with a gas leakage detector in the smallest room where the density limit is exceeded, the volume of the next smallest room becomes the object.

Refrigerant tubing

Total amount of refrigerant (oz.)

Min. volume of the indoor unit installed room (ft.3)

< Density limit (oz./ft.

)

The density limit of refrigerant which is used in multi air conditioners is 0.3 oz./ft.

(ISO 5149).

NOTE

1. If there are 2 or more refrigerating systems in a single refrigerating device, the amount of refrigerant should be as charged in each independent device.

For the amount of charge in this example:

Outdoor unit

e.g., charged amount (22 lbs.)

Indoor unit

Room A Room B Room C Room D Room E Room F

The possible amount of leaked refrigerant gas in rooms A, B and C is 22 lbs. The possible amount of leaked refrigerant gas in rooms D, E and F is 33 lbs.

e.g., charged amount (33 lbs.)

Outdoor unit

Very small room

Small room

Mechanical ventilation device – Gas leak detector

Medium room

Large room

Indoor unit

3. The minimum indoor floor space compared with the amount of refrigerant is roughly as follows (when the ceiling is 9 ft. high):

430

ft.

Min. indoor floor space

Range below the

376

density limit of 0.3 oz./ft.

323

(countermeasures not needed)

269

215

161

108

Range above the density limit of 0.3 oz./ft. (countermeasures needed)

22 44 66

Total amount of refrigerant

lbs.

Page 4

Precautions for Installation Using New Refrigerant

1. Care regarding tubing

1-1. Process tubing

 Material: Use C1220 phosphorous deoxidized copper specified in JIS H3300 “Copper and Copper Alloy Seam-

less Pipes and Tubes.”

 Tubing size: Be sure to use the sizes indicated in the table below.

 Use a tube cutter when cutting the tubing, and be sure to remove any flash. This also applies to distribution

joints (optional).

 When bending tubing ø5/8" or smaller, use a bending radius that is 4 times the outer diameter of the tubing or larger.

Use sufficient care in handling the tubing. Seal the tubing ends with

CAUTION

Material O

Copper tube

Outer diameter 1/4 3/8 1/2 5/8

Wall thickness 1/32 1/32 1/32 5/128

1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A

refrigerant deterioration and compressor defects. Due to the features of the refrigerant and refrigerating machine oil, the prevention of water and other impurities becomes more important than ever.

caps or tape to prevent dirt, moisture, or other foreign substances from entering. These substances can result in system malfunction.

Unit: inch

2. Be sure to recharge the refrigerant only in liquid form.

2-1. Since R410A is a non-azeotrope, recharging the refrigerant in gas form can lower performance and cause

defects of the unit.

2-2. Since refrigerant composition changes and performance decreases when gas leaks, collect the remaining

refrigerant and recharge the required total amount of new refrigerant after fixing the leak.

3. Different tools required

3-1. Tool specifications have been changed due to the characteristics of R410A.

Some tools for R22- and R407C-type refrigerant systems cannot be used.

R407C tools

Item compatible Remarks

Manifold gauge Yes No Types of refrigerant, refrigerating machine oil, and

Charge hose Yes No To resist higher pressure, material must be changed.

Vacuum pump Yes Yes Use a conventional vacuum pump if it is equipped

Leak detector Yes No Leak detectors for CFC and HCFC that

Flaring oil Yes No For systems that use R22, apply mineral oil (Suniso oil)

New tool?

with R410A?

pressure gauge are different.

with a check valve. If it has no check valve, purchase and attach a vacuum pump adapter.

react to chlorine do not function because R410A contains no chlorine. Leak detector for HFC134a can be used for R410A.

to the flare nuts on the tubing to prevent refrigerant leakage. For machines that use R407C or R410A, apply synthetic oil (ether oil) to the flare nuts.

Manifold gauge

Vacuum pump

Outlet Inlet

* Using tools for R22 and R407C and new tools for R410A together can cause defects.

Page 5

3-2. Use R410A exclusive cylinder only.

 When charging with a refrigerant cylinder, use an

electronic scale for charging refrigerant. In this case, if the volume of refrigerant in the cylinder becomes less than 20% of the fully-charged amount, the composition of the refrigerant starts to change. Thus, do not use the refrigerant if the amount in the charging cylinder is less than 20%.

Also, charge the minimum necessary amount to the charging cylinder before using it to charge the air conditioning unit.

Configuration and characteristics of cylinders

Valve

Liquid

Single valve

Charge liquid refrigerant with cylinder in up-side-down position.

Fig. 1

Valve

Liquid

Single valve (with siphon tube)

Charge with cylinder in normal position.

Fig. 2

Page 6

CONTENTS

Page

IMPORTANT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Please Read Before Starting Check of Density Limit Precautions for Installation Using New Refrigerant

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

2. SELECTING THE INSTALLATION SITE . . . . 16

2-1. Indoor Unit 2-2. Outdoor Unit 2-3. Air-Discharge Chamber for Top Discharge 2-4. Installing the Unit in Heavy Snow Areas 2-5. Precautions for Installation in Heavy Snow

Areas 2-6. Dimensions of Wind Ducting 2-7. Dimensions of Snow Ducting

3. HOW TO INSTALL THE INDOOR UNIT . . . . 26

 4-Way Air Discharge Semi-Concealed Type

(X Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

3-1. Suspending the Indoor Unit 3-2. Preparation for Suspending 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. Before Installing the Ceiling Panel 3-7. Installing the Ceiling Panel 3-8. When Removing the Ceiling Panel

for Servicing

3-9. Duct for Fresh Air

 Wall-Mounted Type (K Type) . . . . . . . . . . . . . .34

3-10. Removing the Wall Fixture from the Unit 3-11. Selecting and Making a Hole 3-12. Installing the Rear Panel on the Wall 3-13. Removing the Grille to Install the Indoor Unit 3-14. Preparing the Indoor Side Tubing 3-15. Wiring Instructions 3-16. Wiring Instructions for Inter-Unit Connections 3-17. Shaping the Tubing 3-18. Installing the Drain Hose

 Ceiling-Mounted Type (T Type) . . . . . . . . . . . .47

3-19. Suspending the Indoor Unit 3-20. Duct for Fresh Air 3-21. Installing the Drain Piping

Page

 Concealed-Duct Type (U Type) . . . . . . . . . . . .51

3-22. Required Minimum Space for Installation and

Service 3-23. Suspending the Indoor Unit 3-24. Installing the Drain Piping 3-25. Checking the Drainage 3-26. Increasing the Fan Speed

4. HOW TO INSTALL THE OUTDOOR UNIT . . 56

4-1. Installing the Outdoor Unit 4-2. Drainage Work 4-3. Routing the Tubing and Wiring

5. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 57

5-1. General Precautions on Wiring 5-2. Recommended Wire Length and Wire

Diameter for Power Supply System 5-3. Wiring System Diagrams 5-4. How to Connect Wiring to the Terminal

6. HOW TO INSTALL THE WIRED REMOTE

CONTROLLER (OPTIONAL PART) . . . . . . . . 60

6-1. Installation Site Selection 6-2. Wired Remote Controller Installation 6-3. Basic Wiring Diagram 6-4. Wiring System Diagram for Group Control 6-5. Wiring System Diagram for Multiple Remote

Controllers 6-6. How to Switch the Indoor Temperature Sensor 6-7. Trouble Diagnostics

7. HOW TO INSTALL THE WIRELESS REMOTE

CONTROLLER (OPTIONAL PART) . . . . . . . . 68

7-1. Wireless Remote Controller Installation 7-2. Room Temperature Sensor Setting 7-3. Address Switches 7-4. Setting the Model Code

<RCS-SH80UA.WL>

 4-Way Air Discharge Semi-Concealed Type

(X Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

7-5. Indicator Section Installation 7-6. Operating Controller Installation

 Ceiling-Mounted Type (T Type) . . . . . . . . . . . .71

7-7. Indicator Section Installation 7-8. Operating Controller Installation 7-9. Electrical Wiring 7-10. Test Run Switch 7-11. Misoperation Alarm Indicators

Page 7

Page

<RCS-BH80UA.WL>

7-12. Separate Type Signal Receiving Unit Installation 7-13. Electrical Wiring 7-14. Test Run Switch 7-15. Misoperation Alarm Indicators 7-16. Basic Wiring Diagram 7-17. Wiring System Diagram for Group Control 7-18. Wiring System Diagram for Multiple Remote Controllers

<RCS-SH1UA>

7-19. Test Run Procedure 7-20. Check Items Before the Test Run 7-21. Preparing for the Test Run 7-22. Precautions

8. HOW TO INSTALL THE SYSTEM CONTROLLER

(OPTIONAL PART) . . . . . . . . . . . . . . . . . . . . 84

8-1. System Controller Installation 8-2. Electrical Wiring 8-3. Address Switch Setting 8-4. Mode Setting 8-5. How to Perform Zone Registration 8-6. Connection with Other Equipment 8-7. Memory Back Up Switch 8-8. Test Run

9. HOW TO PROCESS TUBING . . . . . . . . . . . . 96

9-1. Connecting the Refrigerant Tubing 9-2. Connecting Tubing between Indoor and

Outdoor Units 9-3. Insulating the Refrigerant Tubing 9-4. Taping the Tubes 9-5. Finishing the Installation

10. LEAK TEST, EVACUATION AND ADDITIONAL

REFRIGERANT CHARGE . . . . . . . . . . . . .100

10-1. Leak Test 10-2. Evacuation 10-3. Charging Additional Refrigerant 10-4. Finishing the Job

11. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . 103

11-1. Preparing for Test Run 11-2. Caution 11-3. Test Run Procedure 11-4. Items to Check Before the Test Run 11-5. Test Run Using the Remote Controller 11-6. Precautions 11-7. Table of Self-Diagnostic Functions and Corrections

(X, T, U, K Type)

11-8. Examples of Wiring Diagrams

Page 8

1. GENERAL

1-3. Type of Copper Tube and Insulation Material

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. Level

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)

1-2. Accessories Supplied with Outdoor Unit

See Tables 1-1 to 1-9.

Table Type

1-1 4-Way Air Discharge Semi-Concealed

1-2 Wall-Mounted

1-3 Ceiling-Mounted

1-4 Concealed-Duct

1-5 Outdoor Unit

1-6 Wired Remote Controller

1-7 Wireless Remote Controller

1-8 Timer Remote Controller

1-9 System Controller

Copper tubing for connecting the outdoor unit to the indoor unit is available in kits which contain the liquid and gas tubing, fittings and insulation. Consult your nearest sales outlet or A/C workshop.

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

1. Deoxidized annealed copper tube for refrigerant tubing.

2. Foamed polyethylene insulation for copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 5/16 in.

3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to Section 5. “Electrical Wiring” for details.

CAUTION

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

1-4. Additional Materials Required for Installation

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire

(See your local codes.)

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

Page 9

Table 1-1 XH (4-Way Air Discharge Semi-Concealed)

Part Name Figure

Full-scale installation diagram 1

Flare insulator 2

Washer 8

Insulating tape 1

(White)

Hose band 2

Packing 1

Drain insulator 1

Drain hose 1

Drain hose adaptor 1

Sealing putty 1

Tube connector 1

Table 1-2 KH (Wall-Mounted)

‘Q’ty

Wall fixture

Part Name Figure Remarks

Qʼty

Remarks

For determining suspension bolt pitch

For gas and liquid tubes

For suspending indoor unit from ceiling

For gas tube flare nuts

For securing drain hose

For drain joint

For drain outlet

For sealing recessed portion of power supply

For sizing up of liquid tube from 1/4 in. to 3/8 in. (only for 24 type)

For supporting the indoor unit

Insulator

Mounting plate

Tapping screw

Full-scale diagram

Wall fixture

Rawl plug

Cover

Tapping screw

Insulator

Tube connector

Truss-head Phillips 4 × 1 in.

Truss-head Phillips 4× 5/8 in.

For insulation of the tubing of the indoor unit

For securing the indoor unit

For fixing the wall fixture

For determining the place where the indoor unit is

installed

For supporting the indoor unit

For fixing the wall fixture

For improved tubing appearance

For fixing the wall fixture

For insulation of the tubing of the indoor unit

For sizing up of liquid tube from 1/4 in. to 3/8 in.

(only for 24 type)

L shape tube connector

KH3672R

KH3072R

KH3672R *

KH3072R

KH3672R

Simplifies on-site tubing work

Page 10

Table 1-3 TH (Ceiling-Mounted)

‘Q’ty

For temporarily suspending indoor unit

from ceiling

For drain hose joint

1 Set

For gas tube joints

Part Name Figure Remarks

Special washer

Drain insulator 1

Flare insulator

Drain hose adaptor 1

Drain hose clamp 4

Insulating tape

Black

White (heat-resisting)

Vinyl clamp 2

Full-scale installation diagram

Sealing putty 1

For gas tube and drain hose joint

For gas flare joints

For ends of flare insulator

For determining suspension

bolt pitch

For sealing recessed portion of power supply

Drain hose1

Tube connector 1

For sizing up of liquid tube from 1/4 in. to 3/8 in. (only for 24 type)

Table1-4 UH (Concealed-Duct)

Part Name Figure

‘Q’ty

Remarks

Flare insulator 2

(Black)

For gas and liquid tubes

Insulating tape

(White)

Tapping screw TOTA4-10

14 or 20 or 24

Jumper cable* 1

Hose band1

Packing 1

Sealing putty 1

Drain insulator 1

For gas and liquid tube flare nuts

For air intake duct connection

For increasing the fan speed

For securing drain hose

For drain joint

For sealing recessed portion of power supply

For drain joint

Drain hose1

Drain hose adaptor 1

Clamp 9

Tube connector 1

For securing drain hose & refrigerant tubing

For sizing up of liquid tube from 1/4 in. to 3/8 in. (only for 24 type)

* Jumper cable is housed inside the electrical component box.

Table 1-5 (Accessories for the Wired Remote Controller)

Part Name Figure

‘Q’ty

Part Name Figure

‘Q’ty

Wired remote controller (comes with 7-7/8 in. wire)

Machine screws M4 × 1 in.

Wood screws 2

1 Spacers 2

2 Wire joints 4

Page 11

Table 1-6 (Accessories for the Wireless Remote Controller)

<RCS-SH80UA.WL>

Part Name Figure

‘Q’ty

Part Name Figure

‘Q’ty

Operation controller 1 Spacers 2

Run Timer

Indicator section 14

Heating preparations

Wireless remote controller 1 2

Wireless remote controller mounting cradle

Pan-head tapping screws 4× 13/32 in.

Tr uss-head tapping screws 4 × 5/8 in.

Vinyl clamps

1 3

L 5-29/32

Batteries 2 Wire joints 4

<RCS-SH1UA>

Part Name Figure Part Name Figure

Wireless remote controller 1 2

‘Q’ty ‘Q’ty

Tr uss-head tapping screws 4 × 5/8 in.

Wireless remote controller

Batteries

mounting cradle

<RCS-BH80UA.WL>

Part Name Figure

Separate type signal receiving unit (comes with 7-7/8 in. wire)

‘Q’ty

Small screws

M4 × 1-9/16 in.

Part Name Figure

Carrier for ceiling installation 1Wood screws 2

Wireless remote controller 1 Spacers 4

Wireless remote controller

1 Wire joints 4

mounting cradle

Batteries 2 Clamp

Machine screws M4 × 1 in.

Ceiling installation paper pattern

(

3-3/4 × 2-1/32 in.

)

‘Q’ty

Page 12

Table 1-7 (Accessories for the Timer Remote Controller)

Part Name Figure

Timer Remote Controller

Connecting wiring length 4 ft.

Machine screws

‘Q’ty

Part Name Figure

1Wood screws

1 Spacers 2

2 Clamps

M4 × 1 in.

Table 1-8 (Accessories for the System Controller)

Part Name Figure

System controller 1 1

Rubber bushing (7/8 in.)

Screws for fixture (1-3/16 in.)

‘Q’ty

Label (Identification label)

Label

(Terminal base label)

Part Name Figure

SYSTEM CONTROLLER IDENTIFICATION LABEL

ALL Central Control ALL RCU.

ZONE1 Central Control

ZONE1 RCU.

ZONE2 RCU.

ZONE2 Central Control

ZONE3 Central Control

ZONE3 RCU.

ZONE4 Central Control

ZONE4 RCU.

*Please attach this label on surface of the lid after cleaning. *If need to write down some detail, use magic marker.

ALL ON

INPUT

Inter-

unit control wiring

ALL OFF

INPUT

COMMON

U2 Aux.

INPUT

OPERATION STATE

UNUSED

OUTPUT

ALARM OUTPUT

DC12V FROM INDOOR UNIT PCB.

COMMON OUTPUT

‘Q’ty

Page 13

1-5. Tubing Size

Single type

 Refrigerant tubing between the indoor and outdoor units

should be kept as short as possible.

 The length of the refrigerant tubes between the indoor

and outdoor units are limited by the elevation difference between the 2 units. During tubing work, try to make both the tubing length (L) and the difference in elevation (H1) as short as possible. Refer to Table 1-10.

Table 1-9

Indoor unit type 26, 30, 36 types 48 type

Maximuvg length 165 ft. 165 ft.

Charge-less tubing length (actual length) 10 – 100 ft. 15 – 100 ft.

Additional charge per 1 ft. 0.43 oz.

Single

Main tubing L

Maximum indoor-outdoor height difference

If outdoor unit is higher

If outdoor unit is lower

< 100

< 50

Page 14

Table 1-10 Tubing Data for Models

Models

Tubing Data

Tubing size

outer diameter

Liquid tube in. (mm) 3/8 (9.52) 3/8 (9.52) 3/8 (9.52) Gas tube in. (mm) 5/8 (15.88)5/8 (15.88)5/8 (15.88)

Limit of tubing length (ft.)

Limit of elevation difference between the 2 units

Outdoor unit is placed higher (ft.) Outdoor unit is placed

lower (ft.) Max. allowable tubing length at shipment (ft.) Required additional refrigerant *

(oz./ft.)

C(H)2672R

165 165 165

100 100 100

50 50 50

10 – 100 10 – 100 10 – 100

a) 0.43 b) 0.43 b) 0.43

C(H)3072R C(H)3672R

C(H)4872R

Refrigerant charged at shipment (lbs.) 4.2 6.2 7.9

No additional charge of compressor oil is necessary.

If total tubing length becomes 100 to 165 ft., charge additional refrigerant by 0.43 oz./ft.

Table 1-11 List of Connection Tube Sizes

Main tubing (L)

Type capacity of indoor units

Gas tube

Liquid tube

Amount of additional charge per 1 ft.

26 – 48

ø5/8" ø3/8"

0.43 oz.

Page 15

CAUTION

1. This unit requires no additional refrigerant charge up to 100 ft. tubing length. In case of more than 100 ft., additional refrigerant charge is required. Refer to Tables 1-11 and 1-12.

2. In case of multi type installation, indoor units should be installed within the same room. If multi type indoor units are installed in different rooms, temperature control may develop problems because thermostat operation must follow the thermostat condition of 1 indoor unit only (the main unit).

WARNING

Always check the gas density for the room in which the unit is installed.

 Check of limit density

When installing an air conditioner in a room, it is necessary to ensure that even if the refrigerant gas accidentally escapes, its density does not exceed the limit level. If the density might exceed the limit level, it is necessary to set up an opening between it and the adjacent room, or to install mechanical ventilation which is interlocked with the leak detector.

(Total refrigerant charged amount: oz.)

(Min indoor volume where the indoor unit is installed: ft.3)

Limit density 0.3 (oz./ft.3)

The limit density of refrigerant which is used in this unit

is 0.3 oz./ft.

(ISO 5149).

The shipped outdoor unit comes charged with the amount of refrigerant fixed for each type; so add it to the amount that is charged at the field. (For the refrigerant charge amount at shipment, refer to the unit’s nameplate.)

Minimum indoor volume & floor area relative to the amount of refrigerant is roughly as given in the following table.

ft.

538

484

430

376

323

269

215

161

Min. indoor floor area

(when the ceiling is 9 ft. high)

108

ft.

4,842

4,356

3,870

3,384

2,907

2,421

1,935

1,449

Min. indoor volume

Range below the density limit of

0.3 oz./ft. (Countermeasures not needed)

972

486

Total amount of refrigerant

Range above the density limit of

0.3 oz./ft. (Countermeasures needed)

44 66 88 lbs.

CAUTION

Pay special attention to any location, such as a basement or recessed area, etc. where leaked refrigerant can collect, since refrigerant gas is heavier than air.

Page 16

2. SELECTING THE INSTALLATION SITE

Ceiling-Mounted Type

2-1. Indoor Unit

AVOID:

 areas where leakage of flammable gas may be

expected.

 places where large amounts of oil mist exist.

 direct sunlight.

 locations near inverter lamps which may affect the

performance of the unit.

 locations near heat sources which may affect the

performance of the unit.

 locations where external air may enter the room

directly. This may cause “sweating” on the air discharge ports, causing them to spray or drip.

 locations where the remote controller will be splashed

with water or affected by dampness or humidity.

 installing the remote controller behind curtains or

furniture.

 locations where the receiver in the indoor unit is

exposed to the inverter lamp light. Faulty operation of the unit occurs.

Ceiling

Wall

Min. 10 inch

Front view

Min. 10 inch

NOTE

The rear of the indoor unit can be installed flush against the wall.

Air discharge

Min. 2 ft.

Ceiling

Air intake

Side view

4-Way Air Discharge Type

Concealed-Duct Type

DO:

 select an appropriate position from which every

corner of the room can be uniformly cooled.

 select a location where the ceiling is strong enough

to support the weight of the unit.

 select a location where tubing and drain pipe have

the shortest run to the outdoor unit.

 allow room for operation and maintenance as well as

unrestricted air flow around the unit.

 install the unit within the maximum elevation

difference above or below the outdoor unit and within a total tubing length (L) from the outdoor unit as detailed in Table 1-11.

 allow room for mounting the remote controller about

3 ft. off the floor, in an area that is not in direct sunlight nor in the flow of cool air from the indoor unit.

NOTE

Air delivery will be degraded if the distance from the floor to the ceiling is greater than 10 ft.

3 ft.

Min. 6 inch

3 ft.

Wall-Mounted Type

Min. 6 inch

Min. 12 inch

Page 17

2-2. Outdoor Unit

AVOID:

 heat sources, exhaust fans, etc. (Fig. 2-1)

 damp, humid or uneven locations

DO:

 choose a place as cool as possible.

 choose a place that is well ventilated and outside

air temperature does not exceed maximum 115°F constantly.

 allow enough room around the unit for air intake/

exhaust and possible maintenance. (Fig. 2-2)

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

vibration and noise.

 if cooling operation is to be used when the outdoor

air temperature is 23°F or below, install a duct on the outdoor unit.

Installation space

Distance between obstructions and the unit air inlet and outlet must be as shown below.

More than 25/64"

Inlet side C

Outlet side More than

3.3 ft.

More than 25/64"

*4*2

Hot air

Air direction chamber

(field supply)

Outdoor unit

Fig. 2-1

(Obstruction above unit)

Exhaust fan

Heat source

Inlet side More than 8"

(Obstruction on inlet side)

Fig. 2-2

CAUTION

 Concerning inlet-side distance “C” (Fig. 2-2)

The minimum for distance “C” is 6" if there are no obstructions on the outlet side (wall *1 side) and *2 or *4 is not present. In all other cases, the minimum for distance “C” is 8".

 If the unit is installed with the outlet side facing wall *1, then there must be no obstruc-

tions on 2 of the remaining 3 sides: *2, *3, *4.

 If wall *1 is on the outlet side (Fig. 2-2), or if obstructions are present on all 3 sides *2,

*3, and *4 (Fig. 2-2), then the minimum distance for “A” and “B” is 80" (Fig. 2-3). Even if there is no wall on the outlet side, a minimum of 3.3 ft. is required.

Installation requirements

 provide a solid base (concrete block, 4" × 16"

beams or equal), a minimum of 6" above ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Fig. 2-4)

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

vibration and noise.

(Ground)

Fig. 2-3

Anchor bolts (4 pieces)

Fig. 2-4

Page 18

2-3. Air-Discharge Chamber for Top Discharge

Be sure to install an air discharge chamber in the field when:

 it is difficult to keep a space of min. 20" between

the air discharge outlet and an obstacle.

 the air discharge outlet is facing a sidewalk and

discharged hot air may bother passers-by. Refer to Fig. 2-5.

2-4. Installing the Unit in Heavy Snow Areas

In locations with strong wind, snow-proof ducting should be fitted and direct exposure to the wind should be avoided as much as possible.

 Countermeasures against snow and wind

In regions with snow and strong wind, the following problems may occur when the outdoor unit is not provided with a platform and snow-proof ducting:

a) The outdoor fan may not run and damage to the

unit may occur.

b) There may be no air flow.

c) The tubing may freeze and burst.

d) The condenser pressure may drop because of

strong wind, and the indoor unit may freeze.

Air discharge

Fig. 2-5

In regions with significant snowfall, the outdoor unit should be provided with a platform and snow-proof duct.

2-5. Precautions for Installation in Heavy Snow

Areas

(1) The platform should be higher than the max. snow

depth. (Fig. 2-6)

(2) The 2 anchoring feet of the outdoor unit should be

used for the platform, and the platform should be installed beneath the air intake side of outdoor unit.

(3) The platform foundation must be firm and the unit

must be secured with anchor bolts.

(4) In case of installation on a roof subject to strong

wind, countermeasures must be taken to prevent the unit from being blown over.

Without snowproof ducting (Low platform)

Fig. 2-6

Outdoor Unit

Duct

Air Intake

With snowproof ducting (High platform)

Fig. 2-7

Page 19

2-6. Dimensions of Wind Ducting

Reference diagram for air-discharge chamber (field supply)

STK–DRV80U for 2672R / 3072R / 3672R unit

1 Air discharge chamber

2 Air discharge chamber (base)

3-ø5/32 hole

Note: In snowy regions, if there is concern that snow may enter the air discharge

STK-DRE140A for 4872R unit

9-27/32

21-13/16

6-ø15/64 hole

22-7/16

23-15/32

21-39/64

5-3/16

9-27/329-27/32

1-1/16

15/16 17/32

(25/32)

Rectangular hole (both sides)

5-5/32

chamber, remove the base of the chamber (10 screws) before using.

(25/32)(25/32)

Unit: inch

1 Unit front, air discharge chamber

2 Unit left side, air discharge chamber

3 Unit light side, air discharge chamber

4 Reinforcement brackets, 4 locations

9-7/161-1/8

Rectangular hole

1-3/821-5/3212-15/32

2-3/4

11-13/16

22-13/32 21-13/3211

9-27/32

12-7/329-27/32

39-1/4

42-29/32

9-7/16

Rectangular hole

1-1/8

12-15/3221-5/32

Unit: inch

1-3/8

2-3/4

Page 20

Dimensions of Outdoor Unit with air-discharge chamber (field supply)

2672R / 3072R / 3672R unit with STK-DRV80U

4-5/16

13/32

14-31/32

15-15/16

Wind

direction

13-3/8

6-11/16

25-31/32

1/2 1/2

Wind direction

2-17/32

30-23/32

Wind direction

23/32

21-13/16

Wind direction

4872R unit with STK-DRE140A

1/2 1/2

Wind

direction

13-3/8

25-31/326-11/16

Wind direction

1/2

Wind direction

4-5/16

25/32 25/32

25/3225/32

19/32

21-5/8 4-1/16

14-31/32 13/3219/32

9-27/32

Wind direction

5-3/16

Unit: inch

15-15/16

2-11/36 21-13/32

Wind direction

48-7/16

Wind direction

23/32

11-13/16

Wind direction

1/2

4-1/439-1/4

11- 13/ 16

Wind direction

Unit: inch

Page 21

Reference diagram for air-discharge chamber (field supply)

More than 15-3/4

More than 11-13/16 More than 11-13/16

More than 7-7/8

C(H)2672R / 3072R / 3672R / 4872R with STK-DRV80U & DRE140A

Required space around outdoor unit

If the air discharge chamber is used, the space shown below must be secured around the outdoor unit. If the unit is used without the required space, a protective device may activate, preventing the unit from operating.

(1) Single-unit installation

Min. 7-7/8

Min. 39-3/8

Unit: inch

CAUTION

The top and both sides must remain open. If there are obstacles to the front and rear of the outdoor unit, the obstacle at either the front or rear must be no taller than the height of the outdoor unit.

(2) Multiple-unit installation



Installation in lateral rows

CAUTION

The front and top must remain open. The obstacles must be no taller than the height of the outdoor unit.



Installation in front-rear rows

Installation with intakes facing outlets Installation with intakes facing

Unit: inch

intakes or outlets facing outlets

More than 59-1/16

CAUTION

The front and both sides must remain open.

More than 15-3/4

More than 78-3/4

Unit: inch

Page 22

2-7. Dimensions of Snow Ducting

Reference diagram for snow-proof vents (field supply)

STK-BDRE80A for 2672R / 3072R / 3672R unit

1 Unit top, snow-proof vent

2 Unit left side

3 Unit right side

4 Unit reverse side

5 Unit reverse side

6 Unit sides, reinforcement brackets for snow-proof vent

Fastened by screws at 13 locations

25-13/32

17-15/32

9-3/16

16-25/32

27-29/32

Fastened by screws at 3 locations (also on reverse side)

Unit anchor hole

Fastened by screw at 1 location (also on reverse side)

(6 – ø7 hole)

STK-BDR140U for 4872R unit

5-3/32

19-11/16

1-21/32

25/32

3-3/4

30-3/32

19-11/16

28-3/4

30-11/16

11-29/32

3-31/32

9-3/8

13-25/32

5/8

9-3/16

16-25/32

27-29/32

Unit: inch

1 Unit top, snow-proof vent

2 Unit left side

3 Unit right side

4 Unit reverse side

5 Unit reverse side

6 Unit sides, reinforcement brackets for snow-proof vent

9-3/16

28-13/16

47-19/32

Fastened by screws at 3 locations (also on reverse side)

25-13/32

17-15/32

Fastened by screws at 13 locations

3-3/4 19-11/16

25-32

5-29/32

17-23/3219-11/16

30-3/32

Unit anchor hole

(7 – ø7 hole)

13-5/1619-11/16

5/8

11-7/8

3-31/32

9-3/16

28-13/16

47-19/32

Fastened by screw at 1 location (also on reverse side)

15-9/32

1-5/8 28-3/4

30-5/8

1-13/16

Unit: inch

Page 23

Dimensions of outdoor unit with snow-proof vents (field supply)

2672R / 3072R / 3672R unit with STK-BDRE80A

Wind direction

25-13/32

Wind direction Wind direction

30-23/32

30-3/32

Wind direction

7-1/16

25/32

14-31/32 13/3219/32

3/4

Wind direction

15-15/16

11-29/32

Wind direction

16-3/4

4872R unit with STK-BDR140U

Wind direction

25-13/32

Wind direction

48-7/16

47-19/37

30-3/32

24-7/8

Wind direction

7-1/16

25/3225/32

14-31/32 13/3219/32

15-15/16

Wind direction

Unit: inch

11-29/32

28-13/16

Wind direction

Unit: inch

Page 24

Reference diagram for snow-proof vents – 1

Space requirements for setting – (1) C(H)2672R / 3072R / 3672R / 4872R with STK-BDRE80A & STK-BDR140U

[Obstacle to the rear of unit]

[Obstacle to the front of unit]

Top is open: Top is open:

(1) Single-unit installation

(2) Obstacles on both sides

Min. A

Min. B

Min. C

(1) Single-unit installation

Min. D

(2) Multiple-unit installation (2 or more units)

(3) Multiple-unit installation (2 or more units)

Min. G

Min. E M in. E

Note: In cases 2 and 3 the height of the obstacle must be no taller than the height of the outdoor unit.

Outdoor unit

C(H)2672R / 3072R /

3672R / 4872R

Top is blocked by an obstacle:

Outdoor unit

Min. E

Min. F

C(H)2672R / 3072R /

3672R / 4872R

5-29/32

11-13/16

7-7/8

11-13/16

5-29/32

7-7/8

Min. I Min. I

19-11/16

Min. H

Min. J

11-13/16J39-3/8

Top is blocked by an obstacle:

Min. L

Min. K

Outdoor unit

C(H)2672R / 3072R /

3672R / 4872R

19-11/16

5-29/32

Min. M

Outdoor unit

C(H)2672R / 3072R /

3672R / 4872R

39-3/8

Min. N

39-3/8

Unit: inch

Page 25

Reference diagram for snow-proof vents – 2

Space requirements for setting – (2) C(H)2672R / 3072R / 3672R / 4872R with STK-BDRE80A & STK-BDR140U

[Obstacles to the front and rear of unit]

The top and both sides must remain open. Either the obstacle to the front or the obstacle to the rear must be no taller than the height of the outdoor unit.

(1) Single-unit installation

Min. P

Dimension Q If a snow protection duct is attached after the unit is

installed, verify that dimension Q is 19-11/16 in. or more.

Min. O

Outdoor unit

C(H)2672R / 3072R /

3672R / 4872R

39-3/8

5-29/32

(2) Obstacles on both sides

Min. 11-13/36

Min. 11-13/16

Min. 7-7/8

Min. 39-3/8

[Installation in front-rear rows]

• The top and both sides must remain open. Either the obstacle to the front or the obstacle to the rear must be no taller than the height of the outdoor unit.

Min. 11-13/16

Min. 39-3/8 Min. 7-7/8

Min. 59-1/16 Min. 78-3/4

Dimension Q If a snow protection duct is

attached after the unit is installed, verify that dimension Q is 19-11/16 in. or more.

Unit: inch

Page 26

3. HOW TO INSTALL THE INDOOR UNIT

 4-Way Air Discharge Semi-Concealed Type

(X Type)

3-1. Suspending the Indoor Unit

This unit uses a drain pump. Use a carpenter’s level to

Hole-in-anchor Hole-in-plug

Concrete Insert

check that the unit is level.

3-2. Preparation for Suspending

(1) Fix the suspension bolts securely in the ceiling

using the method shown in the diagrams (Figs. 3-1 and 3-2), by attaching them to the ceiling support structure, or by any other method that ensures that the unit will be securely and safely suspended.

Suspension bolt (M10 or 3/8") (field supply)

Fig. 3-1

(2) Follow Fig. 3-2 and Table 3-1 to make the holes in

the ceiling.

Table 3-1

Type

XH2672R

(PNR-XH2442)

XH3672R, XH4872R

(PNR-XH3642)

Length

32-9/32 (820) 22-9/32 (566)

43-11/16 (1,110) 33-11/16 (856)

Unit: inch (mm)

A (Ceiling opening)

(Suspension bolt pitch)

)gninepo gnilieC( 23/9-23

Grille center

Drain hose side

(3) Determine the pitch of the suspension bolts using

the supplied full-scale installation diagram. The diagram and table (Fig. 3-3 and Table 3-2) show the relationship between the positions of the suspension fitting, the unit, and the panel.

Refrigerant tubing joint (gas tube side)

Suspension lug

Table 3-2

Type

Length

ABCDE

Unit: inch (mm)

XH2672R 6-3/16 7-5/32 10-9/32 12-1/8 4-7/8

(PNR-XH2442) (157) (182) (261) (308) (124)

XH3672R, XH4872R 6-3/16 7-5/32 11-15/3213-1/16 4-7/8

(PNR-XH3632) (157) (182) (291) (338) (124)

nsion bolt pitch)epsuS( 61/31-92

Fig. 3-3

Fig. 3-2

Refrigerant tubing side

Drain connection (other side)

(VP25)

Refrigerant tubing joint (liquid tube side)

61/3

Page 27

3-3. Placing the Unit Inside the Ceiling

(1) When placing the unit inside the ceiling, determine

the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 3-4) The size of the opening for the indoor unit can be confirmed by attaching the full-scale installation diagram beneath the unit. (Fig. 3-4) Tubing and wiring must be laid inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing and wiring into position for connection to the unit before placing the unit inside the ceiling.

erom ro hcni 23/91

Full-scale installation diagram (printed on a cardboard packing)

Full-scale installation

diagram

hc n

i 8/7-

Fig. 3-4

(2) The length of each suspension bolt must be

appropriate for a distance between the bottom of the bolt and the bottom of the ceiling of 19/32 in. or more as shown in Fig. 3-4.

(3) Thread the 2 hexagonal nuts (field supply) and

washers onto the 4 suspension bolts as shown in Fig. 3-5. Use 2 sets of nuts and washers (upper and lower), so that the unit will not fall off the suspension lugs.

(4) Remove the protective cardboard used to protect

the fan parts during transport.

(5) Adjust the distance between the unit and surface

of the ceiling. (1-7/8 in.) (Fig. 3-4)

Nuts and washers

(Use above and below)

Double nuts

Suspension bolt

Suspension lug

Upper

Lower

Notch

1-7/8 inch

Fig. 3-5

Page 28

3-4. Installing the Drain Piping

(1) Prepare standard hard PVC pipe for the drain and

Transparent part for checking drainage

Hose band (supplied)

Hard PVC pipe (not supplied)

use the supplied drain hose and hose band to prevent water leaks.

The PVC pipe must be purchased separately. The transparent part allows you to check drainage. (Fig. 3-6)

CAUTION

Tighten the hose clamps so their locking nuts face upward.

Packing (supplied)

Drain hose (supplied)

Fig. 3-6

Drain hose adapter (supplied)

(Fig. 3-6)

Drain insulator (supplied)

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe. (Fig. 3-7)

NOTE

Ensure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

CAUTION



Do not install an air bleeder tube, as this may cause water to spray from the drain tube outlet. (Fig. 3-8)



If it is necessary to increase the height of the drain pipe, the section directly after the connection port can be raised a maximum of 19-11/16 in. Do not raise it any higher than 19-11/16 in., as this could result in water leaks. (Fig. 3-9)



Do not install the pipe with an upward gradient from the connection port. This will cause drain water to flow backwards and leak when the unit is stopped. (Fig. 3-10)



Do not apply force to the piping on the unit side when connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-11)



Provide insulation for any drain pipe that is run indoors.

Fig. 3-7

Air bleeder

Fig. 3-8

11-3/4 in. or less (as short as possible)

19-11/16 in. or less

Fig. 3-9

Upward gradient

Fig. 3-10

Support pieces

Fig. 3-11

Page 29

3-5. Checking the Drainage

After wiring and piping are completed, use the following procedure to check that the water will drain smoothly. For this, prepare a bucket and wiping cloth to catch and wipe up spilled water.

Do not supply power to the

WARNING

unit until the tubing and wiring to the outdoor unit are completed.

(1) Take off the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain pan to check drainage.

(2) Do Test Run to check the drainage after complet-

ing installation. When performing Test Run, be sure to observe the Test Run procedure. Refer to page 104.

Be careful since the fan will

CAUTION

start turning when checking the drainage.

5/16"(4 × 8 mm) tapping screw

(3) After drain checking is finished, return the Opera-

tion Selector switch to the RUN position (ON position ) and remount the tube cover.

To mount the tube cover, use

WARNING

5/16" (4

××

8 mm) tapping screws. Do not use long screws as they may puncture the drain pan and cause water leakage.

Tube cover

Siphon

Fig. 3-12

Page 30

 Ceiling Panel

Latch

Screw

Never touch or attempt to

CAUTION

move the air direction louver by hand or you may damage

the unit. Instead, use the remote control unit if you want to change the direction or air

Air-intake grille

flow.

3-6. Before Installing the Ceiling Panel

(1) Remove the air-intake grille and air filter from the

ceiling panel. (Figs. 3-13 and 3-14)

Ceiling panel

(a) Remove the 2 screws on the latch of the air-

intake grille. (Fig. 3-13)

(b) Press on the 2 latches of the air-intake grille

with your thumbs in the direction of the arrow to open the grille. (Fig. 3-13)

remove the safety cord (hook on the grille side). (Fig. 3-14)

(d) Pull the air-intake grille towards you to remove

it from the ceiling panel.

(2) Pull down the two panel catches on the body of

the indoor unit body. (Fig. 3-15)

Ceiling panel

Panel catch

Electrical component box

Fig. 3-13

Safety cord

Unit body

Panel catch (arrange facing downwards)

(2 locations)

Fig. 3-14

Air filter

45°

Clamp

Ceiling panel wiring connector

Screws M5 with washer

(supplied)

Air filter

Air-intake grille

Fig. 3-15

Page 31

3-7. Installing the Ceiling Panel

(1) Lift the ceiling panel and position it to align the

panel hook with the panel catch of the indoor unit.

NOTE

The ceiling panel must be mounted in the correct direction. Note that the 2 catches of the panel differ in size. Confirm that the catches are correctly matched between the ceiling panel and the indoor unit body.

(2) Next, check to see that the ceiling panel is prop-

erly aligned with the seamline of the ceiling. If it is not, remove the ceiling panel and slightly readjust the indoor unit body to the proper suspension point.

(3) When the ceiling panel has been properly aligned,

use the supplied 4 mounting screws (M5) with washers to permanently fasten the ceiling panel.

(4) Install the wiring connector from the ceiling panel

to the connector in the electrical component box of the indoor unit. After installing the connector, use the clamp on the body of the indoor unit to secure the wiring.

(5) Install the air filter and air-intake grille by perform-

ing the steps in section 3-6 in reverse.

NOTE

Rehook the safety cord before closing the air-intake grille.

3-8. When Removing the Ceiling Panel

for Servicing

When removing the ceiling panel for servicing, remove the air-intake grille and air filter, disconnect the wiring connector inside the electrical component box, and then remove the 4 mounting screws.

Page 32

3-9. Duct for Fresh Air



There is a duct connection part on side of the indoor

For fresh air intake

unit. (Fig. 3-16)



An optional air-intake plenum (including duct connection

box and flange) can be attached to the indoor unit.

Air-intake plenum Type

CMB-GSJ80U

CMB-GSJ140U

PNR-XH2442

(XH2672R)

PNR-XH3642

(XH3672R, XH4872R)

8/3-2

2-5/32

ø-

/31-4ø

(1) Accessories



Check that the following parts are in the box when unpacking.

Name RemarksʻQʼty

Cord with socket (9P) intaking fresh air.

Screw (M5 × L5 in.) (for fastening)

Screw (M4 × L1/2 in.) (for fastening)

Duct connection box 1 (for fresh air)

Duct connection flange1

Connecting line. Not necessary for

Air-intake filter

Duct connection flange / box

(for connecting fresh air duct

(2) Installation



Installation steps (a) to (d) are the same for both the CMB-GSJ80U and the CMB-GSJ140U. The figure illustrates installation of air-intake plenum to the indoor unit. (Fig. 3-17)

(a) Installing the air-intake plenum



Set the air-intake plenum to the indoor unit taking care not to set it in the wrong direction. (Fig. 3-17)



Fasten the air-intake plenum with the accessory screws. (M5 × L5 in., 4 pcs) (Fig. 3-17)

(b) Installing the duct connection box



Fasten the duct connection flange to the duct connection box with the accessory screws. (M4 × L1/2 in., 4 pcs) (Fig. 3-18)



Put the duct connection box into the rectangular hole of the air-intake plenum and fasten it to both sides of the indoor unit and plenum with the accessory screws. (M4 × L1/2 in., 3 pcs) (Fig. 3-18)



Install the indoor unit to the ceiling. (Install the indoor unit according to items 3-1 to 3-6.)

Installation screws

Air-intake plenum

Indoor unit

Detail of fresh air intake

Fig. 3-16

)

Socket cover

Panel lead wire (8P)

Clamper

8P socket (red) (electrical component box)

8P socket (red) (ceiling panel side)

When installing in a pre-

CAUTION

existing location, install the indoor unit before installing the duct connection box.

Fig. 3-17

Page 33

(d) Installing the ceiling panel



Attach the ceiling panel to the chamber. Drawing the panel downwards sets the panel in position temporarily with the panel catch (at 2 locations).



Remove the socket cover of the air-intake plenum and pass the 8P sockets through it. (Fix the panel lead wire with the chamber side clamp.) (Fig. 3-17)



Connect the 8P socket (electrical component box side) to the 8P socket (ceiling panel side) of the indoor unit electrical component box.



Reattach the socket cover.

Duct connection flange

Installation screws

(M4 × 1/2 in.)

Panel catch

Ceiling panel

Duct connection box

Fig. 3-18

Page 34

 Wall-Mounted Type (K Type)

3-10. Removing the Wall Fixture from the Unit

KH2672R

Remove and discard the set screws and take off the rear panel. (Fig. 3-19)

NOTE

Set screws for transportation only

Fig. 3-19

Tubing can be extended in 3 directions as shown in Fig. 3-20. Select the direction that provides the shortest run to the outside unit.

Left-rear tubling

Right-rear tubing (recommended)

3-11. Selecting and Making a Hole

KH2672R

(1) Remove the rear panel from the indoor unit and

place it on the wall at the location selected. Make sure the unit is horizontal using a carpenter’s level or tape measure to measure down from the ceiling.

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

the hole. (Fig. 3-21)

(3) Before making a hole, check carefully that no studs

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

Also avoid areas where electri-

CAUTION

cal wiring or conduits are located.

Fig. 3-20

In case of left-rear or right-rear tubing

Center of left-rear tubing hole

Fig. 3-21

Right tubing

Center of right-rear tubing hole

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

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

drill attachment, cut a hole in the wall. See Table 3-3 and Fig. 3-22.

Table 3-3

Hole Dia. (inch)

3-3/16"

(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" shorter than the thickness of the wall. (Fig. 3-23)

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

indoor side only) and insert in the wall. (Fig. 3-24)

NOTE

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

PVC pipe (locally purchased)

Indoor side

Outdoor side

Fig. 3-22

INSIDE

Wall

Plastic cover

(Field supply)

OUTSIDE

Slight angle

Fig. 3-24

Cut at slight angle

Fig. 3-23

PVC pipe

Page 35

KH3072R, KH3672R

One hole is required for the air conditioner tubing, and may be either on the left or right side. (Also see section 3-14. Preparing the Indoor Side Tubing.)

(1) Tape the full-scale installation diagram on the wall

at the location selected. Make sure the unit is horizontal using a level or tape measure to measure down from the ceiling. (Fig. 3-25)

(2) Determine if the hole is to be drilled at the left or

right hole location.

(3) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid any area where electrical

CAUTION

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

(4) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-26)

(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 in. shorter than the thickness of the wall. (Fig. 3-27)

Tape

Full-scale installation diagram

Fig. 3-25

NOTE

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

Indoor side

Outdoor side

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

(for indoor side only) and insert in the wall. (Fig. 3-28)

Fig. 3-26

PVC pipe (locally purchased)

Cut at slight angle

Fig. 3-27

INSIDE

Plastic cover

Wall

Fig. 3-28

OUTSIDE

PVC pipe

Slight angle

Page 36

KHH2672R

Remove and discard the set screws and take off the wall fixture. (Fig. 3-29)

KHH2672R

Wall fixture

(1) Tape the full-scale installation diagram on the wall

at the location selected. Make sure the unit is hori-

zontal using a level or tape measure to measure down from the ceiling. (Fig. 3-30)

(2) Before drilling a hole, check that there are no studs

Set screws only for transportation

Fig. 3-29

Tape

lacs-lluF

noitallatsni e

margaid

or pipes behind the determined location.

Avoid any area where electrical

CAUTION

wiring or conduit is located. Also take this precaution if the tubing goes through a wall at any other location.

(3) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the wall. The required minimum hole diameter for these models is 3-3/16 in. (Fig. 3-31)

NOTE

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

Fig. 3-30

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

edge to the outside edge and cut PVC pipe at a

Indoor side

Outdoor side

slight angle 1/4 in. shorter than the thickness of the wall. (Fig. 3-32)

(5) Place the plastic cover over the end of the pipe,

(for indoor side only) and insert in the wall. (Fig. 3-33)

Fig. 3-31

PVC pipe (locally purchased)

Cut at slight angle

Fig. 3-32

INSIDE

Plastic cover

Wall

Fig. 3-33

OUTSIDE

PVC pipe

Slight angle

Page 37

3-12. Installing the Rear Panel on the Wall

KH2672R

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 10 screws provid-

ed. (Fig. 3-34) If you are not able to line up the holes in the rear panel with the beam locations marked on the wall, use toggle bolts to go through the holes on the panel or drill 3/16 in. dia. holes in the panel over the stud locations and then mount the rear panel.

(2) Double-check with a ruler or carpenter’s level that the

panel is level. This is important to install the unit properly. (Fig. 3-35)

(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" dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-36)

KH3072R, KH3672R

Fig. 3-34

Fig. 3-35

1-3/16

Fig. 3-36

or more

3/16

dia. hole

Rawl plug (Field supply)

Confirm that the wall is strong enough to support the unit.

a) If Wooden Wall

(1) Attach the wall fixture to the wall with the 12 screws pro-

vided. (Fig. 3-37) If you are not able to line up the holes in the wall fixture 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 in. dia. holes in the wall fixture over the stud locations.

(2) Check with a tape measure or carpenter’s level that the

wall fixture is level. This is important so that the unit is correctly installed.

(3) Make sure the wall fixture 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 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-36)

Wall fixture

Fig. 3-37

Page 38

KHH2672R

wall fixture

Confirm that the wall is strong enough to support the unit.

a) If Wooden Wall

(1) Attach the wall fixture to the wall with the 9 screws

provided. (Fig. 3-38)

If you are not able to line up the holes in the wall fixture with the beam locations marked on the wall,

Fig. 3-38

use rawl plugs or toggle bolts to go through the holes on the panel or drill 13/64 in. dia. holes in the panel over the stud locations and then mount the wall fixture.

3/16 in. dia. hole

(2) Check with a tape measure or carpenter’s level

that the wall fixture is level. This is important so that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the wall.

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

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for appropriate mounting screws. (Fig. 3-39)

Rawl plug

Fig. 3-39

Page 39

3-13. Remove the Grille to Install the Indoor Unit

Grille

KH2672R

Basically, these models can be installed and wired without removing the grille. If access to any internal

part is needed, follow the steps given below:

How to remove the grille

(1) Set the 2 flaps in the horizontal position.

(2) Unscrew the 3 screws. (Fig. 3-40a)

(3) Remove the grille.

(a) Hold both corners of the air intake grille, then

pull out and up to open. (Fig. 3-40b)

(b) Use a standard screwdriver to push up the 3

tabs to remove the grille. (Fig. 3-40b)

remove. (Fig. 3-40a)

How to replace the grille

Air-intake grille

Fig. 3-40a

Air-intake grille

Fig. 3-40b

(1) Close the flaps.

(2) Reinstall the grille into the lower part while aligning

its tabs on the upper part. (Fig. 3-41a) Insert the tabs in the slots and push the lower part of the grille back into position.

(3) Press at each of the 5 tabs to completely close the

grille. Make sure that the grille and frame are firmly fitted together. (Fig. 3-41b)

Fig. 3-41a

Fig. 3-41b

Page 40

KH3072R, KH3672R

How to Remove the Grille

(1) Remove the plastic cover. (Fig. 3-42)

(2) Remove the clamp for the wiring connector.

(Fig. 3-43)

(3) Disconnect the 2 wiring connectors. (Fig. 3-44)

Plastic cover

Screw

(4) Set the flap in the horizontal position. (Fig. 3-45)

(5) Remove the 3 screws. (Fig. 3-45)

Fig. 3-42

(6) Remove the grille. (Fig. 3-45)

NOTE

When replacing the grille, be careful not to crush the lead wires between the grille and the frame. (Fig. 3-45)

Clamp

Screw

Fig. 3-43

Grille

Flap

Screws

Wiring connectors

Fig. 3-44

Frame

Fig. 3-45

Page 41

3-14. Preparing the Indoor Side Tubing

Indoor unit

Bottom cover

Left side cover

Right side cover

L-shaped tube

Frame

KH2672R

Arrangement of tubing by directions

(a) Right tubing

The corner of the right frame needs to be cut by a hacksaw or the like. (Fig. 3-46)

(b) Right-rear or left-rear tubing

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

To mount the indoor unit on the rear panel:

(a) Hang the 3 mounting slots of the unit on the

upper tabs of the rear panel. (Fig. 3-47)

KH3072R, KH3672R

Tubing can be extended in 4 directions as shown in Fig. 3-54.

Arrangement for Right-rear Tubing

Mounting slot

Right tubing outlet

Fig. 3-46

Ta b

Fig. 3-47

Tubing from the outdoor unit

(a) Remove the 2 screws and slide out the side

cover. (Fig. 3-48)

(b) Extend the gas tube from the outdoor side and

connect it directly to the mating tube inside the indoor unit. Use a flare nut. (Fig. 3-49)

Arrangement for Right Tubing

(a) Remove the 2 screws and take off the side cover.

(Fig. 3-48)

(b) Cut out the L-shaped tubing outlet using a

hacksaw. (Fig. 3-50)

connect tubing between the indoor and outdoor units. (Fig. 3-52)

Arrangement for Left and Left-rear Tubing.

(a) Remove the 4 screws (2 on each side) and take

off both left and right side cover. (Fig. 3-51)

Fig. 3-48

Fig. 3-49

Hacksaw

Fig. 3-50

Fig. 3-51

(b) Remove 4 screws to remove the bottom cover.

tubing as in Fig. 3-53.

Fig. 3-52

L-shaped tube

Fig. 3-53

Page 42

KHH2672R

Tubing can be extended in 4 directions as shown in Fig. 3-54.

Arrangement for Left Tubing

Left tubing

Left-rear tubing

Right-rear tubing (Recommended)

(a) Cut out the left tubing outlet. (Fig. 3-55)

Right tubing

Arrangement for Right Tubing

Fig. 3-54

(a) Cut out the right tubing outlet using a hacksaw.

(Fig. 3-56)

Arrangement for Left-rear and Right-rear Tubing

(a) It is not necessary to cut a hole.

Left tubing outlet

Right tubing outlet

3-15. Wiring Instructions

General Precautions on Wiring

Fig. 3-55

Fig. 3-56

(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. A power supply disconnect and circuit breaker for overcurrent protection should be provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded.

(4) All wiring must be connected tightly.

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

compressor, or any moving parts of the fan.

Unauthorized changes in the

WARNING

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.

Page 43

3-16. Wiring Instructions for Inter-Unit Connections

KH2672R

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

electrical codes) into the through-the-wall PVC pipe. Run the wiring toward the indoor side allowing approx. 10 inches to extend from the wall face. (Fig. 3-57)

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

indoor unit and pull it toward the front for connection. (Figs. 3-58a and 3-58b)

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

terminals on the terminal plate (Figs. 3-58a and 3-58b) while referring to the wiring diagram.

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

clamp.

How to remove the cover plate

To access the terminal plate inside the indoor unit, follow these steps.

Rear panel

Wiring

10 in.

Fig. 3-57

Wall

Plastic cover

Terminal plate

(1) Using a Phillips screwdriver, remove the screw on

the cover plate. (Figs. 3-58a and 3-58b)

(2) Remove the cover plate.

Cover plate

Fig. 3-58a

Inter-unit

control line

wiring

Earth plate

Lock nut

Top of conduit connector

Fig. 3-58b

Page 44

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

KHH2672R

codes) into the through-the-wall PVC pipe. Run the wiring toward the indoor side allowing approx. 5" to extend from the wall face. (Figs. 3-59a and 3-59b)

Never fix the wiring by any

CAUTION

means before the indoor unit is fully seated on the rear panel.

Rear panel

Wiring

Wall

Plastic cover

(2) Remove the side cover and the metallic cover.

(Fig. 3-60 or 3-61, depending on model.)

(3) Secure the conduit connector to the chassis with a

lock nut. (Fig. 3-60 or 3-61)

Fig. 3-59a

(4) Give some play to the inter-unit wiring from the

outdoor unit to the corresponding terminals on the terminal plate.

 Be sure to refer to the wiring

CAUTION

system diagram label inside the metallic cover and carry

KH3072R, KH3672R

Wall fixture

Wall

out the correct field wiring. Wrong wiring can cause the unit to malfunction.

 Check local electrical codes

Connector Wiring

and any specified wiring instructions or limitations.

(5) Secure the metallic cover with its screw. Then

replace the side cover.

KHH2672R

Lock nut

Power line

Grounding line

Look nut

Elbow conduit

Metallic cover

Plastic cover

Screw

Fig. 3-59b

KH3072R, KH3672R

Metallic cover

Lock nut

Connector

Side cover

Fig. 3-60

Fig. 3-61

Page 45

KHH2672R

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

the wall hole. (Fig. 3-62)

If using a stepladder, be careful to

CAUTION

(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.

(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.

CAUTION

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

performing a leak test on the connecting part, insulate it with tubing insulation. (Fig. 3-64)) Also, refer to Section 10-5. Connecting Tubing between Indoor and Outdoor Units.

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

inter-unit wiring as shown in Fig. 3-65.

keep your balance and not fall off. To prevent the unit from damage and avoid personal injury, ask for someone’s help when feeding the tubing through the hole because the unit is heavy and difficult to hold in place.

The air conditioner’s performance will deteriorate if a tube is crushed. To prevent crushing of tubing, avoid sharp bends. Use a pipe bending tool to bend tubes. (Fig. 3-63)

Cover

Fig. 3-62

Pipe bending tool

Fig. 3-63

Fig. 3-64

Refrigerant tubing

Conduit

Fig. 3-65

Refrigerant tubing

Inter-unit wiring

Drain hose

b / a = 0.7 or more

Insulation (Field supply)

Drain hose

Inter-unit wiring

KH3072R, KH3672R

(1) Shape the narrow refrigerant tube and drain hose in the

desired direction so that they can easily go into the wall hole. (Fig. 3-66)

(2) Push the wiring, narrow tube, and drain hose through

the hole in the wall.

(3) Bend the tubing (if necessary) to run along the wall in

the direction of the outdoor unit, then tape as far as the fittings. The drain hose should come straight down the wall to a point where water runoff won't stain the wall.

(4) Hang the indoor unit on the wall fixture. (Fig. 3-67)

(5) Install the mounting plate to secure the indoor unit

solidly to the wall. The plate can be positioned in either of the 2 ways shown. (Fig. 3-68)

Screws

Fig. 3-66

Drain hose

Fig. 3-68

Liquid tube

Mounting plate

Wall

Indoor unit

Wall fixture

Fig. 3-67

Page 46

3-17. Shaping the Tubing

Cover

KHH2672R

Refrigerant tubing

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

into the hole. (Fig. 3-69)

Inter-unit

(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 wall fixture.

Fig. 3-69

Drain hose

wiring

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

along the wall in the direction of the outdoor unit and then insulate to the end of the fittings. The drain hose should come straight down the wall to a point where water runoff will not stain the wall.

(4) Connect the refrigerant tubing to the outdoor

Fig. 3-70

Insulating tape

unit.(After performing a leak test on the connection, insulate it with insulating tape. (Fig. 3-70)) Also, refer to Section 10-5. Connecting Tubing between Indoor and Outdoor Units.

(5) Assemble the refrigerant tubing, drain hose and

Refrigerant tubing

Inter-unit wiring

inter-unit wiring as shown in Fig. 3-71.

Drain hose

Fig. 3-71

3-18. Installing the Drain Hose

(1) The drain hose should be slanted downward on the

outdoor side. (Fig. 3-72)

(2) Never form a trap in the course of the hose.

(3) If the drain hose will run in the room, insulate* the

hose so that chilled condensation will not damage furniture or floors. (Fig. 3-73)

* Foamed polyethylene or its equivalent is

recommended.

Do not supply power to the unit

WARNING

or operate it until all tubing and wiring to the outdoor unit are completed.

Indoor unit

Fig. 3-72

Insulation material (field supply) must be used.

Fig. 3-73

Slant

Drain hose

Condensation

Page 47

 Ceiling-Mounted Type (T Type)

3-19. Suspending the Indoor Unit

ront face

(1) Place the full-scale diagram (supplied) on the

ceiling at the spot where you want to install the indoor unit. Use a pencil to mark the drill holes. (Fig. 3-74).

NOTE

Since the diagram is made of paper, it may shrink or stretch slightly because of high temperature or humidity. For this reason, before drilling the holes maintain the correct dimensions between the markings.

(2) Drill holes at the 4 points indicated on the full-scale

diagram.

(3) Depending on the ceiling type:

(a) Insert suspension bolts as shown in Fig. 3-75.

(b) Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-76.

Rear

Hole-in-anchor Hole-in-plug

Full-scale diagram

Fig. 3-74

Concrete Insert

Suspension bolt (M10 or 3/8") (field supply)

Fig. 3-75

Ceiling tiles

Ceiling support

It is important that you use

WARNING

extreme care in supporting the indoor unit from the ceiling. Ensure that the ceiling is sufficiently strong enough to support the weight of the unit. Before hanging the ceiling unit, test the strength of each attached suspension bolt.

(4) Screw in the suspension bolts, allowing them to

protrude from the ceiling as shown in Fig. 3-76. The distance of each exposed bolt must be of equal length within 2 inches. (Fig. 3-77)

unit

Fig. 3-76

Fixture

Fig. 3-77

Ceiling surface

.n i 2

iht i W

Page 48

(5) Before suspending the indoor unit, remove the 2

screws on the latch of the air-intake grilles, open the grilles, and remove them by pushing the claws of the hinges as shown in Fig. 3-78. Then remove both side panels sliding them along the unit toward the front after removing the two screws which fix them. (Fig. 3-79)

Screw

Latch

Pull out the air-Intake grille pushing claws of the hinges

edil

Hinge

(6) Preparation for suspending the indoor unit. The

suspension method varies depending on whether the unit is next to the ceiling or not. (Figs. 3-80 and 3-81)

Air-intake grille

Fig. 3-78

Slide toward front side

Side panel

unit

Fig. 3-79

Fixture

Fig. 3-80

Fig. 3-81

Suspension bolt (field supply)

Ceiling surface

Washer (supplied)

Double nut (field supply)

Suspension bolt (field supply) Washer (field supply)

Washer (supplied)

Double nut (field supply)

Page 49

(7) Suspend the indoor unit as follows.

(a) Mount a washer and two hexagonal nuts on

each suspension bolt as shown in Fig. 3-82.

(b) Lift the indoor unit, and place it on the

washers through the notches, to fix it in place. (Fig. 3-83)

Washer

(supplied)

Suspension bolt

. x orppA

Ceiling surface

Nut (field supply)

h c n

i 1

suspension bolt to suspend the indoor unit as shown in Fig. 3-84.

NOTE

A ceiling surface is not always level. Please confirm that the indoor unit is evenly suspended. For the installation to be correct, leave a clearance of about 3/8 in. between the ceiling panel and the ceiling surface and fill the gap with an appropriate insulation or filler material.

(8) If the tubing and wiring are to go towards the rear

of the unit, make holes in the wall. (Fig. 3-85)

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

to the outside and cut PVC pipe at a slight angle to fit. Insert the PVC pipe in the wall. (Fig. 3-86)

Fig. 3-82

Fig. 3-83

PVC pipe (locally purchased)

Fig. 3-84

Indoor side

Fig. 3-85

INSIDE

Cut at slight angle

Fig. 3-86

Outdoor side

Wall

OUTSIDE

PVC pipe

Slight angle

Page 50

3-20. Duct for Fresh Air

There is a duct connection port (knock-out hole) at the right-rear on the panel top of the indoor unit for drawing in fresh air. If it is necessary to draw in fresh air, remove the cover by knocking it out and connect the duct to the indoor unit through the connection port. (Fig. 3-87) If connection at the right-rear on the panel top is not appropriate, another duct connection port can be made by cutting an opening on the left side of the rear panel of the indoor unit as shown in Fig. 3-88.

Duct connection port (Knock-out hole)

Panel Top

Fig. 3-87

3-21. Installing the Drain Piping



Prepare a standard PVC pipe for the drain and connect it to the indoor unit drain pipe with the supplied hose clamps to prevent water leaks.



Connect the drain piping so that it slopes downward

Right side

Rear side

4-11/32"

from the unit to the outside. (Fig. 3-89)



Never allow traps to occur in the course of the piping.



Insulate any piping inside the room to prevent dripping.



Use the supplied drain pipe to connect the drain pipe with the drain outlet of the indoor unit.



After connecting the drain pipe securely, wrap the

Cut this portion

TH3672R, TH4872R, THH3672RTH2672R, THH2672R

A 3-15/16" 7-3/32"

1-3/8" 1-31/32"

Fig. 3-88

3-15/16"

supplied drain pipe insulator around the pipe, seal the gap at the drain socket with the supplied black insulation tape, then secure it with clamps.

Min. 1/100

(Fig. 3-90)



After the drain piping, pour water into the drain pan to check that the water drains smoothly.

Good

Check local electrical codes

CAUTION

and regulations before obtaining wire. Also, check any specified instruction or limitations.

Packing (supplied)

Not good

Fig. 3-89

Drain hose (supplied)

Fig. 3-90

Drain pipe clamp (supplied)

Hard PVC pipe (not supplied)

Drain hose adapter (supplied)

Page 51

 Concealed-Duct Type (U Type)

3-22. Required Minimum Space for

Installation and Service



This air conditioner is usually installed above the

A (Suspension bolt pitch)

ceiling so that the indoor unit and ducts are not visible. Only the air intake and air outlet ports are visible from below.



The minimum space for installation and service is

min. 9-27/32

23/72-22

Indoor Unit

shown in Fig. 3-91 and Table 3-4.



It is recommended that space is provided (17-23/32 × 17-23/32 in.) for checking and servicing the electrical system.



Fig. 3-92 and Table 3-5 show the detailed dimensions of the indoor unit.

Table 3-4

Air outlet duct flange

Fig. 3-91

Unit: inch (mm)

Type 26 36

A (Length) 42-17/32 (1,080) 61-13/32 (1,560)

Number of duct flanges 34

Table 3-5

Dimension

Type

UH2672R

UH3672R

ABCDEFGHIJK

37-7/8

56-25/32

3-17/32

23 /9

35-7/16 9-21/32

(7-3/32×5)

54-11/32 19-9/32

(9-1/16×6)

23/5-28/

23/31

).D.O(

4/1-01

13/32

23/

23/31

/13

)noisnemid gninepo gnilieC(

23/51-3

61/3

61/5

)hctip tlob

23/72-22

noisnepsuS(

23/13

39-3/8 42-17/32 11-13/32 2-23/32 38-19/32 39-31/32 5-1/8

58-9/32 61-13/32 13-3/16 12-7/32 57-15/32 58-27/32 5-1/8

Refrigerant tubing joint (liquid tube) Refrigerant tubing joint (gas tube) Upper drain port (O.D. 1-1/4 in.) Bottom drain port (O.D. 1-1/32 in.) Suspension lug

Power supply outlet (2-ø1-3/16 hole) Fresh air intake port (ø5-29/32 hole) Flange for the flexible air outlet duct (ø7-7/8 hole)

Tube cover

Electrical component box

Flange for the air intake duct (Option or field supply)

M-ø1/8

(Hole)

Inspection access

(17-23/32

17-23/32)

(Field supply)

23/71-4

Inspection access panel

L-ø1/4 (Hole)

E E E F 2-15/16

A (O.D.)

H (Duct suspension bolt pitch) G (Ceiling opening dimension)

C D (5-29/32)

(Suspension bolt pitch)

13/32

IJJK

3/43/4

4-ø15/32

(Hole)

1-7/321-7/32

1-9/16

2-9/16

31/32 8-9/32

23/1361/31-42

23/31

61/3-14/3-2

6 1

/5-6

23/13

23/11-3

2-3/4

23/72-9

.nim

4/3-51

.nim

(9-21/32×1)

(9-21/32×2)

12-7/32

31/32 6-7/8

1-3/8

5-1/8

11-7/32

Ceiling

Electrical component box

Inspection access

17-23/32

Refrigerant tubing

min. 25-19/32

Unit: inch (mm)

9-27/32 12 16

9-7/16 16 18

23/ 51

Unit: inch

No. of holes

Fig. 3-92

Page 52

3-23. Suspending the Indoor Unit

Hole-in-anchor Hole-in-plug

Concrete Insert

Depending on the ceiling type:

• Insert suspension bolts as shown in Fig. 3-93 or

• Use existing ceiling supports or construct a suitable support as shown in Fig. 3-94.

Suspension bolt (M10 or 3/8") (field supply)

It is important that you use

WARNING

extreme care in supporting the

Fig. 3-93 indoor unit inside the ceiling. Ensure that the ceiling is strong enough to support the weight of

Ceiling tiles

Ceiling support

the unit. Before hanging the unit, test the strength of each attached suspension bolt.

(1) When placing the unit inside the ceiling,

determine the pitch of the suspension bolts referring to the dimensional data on the previous page. (Fig. 3-92) Tubing must be laid and connected inside the ceiling when suspending the unit. If the ceiling is

Fig. 3-94

already constructed, lay the tubing into position for connection to the unit before placing the unit inside

Suspension bolt

the ceiling.

Suspension lug

(2) Screw in the suspension bolts allowing them to

protrude from the ceiling as shown in Fig. 3-93. (Cut the ceiling material, if necessary.)

Nuts and washers

(2 sets)

Upper

(3) Thread the 2 hexagonal nuts and washers (field

supply) onto the 4 suspension bolts as shown in Figs. 3-95 and 3-96. Use 2 sets of nuts and washers (upper and lower), so that the unit will not fall off the suspension lugs.

Lower

Fig. 3-95

Suspension bolt

Hexagonal nut

Fig. 3-96

Page 53



Fig. 3-97 shows an example of installation.

Bolt anchor

Air outlet duct

Air-outlet grille

Ceiling material Indoor unit

3-24. Installing the Drain Piping

(1) Prepare standard hard PVC pipe for the drain and

use the supplied hose band to prevent water leaks. The PVC pipe must be purchased separately. When doing this, leave a gap between the drain socket of the unit and the PVC pipe to allow the drainage to be checked. The transparent drain pipe allows you to check drainage. (Fig. 3-98)

Tighten the hose clamps so

CAUTION

their locking nuts face upward. (Fig. 3-98)

Fig. 3-97

Air-intake grille

Transparent part for checking drainage

Packing (supplied)

Drain hose (supplied)

Suspension bolt

Air-intake duct

Hose band (supplied)

Drain hose adapter (supplied)

Fig. 3-98

Hard PVC pipe (not supplied)

(2) After connecting the drain piping securely, wrap the

supplied packing and drain pipe insulator around the pipe, then secure it with the supplied clamps. (Fig. 3-99)

NOTE

Make sure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

Clamps (supplied)

Drain insulator (supplied)

Fig. 3-99

Page 54

CAUTION

Air bleeder

 Do not install an air bleeder tube as this may cause

Not good

water to spray from the drain pipe outlet. (Fig. 3-100)

 If it is necessary to increase the height of the drain

pipe, the section directly after the connection port

Fig. 3-100

can be raised a maximum of 19-11/16 in. Do not raise it any higher than 19-11/16 in., as this could result in water leaks. (Fig. 3-101)

 Do not install the pipe with an upward gradient from

Good

11-13/16 in. or less

19-11/16 in. or less

the connection port. This will cause the drain water to flow backward and leak when the unit is not operating. (Fig. 3-102)

 Do not apply force to the piping on the unit side

when connecting the drain pipe. The pipe should not

be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-103)

No good

Fig. 3-101

Upward gradient

3-25. Checking the Drainage

After wiring and drain piping are completed, use the following procedure to check that the water will drain

Fig. 3-102

smoothly. For this, prepare a bucket and wiping cloth to catch and wipe up spilled water.

Support pieces

(1) Connect power to the power terminal board (L1, L2

terminal) inside the electrical component box.

(2) Remove the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain pan to check drainage.

(3) Short the check pin (CN5 white) on the indoor control

board and operate the drain pump. Check the water flow and see if there is any leakage.

Be careful since the fan will start

CAUTION

when you short the pin on the indoor control board.

(4) When the check of drainage is complete, open the

check pin (CN5 white) and remount the insulator and drain cap onto the drain inspection port.

To mount the tube cover, use 5/16"

CAUTION

(4 ××8 mm) tapping screws. Do not use long screws as they may puncture the drain pan and cause water leak-age.

Good

Fig. 3-103

Page 55

3-26. Increasing the Fan Speed

If external static pressure is too great (due to long extension of ducts, for example), the air flow volume may drop too low at each air outlet. This problem may be solved by increasing the fan speed using the following procedure:

(1) Remove 4 screws on the electrical component box

and remove the cover plate.

(2) Disconnect the fan motor sockets in the box.

(3) Take out the booster cable (sockets at both ends)

clamped in the box.

(4) Securely connect the booster cable sockets

between the disconnected fan motor sockets in step 2 as shown in the Fig. 3-104.

(5) Place the cable neatly in the box and reinstall the

cover plate.

Fan

motor

Electrical component box

Booster cable

Fan motor socket

(At shipment) (Booster cable installed)

Fig. 3-104

 How to read the diagram

The vertical axis is the external static pressure (Pa) while the horizontal axis represents the air flow (CFM). The characteristic curves for “HT”, “H”, “M” and “L” fan speed control are shown. The nameplate values are shown based on the “H” air flow. For the 26 type, the air flow is 636 CFM, while the external static pressure is 49 Pa at “H” position. If external static pressure is too great (due to long extension of duct, for example), the air flow volume may drop too low at each air outlet. This problem may be solved by increasing the fan speed as explained above.

er usserP citatS

la nr

txE

150

100

) aP

(

tim

Air Flow (CFM)

NOTE

26 Type

Indoor Fan Performance

200

)aP(

) qAn

150

(

0.5

0.4

0.3

0.2

700500300

0.1

900

erusserP c

100

tatS lanretx

0 500 1000

HT : Using the booster cable

36 Type

enil

timiL

enil t

imi

Air Flow (CFM)

0.8

)qAni(

0.6

0.5

0.4

0.3

0.2

0.1

H : At shipment

Fig. 3-105

Page 56

4. HOW TO INSTALL THE OUTDOOR UNIT

4-1. Installing the Outdoor Unit

 Use concrete or a similar material to create the base, and

ensure good drainage.

 Ordinarily, ensure a base height of 2 in. or more. If a drain

pipe is used, or for use in cold-weather regions, ensure a height of 6 in. or more at the feet on both sides of the unit. (In this case, leave clearance below the unit for the drain pipe, and to prevent freezing of drainage water in coldweather regions.)

 Refer to the Fig. 4-1 for the anchor bolt dimensions.

 Be sure to anchor the feet with the anchor bolts (M10). In

addition, use anchoring washers on the top side. (Use large square 32 × 32 SUS washers with diameters of 10.) (Field supply)

4-2. Drainage Work

Follow the procedure below to ensure adequate draining for the outdoor unit.

 For the drain port dimensions, refer to the figure at right.

 Ensure a base height of 6 in. or more at the feet on both

sides of the unit.

 When using a drain pipe, install the drain socket (optional

part STK-DS25T) onto the drain port. Seal the other drain port with the rubber cap supplied with the drain socket.

 For details, refer to the instruction manual of the drain

socket (optional part STK-DS25T).

4-3. Routing the Tubing and Wiring

 The tubing and wiring can be extended out in 4 directions:

front, rear, right, and down.

 The service valves are housed inside the unit. To access

them, remove the inspection panel. (To remove the inspection panel, remove the 3 screws, then slide the panel downward and pull it toward you.)

(1) If the routing direction is through the front, rear, or right,

use a nipper or similar tool to cut out the knockout holes for the inter-unit control wiring outlet, power wiring outlet, and tubing outlet from the appropriate covers A and B.

(2) If the routing direction is down, use a nipper or similar tool

to cut out the lower flange from cover A.

 Route the tubing so that it does

CAUTION

not contact the compressor, panel, or other parts inside the unit. Increased noise will result if the tubing contacts these parts.

 When routing the tubing, use a

tube bender to bend the tubes.

Drain port (2 locations)

6-47/64

13-13/64

11-21/32

33/64 33/64

Drain port

Inter-unit control wiring outlet

Inspection panel

Cover A

Power wiring outlet

8-5/8

Front

25-63/64

5-29/32

942

Fig. 4-1

Fig. 4-2

33/6433/64

Down

Tubing outlet

4-3/8

25/32

25/6414-61/64

15-15/16

3/4

19/32

Anchor bolt (M10)

Rear

Cover B

Right

Page 57

5. ELECTRICAL WIRING

5-1. 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, and a power supply disconnect and circuit breaker for overcurrent protection should be provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded.

(4) Each wiring connection must be done 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.

(7) Regulations on wire diameters differ from locality

to locality. For field wiring rules, must follow your LOCAL ELECTRICAL CODES before beginning. You must ensure that installation complies with all relevant rules and regulations.

(8) To prevent malfunction of the air conditioner

caused by electrical noise, care must be taken when wiring as follows:

 The remote control wiring and the inter-unit

control wiring should be wired apart from the inter-unit power wiring.

 Use shielded wires for inter-unit control wiring

between units and ground the shield on both sides.

(9) If the power supply cord of this appliance is dam-

aged, it must be replaced by a repair shop appointed by the manufacturer, because specialpurpose tools are required.

(10) All wiring used must be Class 1.

5-2. Recommended Wire Length and Wire Diameter for Power Supply System

You must follow LOCAL ELECTRICAL CODES for wiring.

Outdoor Unit

Model Name (A) Power Supply

CH2672R

CH3072R

CH3672R

CH4872R

AWG #12

Max. length 64 ft.

AWG #10

Max. length 92 ft.

AWG #10

Max. length 92 ft.

AWG #10

Max. length 81 ft.

Model Name (A) Power Supply

C2672R

C3072R

C3672R

C4872R

AWG #12

Max. length 76 ft.

AWG #10

Max. length 99 ft.

AWG #10

Max. length 99 ft.

AWG #10

Max. length 81 ft.

Trade Size

of Conduit

3/4 in.

MOP

(Fuse or HACR

type circuit breaker)

30 A

35 A (230/208 V)

Power Supply Terminal Base

Capacity Max. Wire Diameter

50 A

3/4 in. 1-1/4 in.50 A AWG #640 A

Trade Size

of Conduit

type circuit breaker)

3/4 in.

3/4 in. 1-1/4 in.50 A AWG #6

MOP

(Fuse or HACR

25 A

30 A (230/208 V)

35 A

Power Supply Terminal Base

Capacity Max. Wire Diameter

50 A

* AWG = American Wire Gauge

AWG #6

Trade Size

of Conduit

1-1/4 in.

Trade Size

of Conduit

1-1/4 in.

Page 58

Indoor Unit

MOP

(Fuse or HACR

Type

(B) Power Supply

AWG #14

Trade Size

of Conduit

type circuit breaker)

3/4 in. 15 AMax. length 67 ft.X, K, T, U

Control Wiring

AWG #18

Use high voltage wire (300 V)

AWG #18

(0.75 mm2)

Max. 1,650 ft.Max. 3,300 ft. Max. 1,650

5-3. Wiring System Diagrams

Basic wiring diagram for standard control

Indoor

Power supply

208 / 230 V, 60 Hz

Remote controller

WHT

BLK

1 2

L1 L2

Ground

unit

Ground

(E) Control Wiring For Group Control

*2 –

(0.75 mm2)

– ft. (Total)

With ring-type wire terminal. Wire joint connection.

Power supply

208 / 230 V, 60Hz

Outdoor unit INV unit

AWG #18

NOTE

(1) Refer to Section 5-2. Recommended Wire Length

and Wire Diameter for Power Supply System for the explanation of “A”, “B”, “C”, “D”, and “E”, in the above diagrams.

(2) Inter-Unit Control Wiring (C) and remote control-

ler wiring (D), (E) have no polarity. But for other wiring, respect polarity. Be sure to connect as shown in the Wiring System Diagram.

CH Type

5P terminal board

L1 L2 1 2

Inter-unit

power wiring

X, T, U Type

5P terminal board

Inter-unit

power wiring

K Type

4P terminal board

U1 U2

Inter-unit

control wiring

Inter-unit

control wiring

Inter-unit

control wiring

Inter-unit

power wiring

Remote

controller wiring

Remote

controller wirin

Page 59

Loose wiring may cause the

WARNING

terminal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, ensure that all

wiring is tightly connected.

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

Stranded wire

.ni 8/3 pirtS

Ring pressure terminal

Fig. 5-1

5-4. How to Connect Wiring to the Terminal

 For stranded wiring

(1) Cut the wire end with a wire cutter or wire-cutting

pliers, then strip the insulation to expose the stranded wiring about 3/8 in. (Fig. 5-1)

(2) Using a Phillips head screwdriver, remove the ter-

minal screw(s) on the terminal plate.

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

clamp each stripped wire end with a ring pressure terminal. (Fig. 5-1)

(4) Place the ring pressure terminal, and replace and

tighten the removed terminal screw using a screwdriver. (Fig. 5-2)

Special washer

Wire

Screw

Ring pressure terminal

Terminal plate

Fig. 5-2

Wire

Screw and Special washer

Ring pressure terminal

Page 60

6. HOW TO INSTALL THE WIRED REMOTE CONTROLLER (OPTIONAL PART)

(WD)

6-1. Installation Site Selection

 Install the remote controller at a height of between

3–5 ft. above the floor.

 Do not install the remote controller in a place where

it will be exposed to direct sunlight or near a window or other place where it will be exposed to the outside air.

 Be sure to install the remote controller vertically,

such as on a wall.

 The mounting position for the remote controller

should be located in an accessible place for control.

 Never cover the remote controller or recess it into

the wall.

Drainage Work

 When mounting the remote controller on a wall,

refer to Figs. 6-1 and 6-2.

Wall

Hole for routing remote control cable

JIS C8340 1 switchbox (no cover)

Wall

3-21/32 in. or more

(from wall)

Spacer

3-17/32 in. or more

(from wall)

Spacer

3-17/32 in. or more

(from wall)

4-29/32 in. or more (when continuous

installation)

4-29/32 in. or more

(when continuous

installation)

Fig. 6-1

4-29/32 in. or more (when continuous

installation)

Hole for routing remote control cable

JIS CB8340 2 switchboxes (no cover)

Fig. 6-2

Page 61

6-2. Wired Remote Controller Installation

 Do not supply power to the unit or try

WARNING

to operate it until the tubing and wiring to the outdoor unit are completed.

 Do not twist the control wiring with the

CAUTION

power wiring or run it in the same metal conduit, because this may cause malfunction.

 Install the remote controller away from

sources of electrical noise.

 Install a noise filter or take other

appropriate action if electrical noise affects the power supply circuit of the unit.

 If local electrical codes allow, this

remote controller can be mounted using a conventional wall box for flush mounting.

(1) When you open the decorative cover, you will see

two gaps under the remote controller. Insert a coin into these gaps and pry off the back case. (Fig. 6-4)

(2) Attach the back case with the 2 small screws

provided. Using a screwdriver, push open the cutouts on the back case. These holes are for screws. Use the spacers and take care not to tighten the screws excessively. If the back case will not seat well, cut the spacers to a suitable thickness. (Fig. 6-3)

(3) Connect the remote controller wiring (2 wires) cor-

rectly to the corresponding terminals in the electrical component box of the indoor unit.

When wiring, do not connect

CAUTION

the remote controller wires to the adjacent terminal block for the power wiring. Otherwise, the unit will break down.

Wired remote controller

M4 × 25 Screws (2)

Decorative cover

Control panel

Gap

Coin

Concealed box for 1

Spacer

(WD)

Under case (Back case)

Fig. 6-3

Gap

(4) To finish, fit the back tabs of the case into the

remote controller and mount it.

Fig. 6-4

Page 62

6-3. Basic Wiring Diagram

(WD)

CAUTION

Carry out wiring correctly (incorrect wiring will damage the equipment).

Use shielded wires for inter-unit control wiring and ground the shield on both sides. (Fig. 6-5) Otherwise misoperation because of noise may occur.

 Wiring procedure

Install the wiring according to the above wiring diagram.

 Address setting is automatically executed after turn-

ing on the system. An indoor unit address is assigned to each indoor unit.

 Operation takes place successively at intervals of 1

second, by using combinations of the address setting of each unit.

Shielded wire

Ground

Fig. 6-5

 Diagram of outer dimensions

2 3

5/32

4-23/32

/ 3

Ground

23/3

5/8

Page 63

6-4. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of 8) are controlled by a remote controller (main unit). In this case, a remote controller can be connected at any indoor unit.

 Wiring procedure

Wire according to the diagram at right:

 Address setting is executed automatically when

the outdoor unit is turned on.

 Group control using 2 remote controllers

It does not matter which of the 2 remote controllers you set as the main controller. When using multiple remote controllers (up to 2 of them can be used), one is the main remote controller and the other is the sub-remote controller.

 To set up a sub-remote controller, change its

remote control address connector (RCU. ADR) located on its PCB from main to sub position (main: when shipped from factory).

Remote controller (main)

Wire joint

Indoor unit

No. 1

Inter-unit control wiring

Connection wiring for group control

Wire joint

Indoor unit

No. 2

Remote controller

Indoor unit

No. 1

Outdoor unit

Indoor unit

(sub)

No. 3

: Ground (earth)

Indoor unit

No. 8

(WD)

Outdoor unit

: Ground (earth)

Page 64

6-5. Wiring System Diagram for Multiple Remote

Controllers

 When Installing Multiple Remote Controllers

(WD)

This multiple remote controller system is used for operating the unit(s) at different positions. (A maximum of 2 remote controllers can be installed.)

 Setting method

To execute this control, make the setting according to the following procedure.

(1) Of the 2 installed remote controllers, make 1 the

main remote controller (factory-shipped state).

(2) On the other remote controller, change the address

connector on the PCB from main to sub position. In this state, it functions as a sub-remote controller.

 Basic wiring diagram

Install wiring correctly

CAUTION

(incorrect wiring will damage the equipment).

To operate 1 indoor unit with 2 remote controllers set at different places.

Remote controller Remote controller

address connector

Main

RCU check

Sub

RCU. ADR

6-6. How to Switch the Indoor Temperature Sensor

The indoor unit and the remote controller both contain an indoor temperature sensor. The sensors on either unit can be used but normally only the sensor set on the indoor unit is used. However, use the following procedure if you must use the sensor on the remote controller.

(1) Press and hold the + + buttons for

at least 4 seconds. Note: The Unit No. first displayed is the main indoor unit address for group control. Note: Do not press the button.

(2) Select CODE NO. 32 with the Temp. setting ( )

/ buttons.

(3) Change the set data from 0000 to 0001 with the

Timer ( ) / buttons.

(4) Press the button. (Setting is OK if the blinking

display changes to a lit up display.)

(5) This is the usual off condition. At this time,

(remote controller) appears on the LCD display.

(sub)(main)

(Option)

Remote control cable terminal board

Earth

Indoor unit

Remote control cable

(wire it at the

installation site)

NOTE

*1 If using 2 remote controllers, either one (main or

sub-remote controller) can be used to make settings but only the main unit functions as the remote controller sensor.

*2 The remote controller sensor will not function during

group control unless the group address is set in the main remote controller indoor unit.

*3 Do not use the remote controller switch for the

remote control sensor if the remote sensor is being used jointly with the remote controller switch.

Page 65

6-7. Trouble Diagnostics

(1) Contents of remote controller switch alarm display

Possible cause of malfunction

Serial communication errors

Mis-setting

Remote controller is detecting error signal from indoor unit

Indoor unit is detecting error signal from remote controller (and system controller)

Improper setting of indoor unit or remote controller

Indoor unit is detecting error

signaled from signal option

Setting error

Indoor unit is detecting error signaled from outdoor unit

Outdoor unit is detecting error signaled from indoor unit

Automatic address setting failed

Error in receiving serial communication signal (Signal from main indoor unit in case of

Outdoor system address, indoor system address, or indoor unit individual/main/sub setting is not set (Automatic address setting is not completed) Auto address is not completed

Error in transmitting serial communication signal

Indoor unit addre

Remote controller setting is duplicated

Error in transmitting serial communications signal

Error in receiving serial communications signal

Main unit duplication in simultaneous-operation multi control (detected by outdoor unit)

Error in receiving serial communications signal

Error in transmitting serial communications signal

Error in receiving serial communications signal (including unit quantity verification failure)

Error in transmitting serial communications signal

Indoor unit capacity too low

Indoor unit capacity too high

ss setting is duplicated

group control)

ON:

Blinking: OFF:

Wired remote control display

Wireless

remote controller

receiver display

Operation

E01

E02

E03

E08

E09

E10

E11

E14

E04

E05

E06

E07

E15

E16

Timer

Standby

(WD)

An indoor unit detected trouble in the signal from another in

door unit

Communications trouble between units

Setting errorMis-setting

No indoor units connected

Error in transmitti

ng serial communications signal

Error in receiving serial communications signal

Communications failure with MDC

Indoor unit group settings error

Indoor/outdoor unit type mismatch

Main unit duplication in group control (detected by indoor

Outdoor unit address duplication (system address)

Group wiring connected for independent indoor unit

Address not set or group not set

Indoor unit capacity not set

Outdoor unit capacity not set or setting error

Miswiring in group control wiring

Indoor unit type setting error (capacity)

unit)

E20

E17

E18

E31

L01

L02

L03

L04

L07

L08

L09

L10

L11

L13

Simultaneously

Continued

Page 66

(WD)

Ceiling panel connection failure

Activation of

Indoor protection

protective device

Outdoor protection

Thermistor

ult

Thermistor open circuit

• Short circuit (indoor)

Thermistor open circuit

• Short circuit (outdoor)

Possible cause of malfunction

Fan protective thermostat

Float switch

Discharge temperature trouble

High pressure switch or compressor motor thermal protector is activated.

Open phase detected, AC power trouble

No gas

4-way valve locked

High cooling load

Outdoor fan trouble

Inverter compressor trouble (HIC PCB)

Inverter compressor trouble (MDC)

Simultaneous-operation multi control trouble

Compressor current failure (overload)

Indoor heat exchanger temperature

Indoor heat exchanger temperature sensor (E2)

Indoor temperature sensor

Discharge temperature (TD)

Outdoor heat exchanger temperature (C1)

Outdoor heat exchanger temperature (C2)

Outdoor air temperature (TO)

Intake temperature (TS)

Indoor EEPROM error

Outdoor EEPROM error

sensor (E1)

Wired remote control

display

P09

P01

P10

P03

P04

P05

P15

P19

P20

P22

P26

P29

P31

H01

F01

F02

F10

F04

F06

F07

F08

F12

F29

F31

Wireless

remote controller

receiver display

Operation

Timer

Standby

Alternately

Alter.

Simul.

Page 67

(2) LED Indicator Messages on Outdoor Control PCB

Power ON sequence

1. No communication from indoor units in system

2. Communication received from 1 or more indoor units in system

3. Regular communication OK (Capacity and unit quantity match)

LED 1 LED 2 Remarks

If it is not possible to advance to 3, repeats 1 → 2. At 3, changes to normal control.

Normal operation

EEPROM error (F31)

Pre-trip (insufficient gas)

Pre-trip (P20)

Pre-trip (other)

Alarm

Insufficient gas indicator

Refrigerant recovery mode

Automatic address setting

Automatic address setting in progress

Automatic address setting alarm (E15)

Automatic address setting alarm (E20)

Displayed during automatic address setting 1 and initial communication. After these are completed, alarm F31 is displayed.

(0.25/0.75)

(0.75/0.25)

Alternate blinking during alarms

LED 1 blinks M times, then LED 2 blinks N times. The cycle then repeats.

M = 2: P alarm N = Alarm No. * Refer to

(0.25/0.75)

(0.75/0.25)

3: H alarm 4: E alarm 5: F alarm

“1. Examples of alarm display” below.

(0.25/0.75)

(0.75/0.25)

P03

6: L alarm

Blinking alternately

Blinking simultaneously

(WD)

Automatic address setting alarm (Other than E15 and E20)

Blinking (0.25/0.75) indicates that the lamp illuminates for 0.25 seconds, and then is OFF for 0.75 seconds.

Unless otherwise indicated, the blinking is (0.5/0.5).

OFF

(3) Examples of alarm display (other than E15, E16, and E20)

Alarm / Display LED 1 Alternately

P03

P04

P05

P31

H01

H02

H03

•

E04

•

F07

•

L13

•

( Blinks 2 times )

→

)

(

)

(

)

(

(Blinks 3 times)

)

(

)

(

•

(Blinks 4 times)

•

(Blinks 5 times)

(Blinks 6 times)

•

LED 2

→

(Blinks 3 times)

(Blinks 4 times)

(Blinks 5 times)

(Blinks 31 times)

(Blinks 1 times)

(Blinks 2 times)

(Blinks 3 times)

(Blinks 4 times)

(Blinks 7 times)

(Blinks 13 times)

Blinking simultaneously

Note: This table shows example alarms. Other alarms may also be displayed.

Page 68

7. HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER (OPTIONAL PART)

IMPORTANT

When using this air conditioner with the wireless remote controller it may sometimes be impossible to change the operation modes while other indoor unit is running.

When this happens, a double beep tone sounds,

the (operation lamp) lights up, and the (Timer

lamp) and (Standby lamp) blink alternately. Operation is the same even during (AUTO mode) automatic cooling or heating. A beep tone sounds 5 times and no changes can be made when any of the ON/OFF, MODE, Temperature setting buttons were pressed while set under central control by the system controller.

7-1. Wireless Remote Controller Installation

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

(WL)

To ensure that the air conditio

ner 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 ft. 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.

(1) If Wall-mounted Fixed Position

Install the remote controller at a convenient location on a nearby wall. However, before

attaching the remote controller mounting cradle, check that the remote controller can operate from the desired wall pos

ition. (Fig. 7-1)

How to Install Batteries

See Fig. 7-2.

(1) Press and slide the lid on the back of the remote

controller in the direction of the arrow.

Screws for fixture Truss-head tapping screws (4 × L5/8")

Put on

Fig. 7-1

Mounting cradle

Push

(2) Install two AAA alkaline batteries. Make sure the

batteries point in the direction marked in the

battery compartment.

(3) Press the ACL button, then replace the lid. If you

press it, the current time, ON time, and OFF time

are all reset to 0:00.

Cover

Fig. 7-2

ACL button

Page 69

7-2. Room Temperature Sensor Setting

The room temperature sensors are built into the indoor unit and the wireless remote controller. Either of these

room temperature sensors can operate. The system is shipped from the factory set to the indoor unit sensor. To switch to the remote controller sensor, press the sensor switching button located inside the remote controller cover and check that A/C SENSOR on the LCD display panel goes out.

NOTE

If the sensor switch is set to the remote controller side, but no room temperature data is sent to the main unit for 10 minutes, the sensor is automatically switched to the indoor unit side. As much as possible, install the remote controller facing the unit.

7-3. Address Switches

If you are installing more than 1 indoor unit (up to 6) in the same room, it is necessary for you to assign each unit its own address so they each can be operated by their remote controller.

Up to 6 indoor units can be controlled separately through the address switches. The operating control has the reception address switch and the remote controller has the transmission address switch. This function is utilized by matching the transmission and reception address switches.

SET

ACL

Sensor button

Fig. 7-3

ADR

SENSOR

Remote controller address display

Address switch positions

ADR

*Any address

switch position available

ADR

1 2 3

456

ADR

1 2 3

456

ADR

1 2 3

456

7-4. Setting the Model Code

Flap display selector switch

Make the slide switch settings in the battery compartment box of the remote controller depending on the type of indoor unit in which the wireless receiving unit is used.

Operation mode switch

In this Split System Air Conditioner set the switch to “A”. * The switch is factory set to “S” / “A”. * Always press the reset button after switching the setting.

S KN AHC

Fig. 7-4

Operation

mode switch

Flap display

selector switch

S KN

X, T type K type

AHC

Heat pump with

Auto mode (CH type)

Heat pump without

S KN S KN

AHC

Cooling only

Auto mode

U type

AHC

(WL)

Page 70

<RCS-SH80UA.WL>

4-Way Air Discharge Semi-concealed Type

(X Type)

7-5. Indicator Section Installation

Remove the ceiling panel and indicator cover

Air intake grille

Mark section (indicator section)

and install the indicator section.

(1) Remove the ceiling panel. (2) Remove the corner cover behind the mark sec-

Ceiling panel

tion. (3 screws)

(3) Remove the mark section inside the ceiling panel.

(2 screws)

(4) Install the indicator section in the location where

the mark section was attached. (2 screws)

(5) Form the wire to match the panel ribs as shown

3 screws

Corner cover

in Fig. 7-6.

(6) Install the corner cover. (Restrain the wire with

the corner cover.)

Fig. 7-5

7-6. Operating Controller Installation

Pass the wiring through under the shaft.

CAUTION

Do not twist the operating controller wires together with the power supply wires. Doing so can result in malfunction.

If electrical noise is induced in the unit power supply, take appropriate measures, for example installing a

Wiring

noise filter.

Install the operating controller at the indoor unit intake

section.

port

(1) Fasten the operating controller to the indoor unit

intake port section (electrical component box

2 screws

Indicator section

Fig. 7-6

opposite side) with the 2 accessory screws (4 × L13/32 in.).

(2) Connect the operating controller 2 wires (WHT,

BLK) to the remote control wire (WHT) in the electrical component box. (For details on wiring, see “7-9. Electrical wiring” on page 72.)

(3)Install the ceiling panel.

(4) Connect the indicator section and the operating

controller with the 6P connector (white).

(5) Form the wires with vinyl clamps and fasten.

(6) Connect the ceiling panel wiring connector (2P,

3P) to the body connector in the electrical compo- nent box.

(7) For details on test operation, see “Test Run.”

Operating controller

Screws

Electrical component box

Fig. 7-7

Page 71

Ceiling-Mounted Type (T Type)

7-7. Indicator Section Installation

Remove the side panel to install the indicator section. (Fig. 7-8)

(1) Remove the side panel.

Open the air intake grille, remove the screw at one place and then remove the side panel by sliding it toward the front (arrow direction).

(2) Remove cover A and cover B.

Insert a standard screwdriver into the recess of cover A to remove cover A and cover B. (When removing the cover, take care not to

scratch the panel.) (3) Remove cover B from cover A. (4) Install the indicator section at cover A. (5) After passing through the lead wires, install cover

A and the indicator section at the panel hole.

(The protrusion part of cover A is fixed with the

panel hole.) (6) Bundle the lead wires along with the wiring of the

louver motor. (7) Install the side panel.

Indicator section

Cover B

(Not used when the indicator section is installed.)

Recess

Cover A

Recess

Fig. 7-8

PanelIndicator section

Cover A

Side panel

Air intake grille

7-8. Operating Controller Installation

Do not twist the operating

CAUTION

controller wires together with the power supply wires. Doing so can result in malfunction. If electrical noise is induced in the unit power supply, take appropriate measures, for example installing a noise filter.

Install the operating controller on the top face of the air intake section (space between the fan motor and the electrical component box). (Fig. 7-9)

(1) Fasten the operati

ng controller to the ceiling panel of the air intake section with the 2 supplied screws (4 × L13/32 in.).

(2) Draw the lead wires into the electrical component

box and connect the operating controller 2 wires (WHT, BLK) to the remote control wires in the electrical component box.

(3)Connect the indicator section and the operating

controller using the 6P connector in the electrical component box.

Operating controller

Electrical component box

Fig. 7-9

Page 72

(WL)

7-9. Electrical Wiring

Indoor PCB Operating controller

CN1

1 2

W1 (4.3 ft.)

WHT

BLK

Signal receiving unit

(0.7 ft.)W3(4.3 ft.)

CN2

BLU YEL PNK RED

GRY

BLK

Connection method (1) Connect W1 to the indoor PCB WL connector. (2) Connect W3 from the indicator section with W2

from the operating controller using the relay connector.

7-10. Test Run Switch

The test run switch is located in the operating control unit. Regarding the test run, refer to section 11. Test Run.

7-10-1. How to use the test run setting (X, T Types)

Set DIP switch [DS] No. 1 on the wireless receiver

(1)

unit PCB from OFF to the ON position.

Press the ON/OFF operation button on the

(2)

wireless remote controller.

Make a test run using the air conditioner in

(3)

COOL or HEAT mode.

During the test run, each of the 3 indicator lamps

(4)

on the indoor unit flash.

During the test run, the air conditioner runs

(5)

continuously and the thermo

stat does not control

the system. After the test run, be sure to reset DIP switch No. 1

(6)

back to the OFF position and check that no indicator lamps are blinking. (This receiver includes a 60-minute automatic OFF timer function in order to prevent continuous test run.)

BLU

YEL PNK RED GRY

BLK

Relay connector

g. 7-10

1.TEST RUN

2.PCB CHK.

3.RCU: MAIN RCU: SUB

4.NORMAL ALL •

DIP switch No. 1

Indicator section

CN1

All OFF( ) for initial settings.

2 3 4

ADR

2 3

456

Address switch

Fig. 7-11

Flap button

ON/OFF operation button

NOTE

In case of 4-way air discharge type, test run

To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes after power is applied or the air conditioner is turned off and then back on.

When the air conditioner fails to start the test run, 1 or more of the 3 alarm indicator lamps on the indoor unit will flash (See next section).

When the DIP switch is set to “TEST – ON,” temperature control from the wireless remote controller is disabled. Do not use this setting at any time other than for the test run. Doing so will place an excessive load on the system.

To avoid placing an excessive load on the equipment, use this function only when conducting the test run.

operation is not possible without the ceiling panel installation.

Page 73

7-11. Misoperation Alarm Indicators

Alarm indicator lamps on the indoor unit indicate the error cause if the air conditioner fails to operate upon being switched on. The possible alarm indications are given in Table 7-1. Fig. 7-12 shows the location of the alarm lamps on the indoor unit. (See Table 7-1 and Fig. 7-12.)

Table 7-1

Alarm

(OPERATION

lamp) lamp) lamp)

(TIMER

(STANDBY

S.C. errors* between the indoor unit’s controller (PCB) and the remote controller. Compressor protector is working. S.C. errors between indoor and outdoor units. Indoor or outdoor thermistor is malfunctioning. Outdoor unit protector is working. Indoor unit protector is working. TEST RUN switch on the operation controller is in ON state.

* S.C.: Serial communications

Cause of Trouble

OPERATION lamp

TIMER lamp

STANDBY lamp

Fig. 7-12

NOTE

Stick the alarm message label accompanying the wireless remote controller on the electrical component box to indicate the cause of trouble for future reference.

(WL)

Remote control receiver

Page 74

<RCS-BH80UA.WL>

CAUTION

If the signal receiving unit is installed near a rapidstart or inverter type fluorescent lamp (neither one uses glow lamps), it may be impossible to receive signals from the wireless remote controller. To avoid signal interference from fluorescent lamps, install the receiving unit at least 6.6 ft. away from the lamps and install at a location where wireless remote controller signals can be received when the fluorescent lamps are on.

(WL)

7-12.

Separate Type Signal Receiving Unit Installation

Do not twist the operating

CAUTION

If local electrical codes allow, this signal receving unit can be mounted using a conventional wall box

for flush mounting.

(1) Insert a standard s

crewdriver into the gap under

the signal receving unit and pry off the cover (Fig. 7-14)

(2) Attach the signal receving unit with the 2 small

screws provided. Use the spacers and take care not to tighten the screws excessively. If the signal receving unit will not seat well, cut the spacers to a suitable thickness. (Fig. 7-13)

(3)Connect the signal receving unit wiring (2 wire

correctly to the corresponding terminals in the electrical component box of the indoor unit.

Notch

M4 × L1 in Screws (2)

Cover plate

Signal receiving unit

Spacer

•

Fig. 7-13

Fig. 7-14

Switch box (no cover)

When wiring, do not connect the signal receiving unit

CAUTION

wires to the adjacent terminal block for the power wiring. Otherwise, the unit will break down.

Page 75

When using the signal receiving unit on a wall with the front exposed, choose a wall surface that the signal receiving unit can be mounted on.

(1) Insert a standard (minus) screwdriver into the slot on

the lower side of the signal receiving unit and pry off the back case as shown in Fig. 7-14.

(2) The wire routing at the signal receiving unit

comes out of the u

pper case (thin portion at upper center) so use nippers or a similar tool to cut out a notch beforehand large enough for the remote control cable (option) to pass through as shown in Fig. 7-15.

(3) Remove the wire, which is connected prior to ship-

ping, from the connector. Connect the remote control cable (option) to the

(4)

signal receiving unit connector as shown in Fig. 7-16 after the clamp (supplied) with the unit is installed.

(5) After arranging the wiring on the printed circuit

board as shown in Fig. 7-17 so that it is contained within the signal receiving unit, attach the back case. At this time, arrange so that the head of the clamp faces the side.

(6) Remove the cover plate and install the signal

receiving unit using the 2 wood screws.

(7) Fasten to the wall using the cord clip (supplied). (8) Reinstall the cover plate.

To use the signal receiving unit while mounted on the ceiling, install by using the carrier for ceiling installation supplied with the unit.

(1) Remove the cover plate by inserting a standard

(minus) screwdriver into the notch in the lower section and prying it off.

(2) Cut out a section (3-3/4 × 2-1/32 in.) on the

ceiling using the paper pattern (supplied) as a guide.

(3)

Run the wire through the mounting carrier and insert into the installation hole as shown in Fig. 7-19.

(4) Fit securely into the ceiling material at sections

(A) and (B) as shown in Fig. 7-20.

(5) Connect the wire (2-wire core) from the signal

receiving unit with the wire from the indoor unit. (See section on how to wire the receiving unit.) as shown in Fig. 7-20.

(6) Use the supplied spacers to adjust for a thickness

several inches more than the ceiling material and lightly fasten the receiving unit in place with the small screws (M4 × 1-9/16 in., 2 pcs.) supplied with the unit.

(7) Tighten the machine screws after fitting sections

(A) and (B) into the openings, in the gap between the signal receiving unit and ceiling surface as in Fig. 7-21. Do not apply strong force when tightening the screws. Excessive force might warp or damage the cover. When finished, the signal receiving unit should still be able to move slightly when pressed as shown in Fig. 7-21.

(8) Reinstall the cover plate.

Run the remote control cable through a notch in the upper case.

Remote control cord (Option)

Clamp

Fig. 7-17

Fig. 7-19

Fig. 7-21

About 3/32-1/8 in.

Connector

Fig. 7-16Fig. 7-15

Wood screws (2)

Clamp (Supplied)

Remote control cord (Option)

Signal receiving unit

•

Fig. 7-18

Fig. 7-20

(WL)

Page 76

7-13. Electrical Wiring

Be sure to do the wiring

CAUTION

correctly (incorrect

wiring will damage the

equipment).

Recommended wire diameter and allowable length for signal receiving unit wiring and its branch wiring: AWG #18, MAX 1,300 ft.

(WL)

Terminal board for indoor unit remote controller wiring

Wire joint (2 pcs. white, supplied)

1 2

Signal receiving unit wiring (field supply)

Signal receiving unit wiring

WHT

BLK 2

Wire from signal receiving unit

Connection

1. Peel away 9/16 in. of shield from the wire for the connection. Join the 2 wires as shown and crimp-connect

2. them with the wire joint (supplied).

Signal receiving unit wiring

Wire joint CE-1 (supplied)

3. When no crimping tool is available or if a solder connection was made, then cover with insulating tape.

7-14. Test Run Switch

(1)

Remove the cover plate of the signal receiving unit. Set the "TEST RUN" switch of the dip switches to the ON position.

(2) Press the ON/OFF operation button on the

wireless remote controller.

To avoid placing an

CAUTION

excessive load on the equipment, use this function only when conducting the test run.

Signal receiving unit

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

12 3

ADR

(3) Make a test run using the air conditioner in

COOL or HEAT mode.

(4) During the test run, the “OPER.,” “TIMER,”

and “STDBY” LED all blink.

To protect the air conditioner from overloading, the outdoor unit will not start running for approximately 3 minutes after power is applied or the air conditioner is turned off and then back on.

(5) After the test run, press the ON/OFF operation button on the wireless remote controller. Then, set the

TEST RUN switch back to the OFF position to cancel the test run mode. (This receiver includes a 60-minute automatic OFF timer function in order to prevent continuous test run.)

Fig. 7-22

Page 77

7-15. Misoperation Alarm Indicators

A blinking lamp for other than the signal receiving unit filter shows that a problem has occurred in the unit, so make an inspection. (Refer to servicing information in the service manual, etc.) Also, if wired remote controller and dedicated service check lines (854-9-9536044-97: service use) are available, then detailed error information can be obtained by connecting to the service connector as s

hown in the drawing. For information on how to connect to the signal receiving unit, refer to the instruction manual that came with the dedicated service check lines.

Table 7-2

Lamp

OPERATION

TIMER STANDBY

Bright Cause of Trouble

lamp lamp lamp

Alternately Indoor unit protector is activated. Alternately Outdoor unit protector is activated.

ConcurrentMi ConcurrentMis-setting of outdoor unit.

* S.C.: Serial communications

Service connector

ALL• RCU : SUB PCB CHK. TEST RUN

RCU : MAIN NORMAL

Fig. 7-23

OPERATION lamp

TIMER lamp

STANDBY lamp

FILTER lamp

Fig. 7-24

No power supply or mis-wiring of signal receiving unit. S.C.* errors between the indoor unit’s controller (PCB) and signal receiving unit. S.C. errors between indoor and outdoor units.

Compressor protector is activated.

s-setting of indoor unit.

(WL)

Page 78

7-16. Basic Wiring Diagram

CAUTION

Wire joint

Inter-unit control wiring

Wiring procedure

Be sure to do the wiring correctly (incorrect wiring will damage the equipment).

Remote controller

Indoor unit

No. 1

Outdoor unit

: Ground (earth)

Use shielded wires for inter-unit control wiring and ground the shield on both sides. (Fig. 7-25) Otherwise misoperation because of electrical noise may occur.

Shielded wire

Ground

Fig. 7-25

(WL)

Carry out the wiring according to the above wiring diagram.

Address setting is automatically executed after turning on the system. An indoor unit address is assigned to each indoor unit.

Operation takes place successively at intervals of 1 second, by using combinations of the address setting of each unit.

Page 79

7-17. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of

8) are controlled by a signal receiving unit (main unit). In this case, a signal receiving unit can be connected at any indoor unit.

Group control using 2 signal receiving units

It does not matter which of the 2 signal receiving units you set as the main controller.

Remote controller (main)

Wire joint

Indoor unit

No. 1

Connection wiring for group control

Indoor unit

No. 2

(sub)

Indoor unit

No. 3

Indoor unit

No. 8

Wiring procedure

Wire according to the diagram at left:

Address setting is executed automatically when the outdoor unit is turned on.

Each successive unit will respond at one-second intervals following the order of the group address when the remote controller is operated.

When using multiple signal receiving units (up to 2 can be used), one is the main signal receiving unit and the other is the sub-signal receiving unit.

To set up a sub-signal receiving unit, change its remote control address connector (RCU. ADR) located on its PCB from main to sub position (main: when shipped from factory).

(WL)

Outdoor unit

: Ground (earth)

Outdoor unit

Page 80

7-18. Wiring System Diagram for Multiple Remote Controllers

When installing multiple remote controllers

This multiple system is used for operating the unit(s) at different positions. (A maximum of 2 signal receiving units can be installed.)

Setting method

To execute this control, make the setting according to the following procedure.

(1) Of the two installed signal receiving units, make

one the main s

ignal receiving unit (factory-

shipped state).

(2) On the other signal receiving unit, change the

address connector on the PCB from main to sub position. In this state, it functions as a sub-signal receiving unit.

(WL)

Basic wiring diagram

Carry out the wiring correctly

CAUTION

(incorrect wiring will damage the equipment).

To operate 1 indoor unit with 2 signal receiving units set at different locations.

Signal receiving unit

Remote control cable terminal board

Earth

(sub)(main)

(Option)

Indoor unit

Connection wiring

Page 81

<RCS-SH1UA>

7-19. Test Run Procedure

Wall-mounted model (For new refrigerant R410A) Inverter unit (Super Espacio) Constant-speed unit

Wall-mounted Type (K Type)

Check the “Check Items Before the Test Run.”

Verify the combination (wiring) of indoor and outdoor units.

(Item 7-20)

Set the indoor unit controller to “TEST.”

Is operation

possible?

(Item 7-21-3)

Check using the self-diagnostics function table. (Refer to 11-7) Correct any locations that require correction.

YES

Note: Check the indoor-side drainage.

Return the indoor unit controller to “NORM.” (Item 7-21-3)

7-20. Check Items Before the Test Run

(1)

Turn ON the remote power switch at least 5 hours before the test run in order to charge the crank-case heater. (If the outdoor unit is an inverter unit, turn ON the power 12 hours in advance.)

(2) Fully open the service valves on the gas-tube and liquid-tube sides.

Set the sliding switches on the inside of the wireless remote controller cover to the correct settings for that model.

(3)

After changing the settings, press the RESET button.

Verify that sliding switch 1 is in the “K” position.

Wireless remote controller transmitter

(WL)

S KN

S: Flap model (4-direction, ceiling suspended)

K: Swing-only model (wall-mounted), settings completed N: No-flap model (built-in)

Verify that sliding switch 1 is in the “S” position.

S KN

Set sliding switch 2 to the correct setting for these models.

AHC AHC

A: Heat pump model

(H: Heat pump, no auto heating/cooling)

C: Cooling-only model

Sliding switch 1

RESET button

SENSOR button

Sliding switch 2

Page 82

7-21. Preparing for the Test Run

7-21-1. Changing the room temperature sensor

Room temperature sensors are installed inside the indoor unit and the wireless remote controller. Either room temperature sensor can be used.

When “Unit Sensor” is indicated on the wireless remote controller LCD, the indoor unit sensor is operating as the room temperature sensor. To change to the remote controller sensor, open the remote controller cover an

d press the SENSOR button once. The “Unit Sensor” display disappears, and the remote controller sensor becomes the room temperature sensor.

If the temperature data from the remote controller is not communicated to the indoor

CAUTION

unit for a period of 10 minutes when the remote controller sensor is selected, the unit automatically switches back to the indoor unit sensor. Install the remote controller in a location where the signal can reliably be received by the indoor unit.

7-21-2. Using the remote controller

Face the remote controller toward the receiver (indoor unit). The maximum distance where the remote controller signal can be received is approximately 8 m, however this

distance is only a guide. The actual distance may vary somewhat depending on battery capacity and other conditions.

Make sure there are no obstructions which can block the signal between the remote controller and the receiver. When the remote controller signal is received correctly, the indoor unit beeps.

(It beeps twice only when operation is started.)

(WL)

Receiver

Do not drop, throw, or wash the remote controller. Do not place the remote controller in a location exposed to direct sunlight, or near a stove or similar appliance.

7-21-3. Test run

Using the controller

(1)

Slide the main unit controller switch from “NORM.” to “TEST” (for 3072R, 3672R), “ON” to “TEST” (for 2672R).

(The outdoor unit will not operate for approximately 3 minutes after the power is turned ON, or after operation is stopped.)

(2)

All indicator lamps on the display blink while test run is in progress.

(3)

Temperature control is not possible during the test run.

(4)

If normal operation is not possible, the lamps on the display will indicate the problem.

For 3072R, 3672R

Controller

NORM.

OFF TEST

STDBY

TIMEROPER.

For 2672R

Controller

TEST

Indicator

Refer to the self-diagnostics function table and correct the problem. (See 11-7. Table of Self-Diagnostics and corrections.)

(5)

After the test run is completed, move the controller switch from “TEST” to “NORM.” (for 3072R, 3672R), “TEST” to “ON” (for 2672R) and verify that the indicator lamps stop blinking. (A 60-minute automatic OFF timer function is included in order to prevent continuous test run.)

CAUTION

OFF

STDBYTIMEROPER.

Do not use this setting at any time other than for the test run. Doing so will place an excessive load on the system.

Test run is not possible if the power was turned ON when the controller switch was in the “TEST” position. Leave the power ON and move the switch to “NORM.” or “OFF,” then move the switch back to “TES

T.”

Page 83

7-22. Precautions

Request that the customer be present at the time the test run is performed. Explain the Operation Manual to the customer, and then have the customer actually operate the system.

Be sure to pass the manual and warranty certificate to the customer.

Verify that the AC 208 / 230 V wiring is not connected to the terminal plate which is used to connect the inter-unit control wiring.

* If AC 208 / 230 V is accidentally applied to this terminal plate, the fuse (0.5A for both indoor and outdoor units) on the inter-unit control PCB will be tripped in order to protect the PCB. Correct the wiring connections, then disconnect the 2P connectors (indoor unit: blu

e, OC, CN40; outdoor unit: blue, OC) which are connected to the PCB and connect the other 2P connectors (indoor unit: brown, EMG, CN44; outdoor unit: brown, EMG). (See the figure below.) If operation is still not possible with the brown connectors connected, cut the varistor (black) (for both the indoor and outdoor units). (Be sure to turn OFF the power before performing this work.)

Indoor unit control PCB Outdoor unit control PCB

VA5 (Varistor, black)

2P connector (brown) EMG, CN44

2P connector (blue) OC, CN40

Fuse

0.5A

Fuse

0.5A 2P connector (blue)

2P connector (brown)

Var istor (black) VA002

CHK (2P plug)

SW103

(Invertor 2, 3 hp)

(Invertor 4, 5, 6 hp)

TEST OFF ON

Var istor (black)

Fuse

0.5A

Te r mi nal plug (black)

Serial 2 connector (brown)

Serial 1 connector (blue)

Fuse

0.5A

Serial 1 connector (blue)

Serial 2 connector (brown)

(WL)

Page 84

HOW TO INSTALL THE SYSTEM CONTROLLER (OPTIONAL PART)

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

8-1. System Controller Installation

Do not twist the control

CAUTION

wiring with the power wiring or run it in the

same metal conduit, because this may cause

malfunction.

Install the system controller away from sources of electrical noise.

Install a noise filter or take other appropriate action if electrical noise affects the power supply circuit of the unit.

(1) Remove the flat-top screw on the bottom of the

back case. When you open u

p the decorative cover, you will see two gaps under the system controller. Insert a coin into these gaps and remove the back case. (Figs. 8-1, 8-2)

System controller

Coin

M4 × 1-3/16 in. Screws (2)

Gap

Switch box (with cover)

Back case

Flat-top Screw

Fig. 8-1

Gap

(2) Connect the wires to terminal base of the system

controller (see next page).

(3) Attach the back case with the 2 M4 screws

provided.

(4) To finish, fit the back tabs of the back case into

the system controller and mount it using the flattop screw.

Fig. 8-2

Page 85

8-2. Electrical Wiring

How to connect electrical wiring

(1) Connect B1, B2 to indoor PCB CRV connector

using accessary 2P connector. (*No polarity)

Total wire length is less than 985 ft. and size is

AWG#18.

(2) Connect B5, B6 to indoor unit 2P terminal base.

(*No polarity). Wire size is AWG#18.

Basic wiring

B1:

B2:

B3: Not be used

B4: Auxiliary of inter-unit control wiring

B5:

B6:

Power supply: DC12V *No polarity To CRV connector (CN91) on indoor PCB

Inter-unit control wiring. (Low voltage) To indoor unit 2P terminal base (U1, U2) *No polarity

Terminals for remote monitoring

A1: Input for turning on air conditioners concurrently.

A2: Input for turning off air conditioners concurrently.

Common input for turning air conditioners on or off.

A3:

System controller

Accessary connector

Wire joint connection

2P terminal base

Fig. 8-3

Indoor unit PCB

CRV (CN91: WHT)

Indoor unit

A4: ON operation state indicator output.

A5: Alarm indicator output.

A6: Common indicator output.

Basic wiring diagram of control wiring

A max. of 64 indoor units and 30 outdoor units can be connected in 1 system.

Up to 10 system controllers can be connected in 1 system.

RC1

Inter-unit control wiring

1-1

Fig. 8-4

RC2 RC3

2-1 3-1

System controller

Page 86

8-3. Address Switch Setting

SW1

Main/sub selection switch

OFF: System controller operates as main controller. ON: System controller operates as sub-controller.

ALL/ZONE mode selection switch

ALL mode: All indoor units can be controlled by system controller ZONE 1, 2, 3, 4 mode: Indoor units in one of zone 1, 2, 3, or 4 can be controlled by system controller. All indoor units cannot be s

OFF

ON ON ON ON

ALL mode ZONE 1 mode ZONE 2 mode ZONE 3 mode ZONE 4 mode

2 OFF OFF

OFF

OFF OFF OFF

ON ON

OFF

et.

Central control/Remote control mode selection switch.

OFF: Central control mode. Individual setting by remote controller can be inhibited by system controller.

ON: Remote control mode. Setting by system controller is inhibited by other central control equipment.

OFF

2 3 4

SW1

5 6 7 8

Central control Main/Sub selection switch

(OFF: Main, ON: Sub)

When AMY adaptor etc. is

used with system controller,

set the switch to ON position.

When only one system controller is used, set the switch to

OFF position.

Except , when multiple system controllers are used,

set only one system controller to OFF position and others to ON position. ALL mode system controller should be in OFF position. (recommen

ded)

(Central control) button operation switch

OFF: (Central control) button operation is permitted. ON : button operation is inhibited.

*All switches are in OFF position at shipment.

Page 87

SW2

Weekly timer input switches

System controller operation can be set when weekly timer activates (ON/OFF).

Switch No.

System controller operation

1 32

Timer OFF→ON Timer ON→OFF 1 2

All ON

No change

Individual control

of all indoor units

All OFF

All OFF All indoor units to be 1*

OFF

OFF OFF

OFF

to be permitted

All OFF and all

Same as above

indoor units to be

1* All indoor units to be 2*

OFF

All OFF and all

Same as above

indoor units to be

In case of Remote control mode, use or .

1 2

OFF

In case of ZONE 1, 2, 3, 4 mode, ALL, all indoor units means one of ZONE 1, 2, 3, 4.

: 1 (Central control 1) means ON/OFF operation cannot

be executed by remote controller.

: 2 (Central control 2) means ON/OFF, MODE change.

Temp. setting cannot be executed by remote controller.

OFF

2 3 4

SW2

5 6 7 8

Auxiliary switch

Must be set to OFF position.

Beep tone switch

OFF: Beep tone when each button is pushed. ON: No tone when each button is pushed.

Indication switch Normally set to OFF position. When set to ON position, indication is not displayed on LCD of

system controller.

*All switches are in OFF position at shipment.

Page 88

8-4. Mode Setting

According to the function of each system controller, set SW1 as shown in Fig. 8-5.

(1) Central control/Remote control mode

Central control mode

The system controller is used as the central control equipment. Individual setting by remote controller can be inhibited by the system controller

Remote control mode

The system controller is used as the remote controller. Setting by system controller is inhibited by other

central control equipment.

(2) ALL/ZONE mode

ALL mode

All indoor units can be controlled by the system controller.

ZONE mode

Indoor units in one of ZONE 1, 2, 3 or 4 can be controlled by the system controller

Central control

mode

3 4 5 6

ON OFF

ALL

central control

3 4 5 6

ON OFF

ZONE1

central control

3 4 5 6

ON OFF

ZONE2

central control

3 4 5 6

ON OFF

ZONE3

central control

3 4 5 6

ON OFF

ZONE4

central control

Remote control

mode

3 4 5 6

ON OFF

ALL

remote control

3 4 5 6

ON OFF

ZONE1

remote control

3 4 5 6

ON OFF

ZONE2

remote control

3 4 5 6

ON OFF

ZONE3

remote control

3 4 5 6

ON OFF

ZONE4

remote control

Inter-unit control wiring

2 16

18 32

34 48

50 64

ZONE1

central control

address 1-16

ZONE2 central control address 17-32

ZONE3 central control address 33-48

ZONE4 central control address 49-64

(3) The function of the system controller consists of 10 types

according to the combination of central control/remote co

ntrol mode and ALL/ZONE mode setting as shown

in the table 8-1.

(4) Stick the system controller unit label in a con-

Table 8-1

spicuous position.

ALL 1. ALL/Central 6. ALL/Remote

ZONE1 2. ZONE1/Central 7. ZONE1/Remote

ZONE2 3. ZONE2/Central 8. ZONE2/Remote

ZONE3 4. ZONE3/Central 9. ZONE3/Remote

ZONE4 5. ZONE4/Central 10. ZONE4/Remote

Fig. 8-5

Central control Remote control

Page 89

8-5. How to Perform Zone Registration

To operate the system controller properly, zone registration is required after finishing the test run (and after setting all indoor unit addresses) using one of the following methods.

(a) Zone registration using the remote controller (RCS-SH80UG)

Refer to page 90.

(b) Zone registration using the system controller (SHA-KC64UG)

Refer to page 91.

Refer to page 92.

For methods (a) and (b), you should make a zone registration table manually before performing the registration as shown on the next page.

For method (c), zone registration is executed automatically, proceeding from the smallest indoor unit address and smallest central addresses to larger numbers in numerical order. For example:

Central address 123 456

ZONE–group 1-1 1-2 1-3 1-4 1-5 1-6

Indoor unit address 1-1 1-2 2-1 2-2 2-33-1

NOTE

An indoor unit address is assigned to each indoor unit during automatic address

operation. Each indoor unit address combines an R.C. address and indoor unit number as follows:

: Indoor unit address (UNIT No.)1 – 1

Indoor unit No. Refrigerant circuit No. (R.C. address)

This address is displayed on the remote controller for UNIT No. when the UNIT

button is pressed.

The central address represents the zone and group number. These addresses are assigned in ascending numerical order.

Page 90

(a) Zone registration using the remote controller

(RCS-SH80UG)

(Determination of central address)

In this case, after confirming which indoor unit is connected to the remote controller and that the air conditioner in the OFF state, you set the central addresses one at a time.

If the system has no remote controller, connect a remote controller to the system temporarily. Then follow this procedure.

NOTE

The indoor unit address must already have been set before performing zone registration. If necessary, refer to the Installation Manual supplied with the outdoor unit.

(1) Press the

and buttons on the remote

controller at the same time for more than

4 seconds.

(2) Do not press buttton.

(3)Once in this mode, the UNIT No., CODE No., No.

of SET DATA and

indications will flash on

the display as shown Fig. 8-6.

NOTE

In case of group control “ALL” instead of “UNIT No.” will flash on the display. Select the main indoor unit address by pressing the button once.

(4) Set CODE No. to 03 using the and

( ) buttons.

NOTE

CODE No. 03 must be selected to perform zone registration using the remote controller.

(5) Set the Central address you want to assign

to the indoor unit address using the and

Fig. 8-6

() buttons according to the zone

registration table.

(6) Press the button. The CODE No. and Central

address changes from flashing to ON state. If you make a mistake, press the button and

reset the central address.

(7) Press the

button to finish zone registration.

For example, in this case

Indoor unit address: 1–8 Central address : 17 (Zone 2, Group 1)

Fig. 8-7

Page 91

(b) Zone registration using the system controller

(SHA-KC64UG)

In this case, you set all central addresses by the system controller at once manually.

(1) Press the

and

buttons at the same

ZONE

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) After confirming that CODE No. C1 is displayed,

press the button. Once in this mode, a change takes place as shown in Fig. 8-8.

(3) Select the zone and group No. you want to

set with

and (GROUP)

ZONE

buttons. If already set, press the

buttons.

(4) Set the unit No. (indoor unit address) with

and buttons, according to the zone registra-

tion table.

R.C. No. ................... button

Indoor unit No...........

button

If data is registered the unit No. is displayed.

ZONE

SELECT

ZONE

Fig. 8-8

3 4

3 4 7

GROUP

If no data is registered no number is displayed.

Selected group No. if no data is registered.

(5) Press the button.

GROUP No. turns ON and UNIT No. (indoor unit address) changes from flashing to ON state. UNIT No. is registered to the selected ZONE No. and GROUP No. If you make a mistake, press the

button

and reselect the ZONE, GROUP and UNIT No.

(6) Register the other UNIT Nos. in the same way by

following steps (3) to (5).

(7) Finally, complete the registration by pressing the

button.

flashes for a few minutes, then turns OFF.

SELECT

ZONE

GROUP

For example, in this case

Zone 3, Group No. 7 Unit No. (indoor unit address) 2-8

Unit No. 2-8 is registered to Zone 3, Group 7.

Fig. 8-9

Page 92

controller (SHA-KC64UG)

(1) Press the

and buttons at the same

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) Select CODE No. C2 by pressing

and

( ) button and press the button.

C2 changes from flashing to ON state and automatic zone registration will start.

(3)

Any registered GROUP Nos. will be erased.

(4) Central address will be assigned from the smallest

indoor unit address to larger ones in numerical order automatically. On finishing automatic zone registration, changes from flashing to OFF.

(5) If an error occurs, “CHECK” starts

flashing and zone registration finishes at this time. Press the button to start over.

(6) Finally, complete automatic zone registration

mode by pressing the button.

flashes for a few minutes, then turns OFF.

Fig. 8-10

Page 93

How to check for overlapping of central address Nos.

(1) Press the and buttons at the same

time for more than 4 seconds.

and CODE No. C1 will flash.

(2) Select CODE No. C3 by pressing

( ) button and press the button.

C3 changes from flashing to ON state and will flash. Then auto overlap checking will start.

(3) If C3 changes from ON to flashing and

stops flashing and disappears, there is no overlapping. Then finally, complete the auto overlap checking mode by pressing the button.

(4) If some of GROUP No., ZONE No. and UNIT No.

flash, you should try the zone registration again.

Select CODE No. C1 by pressing ,

( ) button and press the button.

Select the flashing GROUP No. with the ZONE

and GROUP buttons. Then press the button and reselect the

ZONE, GROUP and UNIT No.

Then finally, complete the auto overlap

checking mode by pressing the button.

Fig. 8-11

Page 94

ZONE registration table

ZONE GROUP

Central address

Indoor unit

address

(UNIT No.)

Unit location ZONE GROUP

Central address

Indoor unit

address

(UNIT No.)

Unit location

NOTE

Assign indoor unit addresses to the desired positions (central addresses) manually.

2.1.For group control, only the main indoor unit should be assigned.

Sub indoor units cannot be assigned.

Page 95

8-6. Connection with Other Equipment

meti tuptuo/tupnI

emaNslanimret tupt

ON/OFF output Alarm output Potential tree

tuptuo sutatS

A contact, static (relay output)

Contact capacity DC 30V, 0.5A

uo/tupni latigiD

All ON input All OFF input Pulse (photo coupler input)

tupni lortnoC

Contact capacity DC 24V, 10mA

System controller Equipment

Input/output

ON/OFF

Alarm

Output common

ALL ON (+)

ALL OFF (+)

Input common

8-7. Memory Backup Switch

CPEV

AWG#16

CPEV

AWG#16

tupni latigiD

+24

COM

Input/outputTerminal Terminal Example

Wire length: less than 330 ft.

Pulse width: more than

84 ft./sec.

9 Wire length: less than 330 ft.

Check the backup switch is ON on the for back side of the PCB of the system controller.

8-8. Test Run

(1) Power on all indoor units. Next, power on the

system controller.

will flash, checking the indoor unit addresses

automatically.

(2) If group No. displayed on system controller is not the

same as the indoor unit No.* which is connected, see Fig. 9-5 and carry out setting again.

*In case of group control, main unit No. only.

FFONO

Back up switch

Back up battery

Page 96

9. HOW TO PROCESS TUBING

Deburring

The liquid tubing side is connected by a flare nut, and the gas tubing side is connected by brazing.

9-1. Connecting the Refrigerant Tubing

Use of the Flaring Method

Many 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.

Flaring Procedure with a Flare Tool

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

tube cutter. It is recommended to cut approx. 12 – 20 in. longer than the tubing length you estimate.

(2) Remove burrs at each end of the copper tubing

with a tube reamer or file. This process is important and should be done carefully to make a good flare. Be sure to keep any contaminants (moisture, dirt, metal filings, etc.) from entering the tubing. (Figs. 9-1 and 9-2)

Before

After

Fig. 9-1

Copper tubing

Reamer

Fig. 9-2

NOTE

When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. (Fig. 9-2)

(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 the copper tube with a

flare tool.* (Fig. 9-3)

*Use “RIGID

” 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

Flare tool

Fig. 9-3

Flare size: A (inch)

Copper tubing (Outer dia.)

ø1/4

ø3/8

ø1/2

ø5/8

– 0.4

23/64

33/64

21/32

25/32

Flare nut

Copper tubing

Page 97

Caution Before Connecting Tubes Tightly

(1) Apply a sealing cap or water-proof tape to prevent dust

or water from entering the tubes before they are used.

(2) Be sure to apply refrigerant lubricant to the matching

surfaces of the flare and union before connecting them together. This is effective for reducing gas leaks. (Fig. 9-4)

(3) For proper connection, align the union tube and flare

tube straight with each other, then screw on the flare nut lightly at first to obtain a smooth match. (Fig. 9-5)

 Adjust the shape of the liquid tube using a tube bender at

the installation site and connect it to the liquid tubing side valve using a flare.

Apply refrigerant lubricant here and here

Fig. 9-4

Union

Flare nut

Fig. 9-5

Cautions During Brazing

 Replace air inside the tube with nitrogen gas to

prevent copper oxide film from forming during the brazing process. (Oxygen, carbon dioxide and Freon are not acceptable.)

 Do not allow the tubing to get too hot during brazing.

The nitrogen gas inside the tubing may overheat, causing refrigerant system valves to become damaged. Therefore allow the tubing to cool when brazing.

 Use a reducing valve for the nitrogen cylinder.

 Do not use agents intended to prevent the formation

of oxide film. These agents adversely affect the refrigerant and refrigerant oil, and may cause damage or malfunctions.

9-2. Connecting Tubing between Indoor and

Outdoor Units

(1) Tightly connect the indoor-side refrigerant tubing extended

from the wall with the outdoor-side tubing.

(2) To fasten the flare nuts, apply specified torque as at right.

 When removing the flare nuts from the tubing connec-

tions, or when tightening them after connecting the tubing, be sure to use 2 monkey wrenches or spanners as shown. (Fig. 9-6) If the flare nuts are over-tightened, the flare may be damaged, which could result in refrigerant leakage and cause injury or asphyxiation to room occupants.

 When removing or tightening the gas tube flare nut, use 2

monkey wrenches together: one at the gas tube flare nut, and one at part A. (Fig. 9-7)

 For the flare nuts at tubing connections, be sure to use

the flare nuts that were supplied with the unit, or else flare nuts for R410A (type 2). The refrigerant tubing that is used must be of the correct wall thickness as shown in the table at right.

Torque wrench

Indoor unit

Outdoor unit

Spanner

Fig. 9-6

Fig. 9-7

Tube diameter

ø1/4" (6.35 mm)

ø3/8" (9.52 mm)

ø1/2" (12.7 mm)

ø5/8" (15.88 mm)

Tightening torque

(approximate)

14 – 18 N

(140 – 180 kgf

34 – 42 N

(340 – 420 kgf

49 – 61 N

(490 – 610 kgf

68 – 82 N

(680 – 820 kgf

cm)

Tube thickness

1/32 in.

Because the pressure is approximately 1.6 times higher than conventional refrigerant pressure, the use of ordinary flare nuts (type 1) or thin-walled tubes may result in tube rupture, injury, or asphyxiation caused by refrigerant leakage.

 In order to prevent damage to the flare caused by

over-tightening of the flare nuts, use the table above as a guide when tightening.

 When tightening the flare nut on the liquid tube, use a mon-

key wrench with a nominal handle length of 7-7/8 in.

Page 98

 Do not use a spanner to tighten the valve stem caps.

Doing so may damage the valves.

 Depending on the installation conditions, applying

excessive torque may cause the nuts to crack.

Precautions for Packed Valve Operation

 If the packed valve is left for a long time with the valve

stem cap removed, refrigerant will leak from the valve. Therefore, do not leave the valve stem cap removed.

 Use a torque wrench to securely tighten the valve stem

cap.

 Valve stem cap tightening torque:

Packed valve

Valve stem

Valve stem cap

Fig. 9-8

2 tubes arranged together

Charging port

Main valve

Charging port 8 – 10 N • m (80 – 100 kgf • cm) ø3/8" (Liquid side) 19 – 21 N • m (190 – 210 kgf • cm)

ø5/8

" (Gas side) 28 – 32 N • m (280 – 320 kgf • cm)

9-3. Insulating the Refrigerant Tubing

Tubing Insulation

 Thermal insulation must be applied to all unit tubing,

including the distribution joint (purchased separately).

* For gas tubing, the insulation material must be heat

resistant to 248°F or above. For other tubing, it must be heat resistant to 176°F or above.

Insulation material thickness must be 13/32 in. or greater.

If the conditions inside the ceiling exceed DB 86°F and RH 70%, increase the thickness of the gas tubing insulation material by 1 step.

If the exterior of the outdoor unit

CAUTION

valves has been finished with a square duct covering, make sure you allow sufficient space to access the valves and to allow the panels to be attached and removed.

Taping the flare nuts

Wind the white insulation tape around the flare nuts at the gas tube connections. Then cover up the tubing connections with the flare insulator, and fill the gap at the union with the supplied black insulation tape. Finally, fasten the insulator at both ends with the supplied vinyl clamps. (Fig. 9-10)

Insulation material

The material used for insulation must have good insulation characteristics, be easy to use, be age resistant, and must not easily absorb moisture.

After a tube has been insulated,

CAUTION

never try to bend it into a narrow curve because it can cause the tube to break or crack.

Inter-unit control wiring

Insulation

Gas tube

Armoring tape

Fig. 9-9

Sealer (supplied)

Unit side insulator

Flare nut

Insulation tape (white)

(supplied)

Flare insulator (supplied)

Tube insulator (not supplied) Heat resistant 248ºF or above

Vinyl clamps (supplied)

Fig. 9-10

Refrigerant tubing and insulator

Drain insulator and clamp. Large (supplied)

Packing clamp. Small hose band (supplied)

(not supplied)

Drain pipe and insulator (not supplied)

Insulation tape

Vinyl

Flare

clamp

insulator

Seal

The procedure used for installing the insulator for both gas and liquid tubes is the same.

Fig. 9-11

Never grasp the drain or refrigerant connecting outlets when moving the unit.

Liquid tube

Page 99

9-4. Taping the Tubes

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

wiring if local codes permit) should be taped together with armoring tape in 1 bundle. To prevent condensation from overflowing the drain pan, keep the drain hose separate from the refrigerant 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.

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

clamp approx. each meter. (Fig. 9-12)

Inter-unit control wiring

Insulation

Gas tube

Armoring tape

Liquid tube

NOTE

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

9-5. 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. 9-13)

Fig. 9-12

Apply putty here

Tubing

Fig. 9-13

Page 100

10. LEAK TEST, EVACUATION AND

Manifold gauge

ADDITIONAL REFRIGERANT CHARGE

 Perform an air-tightness test for this package A/C. Check

that there is no leakage from any of the connections. Air and moisture in the refrigerant system may 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 refrigerant

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.

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

Preparation

Manifold valve

Check that each tube (both liquid and gas tubes) between the indoor and outdoor units has been properly connected and all wiring for the test run has been completed. Remove

Pressure gauge

the valve caps from both the gas and liquid service valves on the outdoor unit. Note that both liquid and gas tube service valves on the outdoor unit are kept closed at this stage.

 The refrigerant charge at the time of shipment is only

guaranteed sufficient for a tubing length of up to 100 ft. The tubing may exceed this length, up to the maximum permitted length; however, an additional charge is necessary for the amount that the tubing exceeds 100 ft. (No additional refrigerating machine oil is needed.)

Fig. 10-1

Vacuum pump

Outlet Inlet

Fig. 10-2

Lo Hi

Charge hose

Cylinder valve

Nitrogen gas cylinder (In vertical standing position)

10-1. Leak Test

(1) With the service valves on the outdoor unit closed,

remove the 1/4 in. flare nut and its bonnet on the gas tube service valve. (Save for reuse.)

(2) Attach a manifold valve (with pressure gauges) and dry

nitrogen gas cylinder to this service port with charge hoses.

Use a manifold valve for air

CAUTION

purging. If it is not available, use a stop valve for this purpose. The “Hi” knob of the manifold valve must always be kept closed.

Open

Gas tube

Outdoor unit

Liquid tube

Fig. 10-3

100