Sanyo R410A User Manual

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Page 1

Outdoor Units

85464359982001 ©SANYO 2006 SANYO Electric Co., Ltd.

Gunma, Japan

– W-2WAY System Air Conditioner –

 R410A Models Indoor Units

Class 7 9 12 18 24 36 48

X 4-Way Air Discharge Semi-Concealed Type XHX1252 XHX1852 XHX2452 XHX3652

A 1-Way Air Discharge Semi-Concealed Type AHX0752 AHX0952 AHX1252

U Concealed Duct Type UHX0752 UHX1252 UHX1852 UHX2452 UHX3652

Concealed Duct

DHX3652 DHX4852

High-Static Pressure Type

T Ceiling-Mounted Type THX1252 THX1852 THX2452

K Wall-Mounted Type KHX0752 KHX0952 KHX1252 KHX1852 KHX2452

for Refrigerant R410A

* Refrigerant R410A is used in the outdoor units.

INSTALLATION INSTRUCTIONS

Class 90 140

C ECO-i W-2WAY

CHDX09053 CHDX14053

Optional Controllers

Timer Wired Remote Controller RCS-TM80BG

Wireless Remote Controller (For U, D Type) RCS-BH80AAB.WL

Wireless Remote Controller (For X Type) RCS-SH80AAB.WL

Wireless Remote Controller (For A, T Type) RCS-TRP80AAB.WL

RC Wireless Remote Controller (For K Type) RCS-SH1AAB

Simplified Remote Controller RCS-KR1AGB

System Controller SHA-KC64UG

Intelligent Controller SHA-KT256BA

Communication Adaptor SHA-KA128AAB

Remote Sensor ART-K45AGB

LonWorks Interface SHA-LN16UAB

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page a

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

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

If Necessary, Get Help

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

In Case of Improper Installation

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

SPECIAL PRECAUTIONS

When Wiring

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

• 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 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.

• 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.

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WARNING

CAUTION

WARNING

CAUTION

Page 3

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

(1) No partition (shaded portion)

(2) When there is an effective opening with the adjacent

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).

(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.

3. The minimum indoor floor space compared with the amount of refrigerant is roughly as follows: (When the ceiling is 8.8 ft. high)

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.

Total amount of refrigerant (lbs)

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

Density limit (oz/ft.3)

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

(ISO 5149).

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:

The possible amount of leaked refrigerant gas in rooms A, B and C is 353 oz. The possible amount of leaked refrigerant gas in rooms D, E and F is 529 oz.

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NOTE

Outdoor unit

Refrigerant tubing

Indoor unit

Refrigerant tubing

Outdoor unit

Very small room

Small room

Mechanical ventilation device – Gas leak detector

Medium room

Large room

Indoor unit

e.g., charged amount (353 oz)

Indoor unit

Outdoor unit

e.g., charged amount (529 oz)

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

ft.

4000

3500

3000

Min. indoor volume

2500

2000

1500

1000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

400200 600 800 1000 1200

Total amount of refrigerant

454

398

341

284

227

170

114

ft.

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

Page 4

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

ant 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.

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

in the unit.

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

ant 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.

Material O

Copper tube

Outer diameter 1/4 (6.35) 3/8 (9.52) 1/2 (12.7) 5/8 (15.88) 3/4 (19.05)

Wall thickness 1/32 (0.8) 1/32 (0.8) 1/32 (0.8) 5/128 (1.0)

over 5/128 (1.0)

Material 1/ 2 H, H

Copper tube

Outer diameter 7/8 (22.22) 1 (25.4) 1-1/8 (28.58) 1-1/4 (31.75) 1-1/2 (38.1) 1-5/8 (41.28)

Wall thickness 5/128 (1.0) 5/128 (1.0) 5/128 (1.0) 3/64 (1.1)

over 3/64 (1.15)

over

3/64 (1.20)

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 Seamless

Pipes and Tubes.” For tubes of ø7/8" (ø22.22 mm) or larger, use C1220 T-1/2H material or H material, and do not bend the 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, use a bending radius that is 4 times the outer diameter of the tubing or larger.

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

Use sufficient care in handling the tubing. Seal the tubing ends with caps or tape to prevent dirt, moisture, or other foreign substances from entering. These substances can result in system malfunction.

R407C tools

Item compatible Remarks

with R410A?

Manifold gauge Yes No Types of refrigerant, refrigerating machine

oil, and pressure gauge are different.

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

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

Leak detector Yes No Leak detectors for CFC and HCFC that

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

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

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.

Unit: in. (mm)

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CAUTION

New tool?

Manifold gauge

Vacuum pump

Outlet Inlet

Page 5

3-2. Use R410A exclusive cylinder only.

Single-outlet valve

(with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown.

New refrigerant R410A cannot be used for earlier models

1. Compressor specifications are different.

If recharging a R22 or R407C compressor with R410A, durability will significantly decrease since some of the materials used for compressor parts are different.

2. Existing tubing cannot be used (especially R22).

Completely cleaning out residual refrigerating

machine oil is impossible, even by flushing.

3. Refrigerating machine oil differs (R22).

Since R22 refrigerating machine oil is mineral oil, it does not dissolve in R410A. Therefore, refrigerating machine oil discharged from the compressor can cause compressor damage.

R22 refrigerating machine oil Mineral oil (Suniso oil)

R407C refrigerating machine oil Synthetic fluid (ether oil)

R410A refrigerating machine oil Synthetic fluid (ether oil)

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Valve

Liquid

R410A

Page 6

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

Please Read Before Starting Check of Density Limit Precautions for Installation Using New Refrigerant New refrigerant R410A cannot be used for earlier models

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

1-1. Tools Required for Installation (not supplied) 1-2. Accessories Supplied 1-3. Type of Copper Tube and Insulation Material 1-4. Additional Materials Required for Installation 1-5. Tubing Length 1-6. Tubing Size 1-7. Straight Equivalent Length of Joints 1-8. Additional Refrigerant Charge 1-9. System Limitations 1-10. Check of Limit Density 1-11. Installing Distribution Joint 1-12. Optional Distribution Joint Kits 1-13. Example of Tubing Size Selection and

Refrigerant Charge Amount

2. SELECTING THE INSTALLATION SITE . . . . . 19

2-1. Indoor Unit 2-2. Outdoor Unit 2-3. Shield for Horizontal Exhaust Discharge 2-4. Installing the Outdoor Unit in Heavy Snow Areas 2-5. Precautions When Installing in Heavy Snow

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

3. HOW TO INSTALL THE INDOOR UNIT . . . . . 24

 4-Way Air Discharge Semi-Concealed Type

(X Type)

3-1. Preparation for Suspending 3-2. Suspending the Indoor Unit 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. How to Install the Ceiling Panel 3-7. Special Remarks

 1-Way Air Discharge Semi-Concealed Type

(A Type)

3-8. Suspending the Indoor Unit 3-9. Placing the Unit Inside the Ceiling 3-10. Installing the Drain Piping 3-11. Checking the Drainage 3-12. Electrical Power Wiring 3-13. How to Install the Ceiling Panel

 Concealed Duct Type (U Type)

3-14. Required Minimum Space for Installation and

Service 3-15. Suspending the Indoor Unit 3-16. Installing the Drain Piping 3-17. Checking the Drainage 3-18. Increasing the Fan Speed

 Concealed Duct High-Static Pressure Type

(D Type)

3-19. Required Minimum Space for Installation and

Service 3-20. Suspending the Indoor Unit 3-21. Installing the Drain Piping 3-22. Caution for Ducting Work 3-23. Indoor Fan Performance

 Ceiling-Mounted Type (T Type)

3-24. Required Minimum Space for Installation and

Service 3-25. Suspending the Indoor Unit 3-26. Duct for Fresh Air 3-27. Shaping the Tubing 3-28. Installing the Drain Piping

 Wall-Mounted Type (K Type)

3-29. Removing the Rear Panel from the Unit 3-30. Selecting and Making a Hole 3-31. Installing the Rear Panel onto the Wall 3-32. Removing the Grille to Install the Indoor Unit 3-33. Preparing the Tubing 3-34. Shaping the Tubing 3-35. Installing the Drain Hose 3-36. When Using Wireless Remote Controller

Instead of Wired Remote Controller

4. HOW TO INSTALL THE OUTDOOR UNIT . . . 55

4-1. Transporting 4-2. Installing the Outdoor Unit 4-3. Routing the Tubing 4-4. Prepare the Tubing 4-5. Connect the Tubing

5. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 59

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

Diameter for Power Supply System 5-3. Wiring System Diagram

CONTENTS

Page Page

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Page 7

6. HOW TO PROCESS TUBING . . . . . . . . . . . . 63

6-1. Connecting the Refrigerant Tubing 6-2. Connecting Tubing Between Indoor and

Outdoor Units 6-3. Insulating the Refrigerant Tubing 6-4. Taping the Tubes 6-5. Finishing the Installation

7. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . . 67

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

Preparation

8. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8-1. Preparing for Test Run 8-2. Test Run Procedure 8-3. Main Outdoor Unit PCB Setting 8-4. Auto Address Setting 8-5. Remote Controller Test Run Settings 8-6. Caution for Pump Down 8-7. Meaning of Alarm Messages

9. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9-1. 4-Way Air Discharge Semi-Concealed Type

(X Type) 9-2. 1-Way Air Discharge Semi-Concealed Type

(A Type) 9-3. Concealed Duct (High-Static Pressure) Type

(U, D Type) 9-4. Ceiling-Mounted Type (T Type) 9-5. Wall-Mounted Type (K Type)

Page

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 7

Page 8

Table 1-1 Outdoor Unit

1-2. Accessories Supplied

See Tables 1-1 – 1-7.

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

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Carpenter’s level

6. Sabre saw or key hole saw

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)

1-3. Type of Copper Tube and Insulation Material

If you wish to purchase these materials separately from a

local source, you will need:

1. Deoxidized annealed copper tube for refrigerant tubing.

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

“

5. ELECTRICAL WIRING” for details.

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

Check local electrical codes and

regulations before obtaining

wire. Also, check any specified

instructions or limitations.

1. GENERAL

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

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 8

CAUTION

Part name

Connection tubing

Instruction manual paper

Outer diameter ø1-1/8"

Outer diameter ø7/8"

Figure

Inner diameter ø1"

Inner diameter ø3/4"

09053 Model

(10 hp)

Q’ty

14053 Model

(16 hp)

(hp = horse power)

Page 9

Table 1-2 (4-Way Air Discharge Semi-Concealed)

Table 1-3 (1-Way Air Discharge Semi-Concealed)

Table 1-4 (Concealed Duct)

 Use 3/8" for suspending bolts.  Field supply for suspending bolts and nuts.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 9

Part Name Figure

Full-scale installation diagram

Drain hose

Hose band

Drain insulator

Flare insulator

Insulating tape

Packing

Wiring cover

Screw

Washer

Screw

Part Name Figure

Full-scale installation diagram

Drain hose

White (heat-resisting)

Q’ty

Printed on container box

For securing drain hose

For drain joint

For liquid tube

For gas tube

For gas tube joint

For drain joint

For covering erectrical wiring

For full-scale installation diagram

For suspending indoor unit from ceiling

For fixing the wiring cover

Q’ty

Printed on container box

For securing drain hose

Remarks

Hose band

Drain insulator

Flare insulator

Insulating tape

Packing

Washer

Screw

Bushing

Part Name Figure

Drain hose

Hose band 1

Packing 1

Drain insulator 1

Flare insulator 1

Insulating tape

Flare insulator 1

White (heat-resisting)

For securing drain hose

For drain joint

For liquid tube

For gas tube

For gas tube joint

For drain joint

For suspending indoor unit from ceiling

For full-scale installation diagram

For electrical junction box

Q’ty

For securing drain hose

For drain joint

For liquid tube

For gas and liquid tubes flare nuts

For gas tube

Remarks

Washer

Sealing putty 1

Vinyl clamp 8

For suspending indoor unit from ceiling

For sealing recessed portion of power supply

For flare and drain insulators

Page 10

Table 1-5 (Concealed Duct High-Static Pressure)

Table 1-6 (Ceiling-Mounted)

Table 1-7 (Wall-Mounted)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 10

Part Name Figure

Washer

Nut

Flare insulator

Drain socket

Part Name Figure

Full-scale installation diagram 1

Washer 4

Insulating tape 2

Vinyl clamp 8

Drain hose1

Hose band2

Drain insulator 1

T1/8"

T3/16"

White (heat-resisting)

L5-1/2"

Q’ty

For suspending indoor unit from ceiling

Remarks

1 For gas tube

For liquid tube

For drain pipe connection

Q’ty

Remarks

Printed on container box

For temporarily suspending indoor unit from ceiling

For gas and liquid tube jointsFlare insulator

For gas and liquid tubes flare nuts

For flare and drain insulators

For main unit and PVC pipe joints

For drain hose connection

For drain hose joint

Gum eyelet 1

Part Name Figure

Tapping screw

Plastic cover

Insulator

5/32" × 1"

For power supply inlet

Q’ty

For fixing the rear panel

For improved tubing appearance

For insulating flare nut (2452 type only)

Remarks

Page 11

1-5. Tubing Length

Table 1-8 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights

Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown in the figure below.

1: The outdoor connection main tubing ( B portion) is determined by the total capacity of the outdoor units that are connected to

the tube ends.

2: If the longest tubing length (L1) exceeds 295 ft. (equivalent length), increase the sizes of the main tubes (LM) by 1 rank for gas

tubes and liquid tubes. (Use a field supply reducer.) (Select the tube size from the table of main tube sizes (Table 1-9) on the following page (LA table), and from the table of refrigerant tubing sizes (Table 1-14) on the second following page.)

3: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the

gas tubes. (Use a field supply reducer.) (For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table on the following page.)

4: If the size of the existing tubing is already larger than the standard tubing size, it is not necessary to further increase the size.

* If the existing tubing is used, and the amount of on-site additional refrigerant charge exceeds the value listed below, then

change the size of the tubing to reduce the amount of refrigerant.

Max. additional charge for 1 outdoor unit: 62 lbs Max. additional charge for 2 outdoor units: 111lbs

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 11

2. The outdoor connection main tubing ( B portion) is determined by the total capacity of the outdoor units that are connected to the tube ends.

Balance tubing (ø1/4

Explanation of symbols

Distribution joint (APR: purchased separately)

Ball valve (field supply)

T- j o i nt (field supply)

Solidly welded shut (pinch weld)

Main tu

bing length LM = LA + LB … ≤ 262 ft

Main distribution tubes LC – LG are selected according to the capacity after the distribution joint.

Sizes of indoor unit connection tubing 1 – 40 are determined by the connection tubing sizes on the indoor units.

LB LC

Max. 1.3 ft

For extension

LD L3

For extension

R410A distribution joint APR-CHP680BA (for outdoor unit)

APR-CHP1350BA (for outdoor unit) APR-P160BA (for indoor unit)

APR-P680BA (for indoor unit) APR-P1350BA (for indoor unit)

Note: Do not use commercially available T-joints for the liquid tubing and parts. * Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor unit connections and tubing branches.

Item Mark Contents Length (ft.)

L1 Max. tubing length

∆L (L2 – L4)

Allowable tubing length

LM Max. length of main tubing (at max. diameter) 262

, 2...

112

L1+

...

+LE+LF+LG

Allowable elevation difference

Difference between max. length and min. length from the No.1 distribution joint

Max. length of each distribution tube 98

Total max. tubing length including length of each distribution tube (only liquid tubing)

Distance between outdoor units

When outdoor unit is installed higher than indoor unit 164 When outdoor unit is installed lower than indoor unit 131 Max. difference between indoor

Actual length 492

Equivalent length 574

units 49

H3 Max. difference between outdoor units

Allowable length of joint tubing

L = Length, H = Height

T-joint tubing (field-supply); Max. tubing length between the first T-joint and solidly welded-shut end point

NOTE

131

984

6.6

Page 12

1-6. Tubing Size

Table 1-9 Main Tubing Size (LA)

*1: If future extension is planned, select the tubing diameter based on the total horsepower after extension.

However extension is not possible if the resulting tubing size is two ranks higher. *2: The balance tube (outdoor unit tube) diameter is ø1/4". *3: Type 1 tubing should be used for the refrigerant tubes. *4: If the length of the longest tube (L1) exceeds 295 ft. (equivalent length), increase the main tube (LM) size by 1 rank for the gas

and liquid tubes. (Use field-supply reducers.) (Select from Table 1-9 and Table 1-14.) *5: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the

gas tubes.

(For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table above.)

 Size of tubing (LO) between outdoor units

Select the size of tubing between outdoor units based on the main tubing size (LA) as given in the table above.

Note: In case the total capacity of connected indoor units exceeds the total capacity of the outdoor units, select the main tubing

size for the total capacity of the outdoor units. (Especially the main tubing segments of LA, LB and LF.)

Table 1-11 Outdoor Unit Tubing Connection Size

Table 1-12 Indoor Unit Tubing Connection Size

Note: Use C1220T-1/2H material for tubing over ø3/4" (ø22.22).

Table 1-10 Main Tubing Size After Distribution (LB, LC...)

Unit: in. (mm)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 12

BTU/h

(kW)

Total system horsepower

Combined outdoor units

Gas tubing

Liquid tubing

95,500

(28.0)

ø7/8"

(ø22.22)

ø3/8"

(ø9.52)

153,600

(45.0)

1610

ø1-1/8"

(ø28.58)

ø1/2"

(ø12.7)

191,100

(56.0)

10 10

ø5/8"

(ø15.88)

249,100

(73.0)

16 10

(ø31.75)

(ø19.05)

307,100

(90.0)

16 16

ø1-1/4"

ø3/4"

Total capacity after distribution

Below BTU/h

Over BTU/h

24,200

(2.5 hp)

–

Gas tubing

Tubing size

Liquid tubing

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

54,600

(6 hp)

24,200

(2.5 hp)

ø5/8"

(ø15.88)

ø3/8"

(ø9.52)

76,800

(8.1 hp)

54,600

(6 hp)

ø3/4"

(ø19.05)

ø3/8"

(ø9.52)

102,400

(11 hp)

76,800

(8.1 hp)

ø7/8"

(ø22.22)

ø3/8"

(ø9.52)

143,300

(15 hp)

102,400

(11 hp)

ø1"

(ø25.4)

ø1/2"

(ø12.7)

178,800

(19 hp)

143,300

(15 hp)

ø1-1/8"

(ø28.58)

ø1/2"

(ø12.7)

238,900

(25 hp)

178,800

(19 hp)

ø1-1/8"

(ø28.58)

ø5/8"

(ø15.88)

hp = horsepower

334,400

(35 hp)

238,900

(25 hp)

ø1-1/4"

(ø31.75)

ø3/4"

(ø19.05)

–

334,400

(35 hp)

ø1-1/2" (ø38.1)

ø3/4"

(ø19.05)

( A – C)

BTU/h

(kW)

Gas tubing

Liquid tubing

Balance tubing

Indoor unit type7 9 12 18 24 3648

Gas tubing

Liquid tubing

95,500

(28.0)

ø7/8"

(ø22.22)

Brazing connection

ø3/8" (ø9.52)

Flare connection

ø1/4" (ø6.35)

Flare connection

ø1/2" (ø12.7)

153,600

(45.0)

ø1-1/8"

(ø28.58)

ø1/2" (ø12.7)

Balance tube

Liquid tube

ø5/8" (ø15.88)

ø3/8" (ø9.52)ø1/4" (ø6.35)

Gas tube

Page 13

Table 1-16 Refrigerant Charge Amount at Shipment (for outdoor unit)

CHDX09053 CHDX14053

(oz)

423 458

1-9. System Limitations

Table 1-17 System Limitations

Max. No. allowable connected outdoor units 2 *1

Max. capacity allowable connected outdoor units 307,100 BTU/h (32 hp, 90 kW)

Max. connectable indoor units 40

Max. allowable indoor/outdoor capacity ratio 50 – 130 %

*1: Up to 2 units can be connected if the system has been extended.

1-7. Straight Equivalent Length of Joints

Design the tubing system by referring to the following table for the straight equivalent length of joints.

Table 1-13 Straight Equivalent Length of Joints

Table 1-14 Refrigerant tubing (Existing tubing can be used.)

Tubing size (in. (mm))

Material O Material 1/2H • H

ø1/4" (ø6.35) t1/32" (0.8) ø7/8" (ø22.22) t5/128" (1.0)

ø3/8" (ø9.52) t1/32" (0.8) ø1" (ø25.40) t5/128" (1.0)

ø1/2" (ø12.7) t1/32" (0.8) ø1-1/8" (ø28.58) t5/128" (1.0)

ø5/8" (ø15.88) t5/128" (1.0) ø1-1/4" (ø31.75) t3/64" (1.1)

ø3/4" (ø19.05) over t5/128" (1.0) ø1-1/2" (ø38.10) over t3/64" (1.15)

ø1-5/8" (ø41.28) over t3/64" (1.20)

* When bending the tubes, use a bending

radius that is at least 4 times the outer

diameter of the tubes.

In addition, take sufficient care to avoid

crushing or damaging the tubes when

bending them.

1-8. Additional Refrigerant Charge

Additional refrigerant charge amount is calculated from the liquid tubing total length as follows.

Table 1-15 Amount of Refrigerant Charge Per Meter, According to Liquid Tubing Size

Liquid tubing size Amount of refrigerant

(in. (mm)) charge (oz/ft.)

ø1/4" (ø6.35) 0.279

ø3/8" (ø9.52) 0.602

ø1/2" (ø12.7) 1.38

ø5/8" (ø15.88) 1.99

ø3/4" (ø19.05) 2.78

ø7/8" (ø22.22) 3.93

Required amount of charge = (Amount of refrigerant charge per meter of each size of liquid tube × its tube length) + (...) + (...)

* Always charge accurately using a scale for weighing.

* If the existing tubing is used, and the amount of on-site additional

refrigerant charge exceeds the value listed below, then change the

size of the tubing to reduce the amount of refrigerant.

Max. additional charge for 1 outdoor unit : 62 lbs

Max. additional charge for 2 outdoor units :111 lbs

Max. additional charge for 3 outdoor units :133 lbs

Unit: ft.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 13

Gas tubing size (in. (mm))

90° elbow

45° elbow 0.8 0.9 1 1.2 1.3 1.4 1.7 1.9

1/2"

(12.7)

5/8"

(15.88)

1 1.1 1.4 1.6 1.7 1.9 2.3 2.6

3/4"

(19.05)

7/8"

(22.22)1"(25.4)

U-shape tube bent (R2-3/8" – 4" (60 – 100)) 33.4 4.1 4.7 5.1 5.6 6.9 7.8

Tra p b end

Y-branch distribution jointEquivalent length conversion not n

Ball valve for service Equivalent length conversion not needed.

7.5 9.2 10.5 12.5 14.1 15.4 16.4 14.0

1-1/8"

(28.58)

eeded.

1-1/4" (31.8)

1-1/2"

(38.1)

Page 14

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

1-10. Check of Limit Density

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

(Total refrigerant charged amount: oz)

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

< Limit density 0.3 (oz/ft.

)

The limit density of refrigerant R410A 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 in the field. (For the refrigerant charge amount at shipment, refer to the unit’s nameplate.)

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

Pay special attention to any location, such as a basement, etc., where leaking refrigerant can accumulate, since refrigerant gas is heavier than air.

1-11. Installing Distribution Joint

(1) Refer to “HOW TO ATTACH DISTRIBUTION JOINT” enclosed

with the optional distribution joint kit

(APR-CHP680BA, APR-CHP1350BA, APR-P160BA,

APR-P680BA, APR-P1350BA).

(2) When creating a branch using a commercially available

T-joint (header joint system), orient the main tubing so that it is

either horizontal (level) or vertical. In order to prevent accumu-

lation of refrigerant oil in stopped units, if the main tubing is

horizontal then each branch tubing length should be at an

angle that is greater than horizontal. If the main tubing is verti-

cal, provide a raised starting portion for each branch.

(3) If there are height differences between indoor units or if branch

tubing that follows a distribution joint is connected to only 1

unit, a trap or ball valve must be added to that

distribution joint. (When adding the ball valve, locate it

within 1.3 ft. of the distribution joint.)

If a trap or ball valve is not added, do not operate the sys-

tem before repairs to a malfunctioning unit are

completed. (The refrigerant oil sent through the tubing to

the malfunctioning unit will accumulate and may damage

the compressor.)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 14

WARNING

CAUTION

ft.

10000

9500 9000

8500 8000

7500 7000

Min. indoor volume

6500 6000 5500 5000 4500 4000

3500 3000

2500 2000 1500 1000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

1000500 1500 2000 2500 3000

Total amount of refrigerant

Tube branching methods (horizontal use)

15 to 30°

Horizontal

Ty pe s of vertical trap specifications

(When using ball valve)

Main tubing

line

Arrow view

View as seen from arrow

ft.

1136 1079 1022 966 909 852 795 738 682 625 568 511 454

398 341

284 227 170 114 57

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

Ball valve

(BV: purchased

separately)

Indoor unit (1)

(When not using ball valve)

Main tubing

Indoor unit is directed downward

Indoor unit (more than 2 units)

Branch tubing is directed upward.

More than 8 inch

(If only 1 unit is connected, a ball valve is also needed on this side.)

Horizontal

Indoor unit

(Each unit is connected to tubing that is either level or is directed downward.)

Page 15

1-12. Optional Distribution Joint Kits

See the installation instructions packaged with the distribution joint kit for the installation procedure.

Table 1-18

1. APR-CHP680BA For outdoor unit (Capacity after distribution joint is 232,000 BTU/h (68.0 kW) or less.)

Table 1-19 Size of connection point on each part (Shown are inside diameters of tubing)

2. APR-CHP1350BA For outdoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than

Table 1-20 Size of connection point on each part (Shown are inside diameters of tubing)

Model name Cooling capacity after distribution Remarks

1. APR-CHP680BA 232,000 BTU/h (68.0 kW) or less For outdoor unit

2. APR-CHP1350BA 460,700 BTU/h (135.0 kW) or less For outdoor unit

3. APR-P160BA 76,400 BTU/h (22.4 kW) or less For indoor unit

4. APR-P680BA 232,000 BTU/h (68.0 kW) or less For indoor unit

5. APR-P1350BA 460,700 BTU/h (135.0 kW) or less For indoor unit

 Tubing size (with thermal insulation)

Unit: in.

Example:

Unit: in.

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" (ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52)

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8"

(ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52)

460,700 BTU/h (135.0 kW).)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 15

Distribution Joint

Reducing Joints

Gas tubing Liquid tubing

6-59/64

5-5/16

CDEF

Insulation

4-31/64

Distribution Joint

Insulation

4-21/64

3-13/16

HFI

Reducing Joints

2-53/64

Gas tubing Liquid tubing

Insulation

6-57/64

5-5/16

Distribution Joint

C D

Reducing Joints

4-31/64

Distribution Joint

Insulation

4-21/64

3-13/16

HFI

2-53/64

Reducing Joints

Page 16

3. APR-P160BA

Use: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.)

Table 1-21 Size of connection point on each part (Shown are inside diameters of tubing)

4. APR-P680BA

Use: For indoor unit (Capacity after distribution joint is greater than 76,400 BTU/h (22.4 kW) and no more than

Table 1-22 Size of connection point on each part (Shown are inside diameters of tubing)

5. APR-P1350BA

Use: For indoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than

Table 1-23 Size of connection point on each part (Shown are inside diameters of tubing)

Example:

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I Part J

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" ø1/4" (ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Size Part A Part B Part C Part D Part E Part F Part G Part H

in. (mm)

ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" ø1/4"

(ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Size Part A Part B Part C Part D Part E

in. (mm)

ø3/4" ø5/8" ø1/2" ø3/8" ø1/4"

(ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Unit: in.

232,000 BTU/h (68.0 kW).)

460,700 BTU/h (135.0 kW).)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 16

Gas tubing Liquid tubing

4-21/64

Insulation

3-13/16

Distribution Joint

2-53/64

Insulation

4-21/64

3-13/16

Distribution Joint

D E

2-53/64

DCB

Distribution Joint

Insulation

Distribution

Joint

Insulation

Gas tubing Liquid tubing

6-57/64

5-5/16

Gas tubing Liquid tubing

6-57/64

5-5/16

B C

E F

C D

E F

G H

BCD

Reducing Joints

4-31/64

Distribution Joint

Insulation

Distribution Joint

Insulation

4-21/64

3-13/16

F G H

4-21/64

3-13/16

FGH

Reducing Joints

2-53/64

Page 17

1-13. Example of Tubing Size Selection and Refrigerant Charge Amount

Additional refrigerant charging

Based on the values in Tables 1-9, 10, 11, 12 and 15, use the liquid tubing size and length, and calculate the amount of additional

refrigerant charge using the formula below.

= 3.93 × (a) + 2.78 × (b) + 1.99 × (c) + 1.38 × (d) + 0.602 × (e) + 0.279 × (f)

(a) : Liquid tubing Total length of ø7/8" (ft.) (d) : Liquid tubing Total length of ø1/2" (ft.)

(b) : Liquid tubing Total length of ø3/4" (ft.) (e) : Liquid tubing Total length of ø3/8" (ft.)

 Charging procedure

Be sure to charge with R410A refrigerant in liquid form.

1. After performing a vacuum, charge with refrigerant from the liquid tubing side. At this time, all valves must be in the “fully

closed” position.

2. If it was not possible to charge the designated amount, operate the system in Cooling mode while charging with refrigerant

from the gas tubing side. (This is performed at the time of the test run. For this, all valves must be in the “fully open” position.

However if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valves fully closed.)

Charge with R410A refrigerant in liquid form.

With R410A refrigerant, charge while adjusting the amount being fed a little at a time in order to prevent liquid refrigerant from

backing up.

 After charging is completed, turn all valves to the “fully open” position.

 Replace the tubing covers as they were before.

Required additional refrigerant charge (oz)

1. R410A additional charging absolutely must be done through liquid charging.

2. The R410A refrigerant cylinder has a gray base color, and the top part is pink.

3. The R410A refrigerant cylinder includes a siphon tube. Check that the siphon tube is present. (This is indicated on the label at the top of the cylinder.)

4. Due to differences in the refrigerant, pressure, and refrigerant oil involved in installation, it is not possible in some cases to use the same tools for R22 and for R410A.

Example:

 Example of each tubing length

Main tubing Distribution joint tubing

LA = 131 ft. Outdoor side Indoor side LB = 16 ft. A = 7 ft. 1 = 98 ft. LC = 16 ft. B = 7 ft. 2 = 16 ft.

3 = 16 ft. 4 = 65 ft.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 17

CAUTION

Balance tube

Use a flathead screwdriver and open by turning the part with the screw groove to the right, from “–” to “|”.

Outdoor unit

09053 model

1 2 3 4

Liquid tube

Use a hex wrench (width 5/32 inch) and turn to the left to open.

Gas tube Use a flathead screwdriver and

open by turning the part with the screw groove to the right, from “–” to “|”.

48 model 48 model 48 model

36 model

Page 18

Checking of limit density

Density limit is determined on the basis of the size of a room

using an indoor unit of minimum capacity. For instance, when

an indoor unit is used in a room (floor area 161 ft.

× ceiling

height 8.8 ft. = room volume 1417 ft.

), the graph at right

shows that the minimum room volume should be 2455 ft.

(floor area 279 ft.2) for refrigerant of 418 oz.

Overall refrigerant charge amount for the air conditioner: oz

(Minimum room volume for indoor unit: ft.3)

418 (oz)

= 0.29 (oz/ft.

) < 0.3 (oz/ft.3)

1417 (ft.

)

Therefore, openings such as louvers are not required for this

room.

 Obtain liquid tubing size from Tables 1-9, 10, 11, 12 and 15.

Main tubing

LA = ø5/8 (ft.) (Total capacity of indoor unit is 179,400 BTU/h) The longest tubing length in this example

LB = ø1/2 (ft.) (Total capacity of indoor unit is 131,600 BTU/h) (LA = 131 ft.)

LC = ø3/8 (ft.) (Total capacity of indoor unit is 83,800 BTU/h)

Distribution joint tubing

Outdoor side A: ø3/8 (ft.) B: ø3/8 (ft.) (from outdoor unit connection tubing)

Indoor side 1: ø3/8 (ft.) 2: ø3/8 (ft.) 3: ø3/8 (ft.) 4: ø3/8 (ft.) (from indoor unit connection tubing)

 Obtain charge amount for each tubing size

Note that the charge amounts per 1 meter are different for each liquid tubing size. ø5/8 (ft.) → LA : 131 ft. × 1.99 oz/ft. = 261 oz ø1/2 (ft.) → LB : 16 ft. × 1.38 oz/ft. = 22 oz ø3/8 (ft.) → LC + A – B + 1 – 4 : 225 ft. × 0.602 oz/ft. = 135 oz

Total 418 oz

Additional refrigerant charge amount is 418 oz.

Be sure to check the limit density for

the room in which the indoor unit is

installed.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 18

CAUTION

ft.

4000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

400200 600 800 1000 1200

Total amount of refrigerant

Min. indoor volume

3500

3000

2500

2000

1500

1000

454

398

341

284

227

170

114

ft.

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

Page 19

2. SELECTING THE INSTALLATION SITE

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 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 high-frequency emissions are generated.

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 1-8.

 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.

Air delivery will be degraded if the distance from the floor to

the ceiling is greater than 10 ft.

Fig. 2-1

Fig. 2-2

Fig. 2-3

Fig. 2-4

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 19

Ceiling-Mounted Type

Ceiling

Wall

min. 10 in.

Front view

min. 10 in.

NOTE

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

Air discharge

min. 2 ft.

Side view

Air intake

Max. 10 in.

Obstacle

Concealed Duct (High-Static Pressure) Type 4-Way Air Discharge Semi-Concealed Type

3 ft.

NOTE

1-Way Air Discharge Semi-Concealed Type

Ceiling

min. 2 in.

Air discharge

min. 3 ft.

Obstacle

Air intake

min. 2 in.

Wall

Side view

Wall-Mounted Type

min. 6 in.

min.6 in.

min. 6 in.

Front View

Page 20

Fig. 2-5

Fig. 2-6

Fig. 2-7

2-2. Outdoor Unit

AVOID:

 heat sources, exhaust fans, etc.

 damp, humid or uneven locations

 indoors (no-ventilation location)

DO:

 choose a place as cool as possible.

 choose a place that is well ventilated.

 allow enough room around the unit for air intake/

exhaust and possible maintenance.

Installation Space

Install the outdoor unit where there is enough space for ven-

tilation. Otherwise the unit may not operate properly. Fig. 2-6

shows the minimum space requirement around the outdoor

units when 3 sides are open and only 1 side is shuttered,

with open space above the unit. The mounting base should

be concrete or a similar material that allows for adequate

drainage. Make provisions for anchor bolts, platform height,

and other site-specific installation requirements.

 Leave space open above the

unit.

 Construct louvers or other

openings in the wall, if necessary, to ensure adequate ventilation.

 Do not do any wiring or tubing within 1 ft. of the front

panel, because this space is needed as a servicing

space for the compressor.

 Ensure a base height of 4 in. or more to ensure that

drainage water does not accumulate and freeze

around the bottom of the unit.

 If installing a drain pan, install the drain pan prior to

installing the outdoor unit.

* Make sure there is at least 6 in. between the outdoor

unit and the ground.

Also, the direction of the tubing and electrical wiring

should be from the front of the outdoor unit.

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 20

Exhaust fan

Hot air

Heat

Outdoor unit

source

Example of installation of 2 units

(When wall height is below 6 ft.)

* More than 4 in.

CAUTION

NOTE

More than 2 in.

* More than 4 in.

* However, be sure to ensure a space of 1 ft. or more at

either the right side or the rear of the unit.

74-1/64 (Ceiling panel dimensions)

35-3/64 (Ceiling panel dimensions) 35-3/64 (Ceiling panel dimensions)

3-15/16

31-7/64 (Installation hole pitch) 31-7/64 (Installation hole pitch)

70-5/64 (Installation hole pitch)

7-7/8

Top view

More than

1.7 ft.

35-3/64 (Ceiling panel dimensions)

36-7/32 (Installation hole pitch)

37-13/32 (Maximum dimensions)

Page 21

2-3. Shield for Horizontal Exhaust Discharge

It is necessary to install an air-discharge chamber (field

supply) to direct exhaust from the fan horizontally if it is diffi-

cult to provide a minimum space of 7 ft. between the air-dis-

charge outlet and a nearby obstacle. (Fig. 2-8)

In regions with heavy snowfall,

the outdoor unit should be

provided with a solid, raised plat-

form and snow-proof ducting

(field supply). (Fig. 2-9)

2-4. Installing the Outdoor Unit in Heavy Snow

Areas

In locations where wind-blown snow can be a problem,

snow-proof ducting (field supply) should be fitted to the unit

and direct exposure to the wind should be avoided as much

as possible. (Fig. 2-10) The following problems may occur if

proper countermeasures are not taken:

 The fan in the outdoor unit may stop running, causing the

unit to be damaged.

 There may be no air flow.

 The tubing may freeze and burst.

 The condenser pressure may drop because of strong

wind, and the indoor unit may freeze.

2-5. Precautions When Installing in Heavy Snow

Areas

a) The platform should be higher than the maximum snow

depth. (Fig. 2-9)

b) 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 the outdoor unit.

c) The platform foundation must be solid and the unit must

be secured with anchor bolts.

d) When installing on a roof subject to strong wind, coun-

termeasures must be taken to prevent the unit from

being overturned.

Fig. 2-8

Fig. 2-9

Fig. 2-10

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 21

CAUTION

AVOID

Without snowproof ducting

(Without platform)

With snowproof ducting

(High platform)

Fall en snow

Page 22

2-6. Dimensions of Wind Ducting

Reference diagram for air-discharge chamber (field supply)

2-unit installation

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 22

unit: in.

Ceiling panel

33-3/16 35-3/64

(Ceiling panel dimensions)

35-15/64

(Maximum bracket dimensions)

Air direction: Front direction Air direction: Right direction

35-3/64

2-11/64 15/16

97-29/32

(Ceiling panel dimensions)

65-53/64 (32-5/64)

35-3/64

(Ceiling panel dimensions)

2-11/6415/16

33-3/16

35-3/64

97-29/32

65-53/64 (32-5/64)

35-15/64

(Ceiling panel dimensions)

Ceiling panel

(Maximum bracket dimensions)

Front view Front viewRight side view Right side view

Note: Can be installed so that the air direction is to the front, right, left or rear direction.

74-7/32

(2-unit installation: maximum dimensions)

5-25/32

33-3/16

31-7/64

33-3/16

31-7/64

(Installation hole pitch)

Top view

unit: in.

36-7/32

7-7/8

(Installation hole pitch)

2-11/64 15/16

97-29/32

35-3/64

(Ceiling panel dimensions)

65-53/64 (32-5/64)

Front view Right side view

Page 23

2-7. Dimensions of Snow Ducting

Reference diagram for snow-proof ducting (field supply)

2-unit installation

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 23

31-17/32

Air direction: Front direction

Ceiling panel

53-55/64

31-17/32

31-17/32 (Air intake duct)

9-13/32

45-5/16

(Ceiling panel dimensions)

36-7/64

35-3/64

53-55/64

33-3/16 (Air outlet duct)

9-13/32

1 pc.

4 pc.

9-13/32

(Ceiling panel dimensions)

(32-5/64)

97-29/32

65-53/64

31-17/32 53-55/64

45-5/16

9-13/32

(Ceiling panel dimensions)

35-3/64

32-7/832-7/8

9-13/32

15/16 15/16

36-7/64

9-13/32

Air direction: Right direction

Ceiling panel

35-3/64

53-55/64

9-13/32 9-13/32

unit: in.

33-3/16 (Air outlet duct)

31-17/32 (Air intake duct)

Front view

Note: Can be installed so that the air direction is to the front, right, left or rear direction.

Installation hole pitch

31-17/32

74-1/64 (Ceiling panel dimensions)

35-3/64

31-7/64

7-7/8

223

Right side view

35-3/64

3-15/16

31-7/64

70-5/64

Ceiling panel dimensions

Top (Before installation of snowfall protection duct)

36-7/32

35-3/64

37-13/32

Installation hole pitchInstallation hole pitch

31-17/32

Ceiling panel

Front view

35-3/64

9-29/64 9-29/64

(Ceiling panel dimensions)

7/82-11/64

Right side view

unit: in.

45-5/16

36-7/64

92-53/64

Front view

97-29/32

65-53/64

ht side view

36-7/64

45-5/16

36-7/64

45-5/16

Page 24

3. HOW TO INSTALL THE INDOOR UNIT

 4-Way Air Discharge Semi-Concealed Type (X Type)

3-1. Preparation for Suspending

This unit uses a drain pump. Use a carpenter’s level to check that the unit is level.

3-2. Suspending the Indoor Unit

(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.

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

Table 3-1

Unit: in. (mm)

(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, unit, and panel.

Table 3-2

Fig. 3-1

Fig. 3-2

Note: For DC Fan Tap Change Procedure

for 4-Way Cassette, see page 30.

Fig. 3-4

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) 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.

Unit: in. (mm)

Fig. 3-3

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 24

-in-anchor

-in-plug

Concrete Insert

Type

Length

12, 18, 24, 36

ABCD

31-1/32

(788)

28-15/32

(723)

34-27/32

(885)

34-27/32

(885)

Type

Length

12, 18, 24

ABCD

4-29/64

(113)

4-29/64

(113)

6-13/16

(173)

6-13/16

(173)

10-5/64

(256)

12-9/16

(319)

8-17/64

(210)

8-17/64

(210)

3-15/32

(88)

3-15/32

(88)

Drain outlet(other side)

(VP25)

Refregerant tubing joint(liquid side) Refregerant tubing joint(gas side)

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

A (suspension bolt pitch)

C (ceiling opening dimension)

B (suspension bolt pitch)

Suspension lug

Over 19/32 (15)

Supplied bolt

Powe r supply outlet

Inter-unit control wiring

Full-scale installation diagram (printed on top of container box)

1-3/8 (35)

15/32 – 43/64

(12 – 17)

Page 25

Fig. 3-5

(2) The length of suspension bolts must be appropriate

for a distance between the bottom of the bolt and the bottom of the unit of more than 19/32 in. as shown in Fig. 3-5.

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

supply) onto each of the 4 suspension bolts as shown in Fig. 3-5. Use 1 nut and 1 washer for the upper side, and 2 nuts and 1 washer for the lower side, so that the unit will not fall off the suspension lugs.

(4) Adjust so that the distance between the unit and the

ceiling bottom is 15/32 to 43/64 in. Tighten the nuts on the upper side and lower side of the suspension lug.

(5) Remove the protective polyethylene used to protect

the fan parts during transport.

3-4. Installing the Drain Piping

(1) Prepare a standard hard PVC pipe (O.D. 1-1/4 in.) for

the drain and use the supplied drain hose and hose band to prevent water leaks. The PVC pipe must be purchased separately. The unit’s transparent drain port allows you to check drainage. (Fig. 3-6)

 Insert the drain pipe until it contacts the socket, as

shown in Fig. 3-6, then secure it tightly with the hose band.

 Do not use adhesive when connecting the supplied

hose.

Reasons: 1. It may cause water to leak from the

connection. Since the connection is slippery just after the adhesive has been applied, the pipe easily slips off.

2. The pipe cannot be removed when maintenance is needed.

 Do not bend the supplied drain hose 90° or more.

The hose may slip off.

 Align the hose bands with the end of the hose.

Tighten the hose band firmly. Please make sure that the bead is not covered by the hose band. (Fig. 3-6)

(2) After checking the drainage, wrap the supplied packing

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

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

Tighten the hose clamps so their locking nuts face upward. (Fig. 3-6)

 Do not install an air bleeder

as this may cause water to spray from the drain pipe outlet. (Fig. 3-8)

Fig. 3-6

Fig. 3-7

Fig. 3-8

Unit: in. (mm)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 25

Suspension bolt

Nuts and washers (use for upper and lower)

Double nut

Connection pipe

(drain port)

Hose band

Align the hose band with the end of the pipe

Suspension lug

15/32 – 43/64 (12 – 17)

Hard PVC

socket

Supplied

drain hose

VP-25

(Field supply)

Packing

(supplied)

Notch

Hard PVC pipe VP-25

(Field supply)

PVC adhesive

CAUTION

NOTE

Bead

Drain insulator (supplied)

Air bleeder prohibited

CAUTION

Page 26

Fig. 3-9

Fig. 3-10

Fig. 3-11

Fig. 3-12

 In cases where it is necessary to raise the height

of the drain piping, the drain piping can be raised to a maximum height of 33-15/32" above the bottom surface of the ceiling. Under no conditions attempt to raise it higher than 33-15/32" above the bottom surface of the ceiling. Doing so will result in water leakage. (Fig. 3-9)

 Do not install the pipe with an upward gradient

from the connection port. This will cause the drain water to flow backward and leak when the unit is not operating. (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 pipes that are run

indoors.

3-5. Checking the Drainage

After wiring and drain 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.

(1) Connect power to the power terminal board (R, S

terminals) inside the electrical component box.

(2) Slowly pour about 0.3 gal of water into the drain pan

to check drainage. (Fig. 3-12)

(3) Short the check pin (CHK) on the indoor control

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

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

check pin (CHK) and remount the tube cover.

Be careful since the fan will start when you short the pin on the indoor control board.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 26

CAUTION

11-3/16 in. or less (as short as possible)

33-15/32 in. or less

0 – 45°

* Length of supplied drain hose = 9-27/32 in.

Upward gradient prohibited

Support pieces

Drainage check

CAUTION

Over 3-15/16 in.

Water (Approx. 0.3 gal)

Plastic container

for water intake

Drain pan outlet

Page 27

3-6. How to Install the Ceiling Panel

3-6-1. Before Installing the Ceiling Panel

Checking the unit position

(1) Check that the ceiling hole is within this range:

33-55/64 × 33-55/64 to 35-53/64 × 35-53/64 in.

(2) Use the full-scale installation diagram (from the

packaging) that was supplied with the unit to determine the positioning of the unit on the ceiling surface. If the positions of the ceiling surface and unit do not match, air leakage, water leakage, flap operation failure, or other problems may result.

 Never place the panel face-down. Either hang

it vertically or place it on top of a projecting object. Placing it face-down will damage the surface.

 Do not touch the flap or apply force to it.

(This may cause flap malfunction.)

must be within the range of 15/32 – 43/64 in.

If not within this range, malfunction or other trouble may result.

Fig. 3-13

Fig. 3-14

Fig. 3-15

Remove the air-intake grille and air filter from the ceiling panel. (Figs. 3-16, 3-17 and 3-18)

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

grille. (Fig. 3-16)

b) Slide the air-intake grille catches in the direction

shown by the arrows to open the grille. (Fig. 3-17)

c) With the air-intake grille opened, remove the grille

hinge from the ceiling panel by sliding it in the direction shown by the arrow . (Fig. 3-18)

Removing the corner cover

a) Slide the corner cover to the direction shown

by the arrow to remove the corner cover. (Fig. 3-18).

Fig. 3-17

Fig. 3-18

Fig. 3-16

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 27

Main unit

CAUTION

Ceiling side

Ceiling opening dimension

Flap

Latch

Screw

Corner cover

Air-intake grille hinge

Push

Air-intake grille

Corner cover

Ceiling panel

Strap

Page 28

3-6-2. Installing the Ceiling Panel

After completing the wiring process, install the supplied wiring cover before installing the panel. It is not possible to install the wiring cover after installing the panel. The power must be turned ON in order to change the flap angle. (Do not attempt to move the flap by hand. Doing so may damage the flap.)

(1) Insert the temporary fasteners (stainless steel) on

the inside of the ceiling panel into the square holes on the unit to temporarily fasten the ceiling panel in place. (Fig. 3-20-1)

 The ceiling panel must be installed in the correct

direction relative to the unit. Align the REF. PIPE and DRAIN marks on the ceiling panel corner with the correct positions on the unit.

 To remove the ceiling panel, support the ceiling

panel while pressing the temporary fasteners toward the outside. (Fig. 3-20-1)

(2) Align the panel installation holes and the unit screw

holes.

(3) Tighten the supplied washer head screws at the

4 panel installation locations so that the panel is attached tightly to the unit. (Fig. 3-20-2)

(4) Check that the panel is attached tightly to the

ceiling.

 At this time, make sure that there are no gaps

between the unit and the ceiling panel, or between the ceiling panel and the ceiling surface. (Fig. 3-21)

 If there is a gap between the panel and the ceiling,

leave the ceiling panel attached and make fine adjustments to the installation height of the unit to eliminate the gap with the ceiling. (Fig. 3-21)

Fig. 3-20-1

Fig. 3-20-2

Fig. 3-21

Fig. 3-22

 If the screws are not sufficiently tight-

ened, trouble such as that shown in the figure below may occur. Be sure to tighten the screws securely.

 If a gap remains between the ceiling

surface and the ceiling panel even after the screws are tightened, adjust the height of the unit again.

The height of the unit can be adjusted from the ceiling panel corner hole, with the ceiling panel attached, to an extent that does not affect the unit levelness, the drain hose, or other elements.

Fig. 3-23

Fig. 3-19-1

Fig. 3-19-2

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 28

Inter-unit control wiring

Screw (supplied)

M4-8 or 5/32" – 5/16"

Push when you remove

Celling panel

Wiring cover (supplied) Power supply outlet

Square hole in unit

Temporary fastener

Drain tubing corner

Refrigerant tubing corner

After completing the wiring process, install the supplied wiring cover before installing the panel. It is not possible to install the wiring cover after installing the panel.

DRAIN mark

CAUTION

Air leakage

Air leakage from ceiling surface

Staining

Condensation, water leakage

Ceilin

surface

Adjust so that there are no gaps.

Washer head screws

Main unit

Do not allow

Ceiling panel

gaps

REF,PIPE mark

Panel installation hole (4 locations)

Insert a wrench or other tool into the corner cover installation hole and make fine adjustments to the unit nut.

Page 29

3-6-3. Wiring the Ceiling Panel

(1) Open the cover of the electrical component box.

(2) Connect the 7P wiring connector (red) from the

ceiling panel to the connector in the unit electrical component box.

 If the connectors are not connected, the Auto flap will

not operate. Be sure to connect them securely.

 Check that the wiring connector is not caught

between the electrical component box and the cover.

 Check that the wiring connector is not caught

between the unit and the ceiling panel.

3-6-4. How to Attach the Corner & Air-Intake Grille

Attaching the corner cover and air-intake grille

A. Attaching the corner cover

(1) Check that the safety cord from the corner cover is

fastened to the ceiling panel pin, as shown in the figure.

(2) Use the supplied screws to attach the corner cover

to the ceiling panel.

B. Attaching the air-intake grille

 To install the air-intake grille, follow the steps for

Removing the grille in the reverse order. By rotating the air-intake grille, it is possible to attach the grille onto the ceiling panel from any of 4 directions. Coordinate the directions of the air-intake grilles when installing multiple units, and change the directions according to customer requests.

 When attaching the air-intake grille, be careful

that the flap lead wire does not become caught.

 Be sure to attach the safety cord that prevents

the air-intake grille from dropping off to the ceiling panel unit as shown in the figure at right.

 With this ceiling panel, the directions of the air-intake

grille lattices when installing multiple units, and the position of the label showing the company name on the corner panel, can be changed according to customer requests, as shown in the figure below. However, the optional wireless receiver kit can only be installed at the refrigerant-tubing corner of the ceiling unit.

Fig. 3-24

Fig. 3-25

Fig. 3-26

Fig. 3-27

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 29

(Direction that the unit faces has been changed to facilitate explanation.)

Electrical component box cover

Screws (3 locations)

Ceiling panel side

Ceiling panel wiring connector

Locations of the air-intake grille catches at the time the product is shipped. * The grille can be installed with these

catches facing in any of 4 directions.

Unit drain hose side

Unit electrical component box

Mains side

Clamp

* Pass the wiring connector through the clamp to fasten it in place, as shown in the fi

Hole for ceiling panel hook

ure.

Place the corner cover so that the 3 tabs fit into the holes in the ceiling panel. Then fasten it in place with the supplied screws.

Hook that prevents the grille from dropping

Unit refrigerant tube side

Optional wireless receiver kit * Can only be installed in this position.

Can be installed rotated 90˚

Page 30

3-6-5. Checking After Installation

 Check that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceiling

surface. Gaps may cause water leakage and condensation.

 Check that the wiring is securely connected.

If it is not securely connected, the auto flap will not operate. (“P09” is displayed on the remote controller.) In addition, water leakage and condensation may occur.

3-6-6. 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.

3-6-7. Adjusting the Auto Flap

The air-direction louver on the ceiling panel outlet can be adjusted as follows.

 Adjust the louver to the desired angle using the remote controller. The louver also has an automatic air-sweeping

mechanism.

 Never attempt to move the louver by hand.  Proper air flow depends on the location of the air conditioner, the layout of the room and furniture, etc. If cooling or

heating seems inadequate, try changing the direction of the air flow.

3-7. Special Remarks

DC Fan Tap Change Procedure

<Steps> Be sure to turn OFF the power (at mains) before beginning the work below. (1) In the table below, check the field-supply parts that will be used. (If this setting is not made, the airflow may

decrease and condensation may occur.)

(2) Setting (a)

Open the cover of the electrical component box. Short the short-circuit pin TP3 (2P, yellow) on the indoor unit control PCB.

(3) Setting (b)

Open the cover of the electrical component box. Short the short-circuit pin TP6 (2P, white) on the indoor unit control PCB.

Fig. 3-28

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 30

NOTE

Setting

(a)

(b)

Setting (a): Go to (2). Setting (b): Go to (3).

Air shield material (for use with 3-direction discharge)*

Air shield material (for use when a discharge duct is connected)*

Air shield material (for use with 2-direction discharge)*

* Use field-supply air shield material.

Indoor unit control PCB

* PCB model No.: CR-SXRP56B-B

Page 31

 1-Way Air Discharge Semi-Concealed Type (A Type)

3-8. Suspending the Indoor Unit

(1) Follow the diagrams to make the holes in the ceiling.

(Figs. 3-29 and 3-30)

(2) Depending on the ceiling type:

 Insert suspension bolts as shown in Fig. 3-31

 Use existing ceiling supports or construct a suitable

support as shown in Fig. 3-32.

 Make sure that the length of suspension bolts from the

bottom of the unit is 19/32 in. or more. (Fig. 3-33)

Fig. 3-29

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

(3) Calculate the suspension bolt pitch using the full-

size installation diagram (printed on the package). The relationship between the positions of the suspension lugs, unit, and ceiling panel is as shown in Fig. 3-30.

(4) Cut the ceiling material, if necessary.

(Figs. 3-29 and 3-30) If the system requires fresh air to be drawn into the unit, cut and remove the insulation (both externally and internally) at the location shown as in Figs. 3-34 and 3-35.

When making the cuts to the insulation, be careful not to damage the drain pan.

Fig. 3-31

Unit: in.

Fig. 3-30

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 31

29-59/64 (Panel outer dimensions) 28-47/64 (Ceiling opening dimension)

1-27/64

25-63/64 (Suspension bolt pitch)

22-3/64

(1-27/64)

19/32

WARNING

CAUTION

5-19/64 1-49/64

2-31/64

9-29/64

3-3/16

Flared refrigerant connection outlet (liquid tube)

Hole-in-anchor Hole-in-plug

15-3/4 (Suspension bolt pitch)

23-15/64 (Ceiling opening dimension)

24-13/32 (Outline dimension of panel)

23-5/8

19/32

3-47/64

Drain pipe connection (Be sure to connect the supplied flexible hose.)

22-3/64

10-1/32

Flared refrigerant connection outlet (gas tube)

1-19/64

Concrete

Suspension bolt

(M10 or 3/8")

2-9/16

1-49/64

Inter-unit Control Wiring

Powe r supply outlet

Insert

12-19/64

1-3/16

Page 32

Fig. 3-34

Fig. 3-33

Fig. 3-32

3-9. Placing the Unit Inside the Ceiling

(1) Use the supplied M5 or 3/16" screws (4) to attach

the full-size installation diagram to the indoor unit suspension lugs, in order to obtain the ceiling opening dimensions for suspending the unit.

Caution: Piping and wiring work must be performed

inside the ceiling after the unit is suspended. Therefore if the ceiling is already installed, the wiring and piping work should be completed up to the connection points prior to suspending the unit.

(2) Attach the special washers (supplied) and nuts (field

supply) to the suspension bolts (4 locations).

Be sure to use a level gauge and confirm that the unit is level. If it is not level, water leakage may occur.

Fig. 3-35

Unit: in.

 Use M10 or 3/8" nuts.  The length of the suspension bolts must be such that

there is a space of at least 19/32 in. below the bottom of the suspension lugs, as shown in Fig. 3-33. If the length of the suspension bolts is too long, the bolts may interfere with the ceiling panel and louver motor, preventing their installation.

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

supply) onto each of the 4 suspension bolts as

shown in Fig. 3-36. Use 1 nut and 1 washer for the

upper side, and 2 nuts and 1 washer for the lower

side, so that the unit will not fall off the suspension

lugs.

(4) Lift up the indoor unit and fit the suspension bolts

into the notches in the suspension lugs.

(5) Adjust so that the distance between the bottom of

the indoor unit suspension lugs and the bottom of

the ceiling panel is 25/32 – 1 in. Then tighten the

nuts above and below each suspension lug. The

full-size installation diagram can be used to help

adjust the height of the indoor unit.

Unit: in.

Fig. 3-36

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 32

CAUTION

Ceiling tiles

Ceiling suppor

CAUTION

Suspension

lug

25/32 – 1 in.

For fresh air intake (ø3-15/16 hole)

6-11/16

8-1/16

Nuts and washers (Used above and below.)

Full-scale installation diagram

over 19/32 in.

For fresh air intake (ø3-15/16 hole)

Suspension bolt

Suspension lug

3-5/32

6-11/16

Double nuts

over 19/32 in.

Notch

25/32 – 1 in.

Page 33

Fig. 3-37

Fig. 3-38

 The indoor unit includes a drain pump. Be sure to

use a level gauge and verify that the unit is level.

 Before inserting the ceiling material, complete as

much of the drain piping work and refrigerant tubing work as possible.

(6) The distance between the unit and the opening of

the ceiling and the distance between the bottom surface of the ceiling and the bottom surface of the flange of the unit should follow the dimensions given in Figs. 3-37 and 3-38.

3-10. Installing the Drain Piping

(1) Prepare standard hard PVC pipe (O.D. 1-1/4") for

the drain and use the supplied drain hose and hose band to prevent water leaks. The PVC pipe must be purchased separately. The unit’s transparent drain port allows you to check drainage. (Fig. 3-39)

 Do not use adhesive at the drain connection port on

the indoor unit.

 Insert the drain pipe until it contacts the socket, as

shown in the figure at right, then secure it tightly with the hose band.

 Tighten the hose clamps so their locking nuts face

upward. (Fig. 3-39)

 Do not use the supplied drain hose bent at a 90°

angle. (The maximum permissible bend is 45°.)

 Check the drainage at the unit drain port

(transparent).

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe, then secure it with the supplied clamps. (Fig. 3-40)

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

Fig. 3-39

Fig. 3-40

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 33

CAUTION

2-1/8

19/32

Suspension bolts

Tubing side

Suspension bolts

19/32

25/32

Align the hose band with end of the hose, and tighten so that it does not contact the bead.

Drainage check section on drain port (transparent)

Drain hose

(supplied)

Bead

Ceiling material

25/32

Hard PVC

socket VP-25

(not supplied)

Packing (supplied)

2-1/8

Hard PVC pipe

VP-25

(not supplied)

PVC adhesive

NOTE

Drain insulator (supplied)

Page 34

Fig. 3-41

Fig. 3-43

Fig. 3-42

Fig. 3-44

3-11. Checking the Drainage

After wiring and drain 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.

(1) Connect power to the power terminal board (R, S

terminals) inside the electrical component box.

(2) Pour about 0.2 gal of water into the drain pan using a

siphon pump through the air outlet grille. (Fig. 3-45)

(3) Short the check pin (CHK) on the indoor control board

and operate the drain pump. Check the water flow

through the transparent drain pipe and see if there is any

leakage.

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

pin (CHK) and remount the insulator.

Be careful since the fan will start when you short the pin on the indoor control board.

The bottom drain port is for use only during test runs and servicing inspections. Do not connect the drain pipe to the bottom drain port.

Fig. 3-45

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

to spray from the drain pipe outlet. (Fig. 3-41)

 In cases where it is necessary to raise the height of

the drain piping, the drain piping can be raised to a maximum height of 33-15/32" above the bottom surface of the ceiling. Under no conditions attempt to raise it higher than 33-15/32" above the bottom surface of the ceiling. Doing so will result in water leakage. (Fig. 3-42)

 Do not use natural drainage.  Do not install the pipe with an upward gradient from

the connection port. This will cause the drain water to flow backward and leak when the unit is not operating. (Fig. 3-43)

 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. 3-44)

 Provide insulation for any pipes that are run indoors.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 34

CAUTION

Air bleed valve

11-13/16 in. or less

33-15/32 in. or less

0 – 45°

* Length of supplied drain hose = 9-27/32 in.

Uphill slope

Support

bracket

CAUTION

Drainage check

water (0.2 gal)

Drain tube connection (transparent)

Discharge port

Page 35

Fig. 3-46

 Route the power wiring into the indoor unit through the power inlet on the side of the unit. At this time, be

sure that the wiring passes through the power inlet in the unit power section. If the wiring does not pass through this inlet, it may become pinched by the ceiling panel, and may result in fire.

 Pass the wiring through the power inlet on the electrical component box and connect it to the terminal plate.

Then fasten the wiring in place with the clamp.

3-12. Electrical Power Wiring

(1) Wiring connections

The power inlet is on the side of the indoor unit where the refrigerant tubing is located. The electrical component box is on the lower air intake surface of the indoor unit. (Fig. 3-46)

(2) Wiring

3-13. How to Install the Ceiling Panel

3-13-1. Before Installing the Ceiling Panel

Checking the position of the indoor unit

(1) Check that the dimensions of the ceiling opening are

the following:

28-47/64" × 23-17/64"

* For details, refer to the installation manual that was

supplied with the indoor unit.

(2) Check that the positions of the ceiling surface and

indoor unit are as shown in Fig. 3-47. If the positions

of the ceiling surface and indoor unit are not correct,

problems such as air leakage, water leakage, and flap

operation trouble may occur.

 Do not rest the panel facing downwards, lean up against

a wall, or leave it sitting on top of a protruding object. Doing so may scratch the panel surface.

 Do not apply excessive force to the flap.

(Doing so may damage the flap.)

Fig. 3-47

Be sure that this distance is within the range of 25/32 – 1 in. If it is not within this range, malfunction or other problems may result.

Fig. 3-48

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 35

Refrigerant tubing joint (gas tube)

Refrigerant tubing joint (liquid tube)

Drain pipe connection (Be sure to connect the supplied flexible hose.)

Inter-unit Control Wiring

Power supply outlet

WARNING

Component Parts

Part name Quantity Appearance Part name Quantity Appearance

Ceiling panel

Washer-head screw

Screw

ø11/16

4 × 12 or 5/32" × 15/32"

For fastening side panel

M5 × 40 or 5/16" × 9/16"

Indoor unit

25/32 – 1 in.

Ceiling surface

Ceiling opening dimension

Flap

Page 36

Removing the intake grille

Slide the intake grille hooks (2 locations) in the direction of the arrow to open the intake grille. (fig. 3-49a)

When the intake grille is open, press a flathead screwdriver against the rear tabs (2 locations) and pull out the intake grille. (Fig. 3-49b)

Removing the side panel

Grasp the finger grip on the side panel and slide the panel in the direction of arrow to remove the panel. (There are 2 panels: 1 each on the left and right sides.) (Fig. 3-51)

Fig. 3-50

Fig. 3-49a

Fig. 3-49b

Fig. 3-51

3-13-2. Installing the ceiling panel

(1) Fasten the hooks on both sides of the ceiling panel

to the indoor unit. The hooks on one side (2

locations) are stationary, while the hook on the other

side is moveable. (Fig. 3-52)

(2) Angle the panel somewhat and fasten the stationary

hook into the fastener on the side of the unit.

(3) After verifying that the hook is fastened, press the

other end up until the ceiling panel is level. Then

press upwards until the moveable hook is fastened

into the fastener on the unit.

(4) Verify that the hooks on both sides of the ceiling

panel are securely fastened to the unit. If the hooks

are not securely fastened, the panel may fall. At this

point, the panel is now provisionally fastened to the

unit.

 When removing the panel, press the movable hook

toward the inside while supporting the panel. (Fig. 3-53)

Fig. 3-52

Fig. 3-53

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 36

Press on the tabs with a flathead (minus) screwdriver while pulling out the intake grille.

Ta b

Slide

Hinge

Screw

Hook

Intake grille

Side panel

Stationary hook

Hook receiver

Moveable hook

Press to remove.

Page 37

(5) Align the installation holes on the panel with the

bolt holes on the unit.

(6) Insert the supplied washer head bolts into the 4

panel installation holes, and tighten until the panel is securely fastened against the unit. (Fig. 3-54)

(7) Verify that the panel is securely fastened against

the unit.

 At this time, make sure that there is no gap

between the indoor unit and the ceiling panel, or between the ceiling panel and the ceiling surface. (Fig. 3-55)

 If there is a gap between the ceiling panel and the

ceiling, leave the panel attached and adjust the installation height of the indoor unit upwards until the gap with the ceiling is eliminated. (Fig. 3-56)

 If the adjustment is small enough that it will not

affect the levelness of the indoor unit or the drain piping, then the unit height can be adjusted from the side panel installation holes, with the ceiling panel still attached.

Fig. 3-54

Fig. 3-56

CAUTION

• If the screws are not fully tightened, problems such as those shown below may occur. Be sure to tighten the screws securely.

• If there is a gap between the ceiling surface and the ceiling panel even when the screws are fully tightened, readjust the height of the indoor unit. (Fig. 3-56)

Fig. 3-55

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 37

Indoor unit

Must be no gap.

Ceiling surface

Ceiling panel

Indoor unit

Ceiling panel

Washer-head screw

Insert a wrench or other standard tool into the side panel installation holes and make fine adjustments to the indoor unit nuts.

Air leakage

Ceiling panel air leakage

Stains

Condensation and water leakage

Adjust so that there is no gap.

Page 38

3-13-3. Wiring the ceiling panel

(1) Loosen the 2 screws on the electrical component

box lid, and remove the lid. (Fig. 3-57)

(2) Fasten the wiring connector (7P, red) which comes

out from the ceiling panel using the lead wire clamps (2 locations) on the unit. Then connect it to the connector (7P, red) inside the indoor unit electrical component box. (Fig. 3-58)

 If the connector is not connected, “P09” is displayed

on the remote controller, and the automatic flap will not operate. Be sure to securely connect the connector.

 Check that the wiring connector is not pinched

between the electrical component box and the lid.

 Check that the wiring connector is not pinched

between the indoor unit and the ceiling panel.

3-13-4. Installing the side panel and intake grille

A. Installing the side panel

(1) Grasp the side panel finger grip and slide the panel

in the direction of the arrow to install the side panel. (Fig. 3-59)

(2) Fasten the side panel onto the ceiling panel using

the supplied screws (4 × 12 or 5/32" × 15/32").

B. Installing the intake grille

 To install the intake grille, follow the procedure for

removing it in the reverse order. (Fig. 3-60)

 When installing the intake grille, be careful that the

flap lead wire does not become pinched. (Fig. 3-60)

3-13-5. Other

A. Check after installation

 Check again that there is no gap between the indoor

unit and the ceiling panel, or between the ceiling panel and the ceiling surface.

* If there is a gap, then water leakage and condensa-

tion may occur.

 Check that the wiring connections are secure.

* If the wiring is not connected, the automatic flap will

not operate. (“P09” is displayed on the remote controller.) In addition, water leakage, condensation, and other problems may occur.

B. If a wireless remote controller is used

 For details concerning the installation procedure,

refer to the installation manual which was supplied with the optional wireless remote controller and indoor unit internal receiver.

Fig. 3-57

Fig. 3-58

Fig. 3-59

Fig. 3-60

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 38

Screw

Electrical compornent box

Indoor unit connector

Ta bs

Slide the side panel so that the side panel tabs are fastened to

the ceiling panel. Then fasten in place with the supplied screws

(4 × 12 or 5/32" × 15/32").

Electrical compornent box cover

Inter-unit control wiring

Power supply outlet

Fasten with screws

(4 × 12 or 5/32" × 15/32")

Ta b

Slide

Screw

Page 39

Fig. 3-61

Fig. 3-62

 Concealed Duct Type (U Type)

3-14. Required Minimum Space for

Installation and Service

 This air conditioner is usually installed above the 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 shown in

Fig. 3-61 and Table 3-3.

 It is recommended that space is provided (17-23/32 × 17-23/32 in.)

for checking and servicing the electrical system.

 Fig. 3-62 and Table 3-4 show the detailed dimensions of the indoor

unit.

Table 3-3

Unit: in.

Table 3-4

Unit: in. (mm)

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 39

Type

A (Length)

Number of duct flanges

7, 12, 18

30-23/32 (780)

42-17/32 (1,080)

61-13/32 (1,560)

Type

7, 12, 18

Dimension

ABCDEFGH I JK

26-1/16

37-7/8

56-25/32

23-5/8

(7-7/8 × 3)

35-7/16

(7-3/32 × 5)

54-11/32

(9-1/16 × 6)

27-9/16 30-23/32 11-13/32 10-5/16 26-25/3228-5/327-3/32–13-3/88 12

39-3/8 42-17/32 11-13/32 10-23/32 38-19/32 39-31/32 5-1/8

58-9/32 61-13/3213-3/16 12-7/32 57-15/3258-27/32 5-1/8

A (Suspension bolt pitch)

min. 9-27/32

22-27/32

Air outlet duct flange

Indoor unit

9-21/32

(9-21/32 × 1)

19-9/32

(9-21/32 × 2)

min.

Electrical

9-27/32

component box

Inspection access

17-23/32

Refrigerant tubing

min. 25-19/32

min.

15-3/4

No. of holes

9-27/3212 16

9-7/16 16 18

3-17/32

7-9/32

2-5/322-5/32

13/32

7-7/8

10-1/4

(O.D.)

13/32

31/32

3-15/32

10-13/16

3-15/16

(Ceiling opening dimension)

1-7/32 1-7/32

22-27/3231/32

(Suspension bolt pitch)

L-ø1/4

(Hole)

EEEF

A (O.D.)

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

(Suspension bolt pitch)

Refrigerant tubing joint (liquid tube)

13/32

IJJK

3/43/4

4-ø15/32

(Hole)

18-ø1/8

(Hole)

Inspection access

1-9/16

(5-29/32)

2-15/16 2-9/16

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)

Inter-unit control wiring

12-7/32

31/32 8-9/32

13/32

(17-23/32

17-23/32)

(Field supply)

4-17/32

24-13/16 31/32

1-3/16

6-5/16

2-3/4

31/32

2-3/4

3-11/32

Inspection access panel

5-1/8

11-7/32

Ceiling

31/32

6-7/8

1-3/8

7-15/32

Page 40

Fig. 3-63

3-15. Suspending the Indoor Unit

Depending on the ceiling type:

• Insert suspension bolts as shown in Fig. 3-63

• Use existing ceiling supports or construct a suitable support as shown in Fig. 3-64.

Fig. 3-64

Fig. 3-65

It is important that you use extreme care in supporting the indoor unit inside the ceiling. Ensure that the ceiling is strong enough to support the weight of 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. 3-61 and Table 3-3) Tubing must be laid and connected inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing into position for connection to the unit before placing the unit inside the ceiling.

(2) Screw in the suspension bolts allowing them to protrude from

the ceiling as shown in Fig. 3-63. (Cut the ceiling material, if necessary.)

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

each of the 4 suspension bolts as shown in Figs. 3-65 and 3-66. Use 1 nut and 1 washer for the upper part, and 2 nuts and 1 washer for the lower part, so that the unit will not fall off the suspension lugs.

 Fig. 3-67 shows an example of installation.

Fig. 3-66

Fig. 3-67

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 40

WARNING

Hole-in-anchor Hole-in-plug

Concrete Insert

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

Ceiling tiles

Ceiling support

Nuts and washers (use for upper and lower)

Double nuts

Suspension bolt

Hexagonal nut

Suspension bolt

Suspension lug

Notch

Air outlet duct

Air-outlet grille

Ceiling material Indoor unit

Bolt anchor

Suspension bolt

Air-intake grille

Air-intake duct

Double nuts

Page 41

Fig. 3-68

Fig. 3-69

3-16. Installing the Drain Piping

(1) Prepare standard hard PVC pipe (O.D. 1-1/4") for the drain

and use the supplied hose band to prevent water leaks. The PVC pipe must be purchased separately. The transparent drain part on the unit allows you to check drainage. (Fig. 3-68)

 Do not use adhesive at the drain connection port on the

indoor unit.

 Insert the drain pipe until it contacts the socket, as shown in

the figure at right, then secure it tightly with the hose band.

 Do not use the supplied drain hose bent at a 90° angle.

(The maximum permissible bend is 45°.)

 Tighten the hose clamps so their locking nuts face upward.

(FIg. 3-68)

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

packing and drain pipe insulator around the pipe, then secure it with the supplied vinyl clamps. (Fig. 3-69)

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

 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". Do not raise it any higher than 19-11/16", as this could result in water leaks. (Fig. 3-71)

 Do not install the pipe with an upward gradient from the connec-

tion port. This will cause the drain water to flow backward and leak when the unit is not operating. (Fig. 3-72)

 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. 3-73)

3-17. Checking the Drainage

After wiring and drain 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.

(1) Connect power to the power terminal board (R, S terminals)

inside the electrical component box.

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

about 0.3 gal of water into the drain pan to check drainage.

(3) Short the check pin (CHK) on the indoor control board and oper-

ate the drain pump. Check the water flow through the transparent drain port and see if there is any leakage.

 Do not install an air bleeder as this may

cause water to spray from the drain pipe outlet. (Fig. 3-70)

Fig. 3-70

Fig. 3-71

Fig. 3-72

Fig. 3-73

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 41

Align the hose band with end of the hose, and tighten so that it does not contact the bead.

Drainage check section on drain port (transparent)

Drain hose (supplied)

Hard PVC

socket VP-25

(not supplied)

Hard PVC pipe

VP-25

(not supplied)

CAUTION

NOTE

CAUTION

Bead

Air bleeder

Prohibited

Good

Packing (supplied)

PVC adhesive

Drain insulator (supplied)

Vinyl clamps

11-13/16" or less

19-11/16" or less

Upward gradient

Prohibited

Support pieces

Page 42

Fig. 3-74

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

and remount the insulator and drain cap onto the drain inspection port.

Be careful since the fan will start when you short the pin on the indoor control board.

(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 Fig. 3-75.

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

plate.

Fig. 3-75

Fig. 3-76

How to read the diagram

The vertical axis is the external static pressure (psi, in.Aq) while the horizontal axis represents the air flow (ft.

/minute). 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 24 type, the air flow is 635 ft.3/minute, while the external static pressure is 7.1 × 10-3psi at “H” position. 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 as explained above.

3-18. 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:

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 42

CAUTION

Indoor Fan Performance

( 10

-3

psi)

21.8

(in.Aq)

0.6

( 10

Power supply outlet

Inter-unit control wiring

-3

psi)

21.8

18 Type7, 12 Type

(in.Aq)

0.6

Fan

motor

Booster cable

Fan motor socket

(At shipment) (Booster cable installed)

Electrical component box

Booster cable

14.5

Limit li

Limit line

7.3

External Static Pressure

177

Air Flow (ft.

-3

psi)

( 10

21.8

Limit line

14.5

Limit line

7.3

External Static Pressure

353

Air Flow (ft.3/minute)

NOTE

24 Type

HT : Using the booster cable

353

/minute)

706

0.4

0.2

( 10

(in.Aq)

0.6

0.4

0.2

21.8

14.5

External Static Pressure

H : At shipment

it line

14.5

Lim

Limit line

7.3

External Static Pressure

Air Flow (ft.3/minute)

-3

psi)

Limit li

Limit line

7.3

706

Air Flow (ft.3/minute)

353

36 Type

1059

0.4

0.2

530

(in.Aq)

0.6

0.4

0.2

Page 43

 Concealed Duct High-Static Pressure Type (D Type)

3-19. Required Minimum Space

for Installation and Service

 This air conditioner is usually installed above the 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 shown

in Fig. 3-77.

 It is recommended that space be provided (23-5/8" ×

23-5/8") for checking and servicing the electrical system.

 Fig. 3-78 and Table 3-3 show the detailed dimensions of

the indoor unit.

Fig. 3-78

Fig. 3-77

Unit: in.

Table 3-5

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 43

5-1/8

19-11/16

11-27/64

Min. 23-5/8

(Space for service)

5-1/8

31-7/32

7 × 3-15/16 = 27-9/16

22 - ø1/8 (Hole for full circumference)

2-5/32 1-37/64

1-57/64

38-37/64

Suspension

bolt pitch

Inspection access (23-5/8" × 23-5/8")

Drain pan

Ceiling face

25/32

3-35/64

2-23/64

Suspension bolt pitch

Electrical

component

box

Air suction side

Refrigerant tubing

Min. 23-5/8

Space for

service

Min. 22-53/64

Min. 5-1/8

Type

Length

16-17/32

17-23/32

12-13/64

2-5/322-5/32

3-15/16

15-35/64

16-47/64

24-13/32

19-11/16 2-3/4

2-43/64

3-55/64

16 - ø1/8 (Hole for full

circumference)

25/6425/64

(Suspension bolt pitch)

3-5/32 11-27/64

19/32

1-3/8 1-3/8

1-31/32

2-5/32

11-13/16

3-15/16

1-13/16

19-11/16

38-37/64

(Suspension bolt pitch)

39-49/64

4 × 3-15/16 = 15-3/4

Electrical component box

4-ø20 hole for suspension bolt

Refrigerant liquid line (ø3/8 or ø1/4) Refrigerant gas line (ø3/4 or ø5/8) Power supply outlet

19/32

Drain connection (25A, O.D. 1-1/4") Duct connection for suction Duct connection for discharge

Inter-unit control wiring

3-15/16

Drain pan

3-15/16

3-55/64

1-11/32

Page 44

Fig. 3-79

3-20. Suspending the Indoor Unit

Depending on the ceiling type:

 Insert suspension bolts as shown in Fig. 3-79

 Use existing ceiling supports or construct a suitable support as

shown in Fig. 3-80.

Fig. 3-80

Fig. 3-81

It is important that you use extreme care in supporting the indoor unit inside the ceiling. Ensure that the ceiling is strong enough to suport the weight of 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 given

previously. (Figs. 3-77 and 3-78)

Tubing must be laid and connected inside the ceiling when

suspending the unit. If the ceiling is already constructed, lay

the tubing into position for connection to the unit before placing

the unit inside the ceiling.

(2) Screw in the suspension bolts allowing them to protrude from

the ceiling as shown in Fig. 3-79. (Cut the ceiling material, if

necessary.)

(3) Suspend and fix the indoor unit using the 2 hexagonal nuts

(field supply) and special washers (supplied with the unit) as

shown in Fig. 3-81.

Fig. 3-82

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 44

WARNING

Hole-in-anchor Hole-in-plug

Concrete Insert

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

Ceiling tiles

Ceiling support

Air-outlet grille

Hexagonal nuts and washers

(2 sets)

Suspension bolt

25/32" – 1-31/32"

Air-intake grille

Page 45

Fig. 3-83

Fig. 3-84

Fig. 3-85

3-21. Installing the Drain Piping

(1) Prepare standard hard PVC pipe (O.D. 1-1/4") for the

drain and use the supplied drain socket to prevent water leaks. The PVC pipe must be purchased separately. When doing this, apply adhesive for the PVC pipe at the connection point.

(2) If connecting a drain joint (supplied) to the threaded

drain port, first wrap the drain port threads with sealing tape, then connect the joint. (Fig. 3-83)

(3) After connecting the drain pipe securely, wrap insulator

(field supply) around the pipe.

(4) Ensure the drain pipe has a downward gradient (1/100

or more) and prepare traps as indicated in Fig. 3-84.

(5) Also, in another part of the pipe arrangement, prepare

traps with an inspection plug to clean dust or debris that may cause leaking of water. (Fig. 3-85)

(6) After connecting the drain piping, slowly pour water into

the drain pan to check that the water drains smoothly.

3-22. Caution for Ducting Work

 This unit has high static pressure (applicable external static

pressure Max. 24.2 ××10-3to 31.3 ××10-3psi (0.68 – 0.88 in.Aq). In the case of small pressure resistance (for instance, a short duct), install a damper for adjusting air flow volume as air flow volume / air flow noise increases.

 If the air conditioner is to be installed in a room such as

an office or meeting room which needs a low sound level, provide a supply and return noise absorption chamber with an acoustic liner.

 Include an air filter (field supply) at the return duct.

3-23. Indoor Fan Performance

How to Read the Diagram

The vertical axis is the External Static Pressure (psi, in.Aq) while the horizontal axis represents the Air Flow (ft.

/minute). The characteristic curve for the “H,” “Med,” and “Lo” fan speed control. The nameplate values are shown based on the “H” air flow. Therefore in the case of 36 Type, the flow is 1059 ft.3/minute, while the External Static Pressure is 0.72 in.Aq at “H” position. If the 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.

Fig. 3-86

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 45

Sealing tape

Drain pan

Drain opening (25A or 1-11/32

Drain joint (supplied)

" male screw)

Downward gradient

Min. 1/100

Good

Not good

36.3

29.0

21.8

14.5

External Static Pressure

7.3

NOTE

36 Type48 Type

Limit line

883 1059 1236

Air Flow (ft.3/minute)

H : At shipment

Limit line

Inspection plug

(in.Aq)( 10-3 psi)

1.0

0.8

0.6

0.4

0.2

Min.

3-15/16 in.

Min. 1-31/32 in.

36.3

29.0

21.8

14.5

External Static Pressure

7.3

Limit li

1059 1236 1412

Air Flow (ft.3/minute)

(in.Aq)( 10-3 psi)

1.0

0.8

Limit li

0.6

0.4

H,M

0.2

Page 46

 Ceiling-Mounted Type (T Type)

3-24. Required Minimum Space for Installation and Service

(1) Dimensions of suspension bolt pitch and unit

Table 3-6

(2) Refrigerant tubing • drain hose position

Fig. 3-87

Fig. 3-88

Unit: in.

(3) Unit opening position (Refrigerant tubing • drain hose • power inlet port • remote controller wiring inlet port)

*1 Use a compass saw, jig saw or similar tool and cut along the indented portion of the side panel.

Unit: in.

Fig. 3-89

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 46

Dimension

Type

12, 18

ABC

33-21/32 35-53/64 8-17/64

44-19/64 46-29/64 8-17/64

9-7/8

Left side

Rear (figure shows view from front)

1-1/4

6-47/64

1-17/32

3-5/16

Left drain position Right drain position

2-23/64

Closed with rubber stopper at time of shipment.

1-1/4

6-11/16

12-19/32

(Suspension bolt pitch)

2-21/64 2-61/64

Liquid tubing

Gas tubing

Ceiling side

(Suspension bolt pitch)

3-61/64 3-13/16

9/64

4-9/64

5-3/4

2-3/64

6-47/64

1-17/32

26-49/64

1-5/641-5/64

Right side

Air outlet

8-1/2

(Liquid tubing • Gas tubing)

6-11/32

9-7/8

Air intake

Rear outlet port

Inter-unit control wiring

Left-side drain hose outlet port

(ø1-3/16", knock-out, use rubber grommet) Outside air intake duct connection port

(ø3-15/16

", knock-out)

6-47/64

Side panel

Power supply outlet (ø1-3/16", knock-out)

Rear tubing hole

3-5/16

Left-side drain hose outlet port

3-35/64

10-5/16

4-59/64 2-53/64

13-21/32

3-11/64

4-11/64

Right-side drain hose outlet port

Side panel

Position of plate inside side panel

Page 47

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

Fig. 3-93

Fig. 3-94

Fig. 3-95

(4) Wall and ceiling side opening position

Fig. 3-91

Fig. 3-90

Fig. 3-92

3-25. Suspending the Indoor Unit

(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. 3-91).

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. 3-92.

b) Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-93.

* If the optional drain up kit is installed, create a ø3-15/16" hole along the dotted line (part marked with * in figure).

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

protrude from the ceiling as shown in Figs. 3-92 and 3-93. The distance of each exposed bolt must be of equal length within 1-15/16". (Fig. 3-94)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 47

Figure shows view from front

5-45/64

NOTE

3-35/64

ø3-15/16 wall side opening

ø3-15/16 wall side opening (for left-side drain hose)

5-5/16

Ceiling

ø3-15/16 ceiling opening

Figure shows view from top

Wall

Full-scale installation diagram

Hole-in-anchor Hole-in-plug

3-35/64 *

6-7/64

4-59/64

Ceiling

Concrete Insert

Wall

WARNING

unit

Ceiling surface

Fixture

Within

1-15/16"

Screw

Latch

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

Slide

Air-intake grille

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

Ceiling tiles

Ceiling support

Hinge

Page 48

(5) Before suspending the indoor unit, remove the 2 or 3 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. 3-95. Then remove both side panels sliding them along the unit toward the front after removing the 2 attachment screws. (Fig. 3-96)

(6) Carry out the preparation for suspending the indoor unit. The

suspension method varies depending on whether there is a suspended ceiling or not. (Figs. 3-97 and 3-98)

(7) Suspend the indoor unit as follows:

a) Mount 1 washer and 2 hexagonal nuts on each suspension bolt as

shown in Fig. 3-99.

b) Lift the indoor unit, and place it on the washers through the notches,

in order to fix it in place. (Fig. 3-100)

c) Tighten the 2 hexagonal nuts on each suspension bolt to suspend

the indoor unit as shown in Fig. 3-101.

The 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" 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. 3-102)

(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. 3-103)

Fig. 3-96

Fig. 3-97

Fig. 3-98

Fig. 3-99

Fig. 3-100

Fig. 3-101

Fig. 3-102

The hole should be made at a slight downward slant to the outside.

Fig. 3-103

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 48

Slide toward front side

Side panel

NOTE

Unit

Fixture

Suspension bolt (field supply)

Ceiling surface

Washer (supplied)

Double nut (field supply)

Unit

Suspension bolt (field supply) Washer (field supply)

Washer (supplied)

Double nut (field supply)

Washer

(supplied)

Suspension bolt

Approx.

Ceiling surface

Nut (field supply)

63/64

NOTE

Indoor side

Outdoor side

PVC pipe (locally purchased)

Cut at slight angle

INSIDE

Wall

OUTSIDE

PVC pipe

Slight angle

Page 49

 Attach so that the hose band fastener is

on the side of the drain port. (Fig. 3-108)

 Attach the hose bands so that each is

approximately 13/64 – 63/64 in. from the end of the supplied drain hose.

Fig. 3-107

Fig. 3-104

If the tubing is to be routed out together, use a box cutter or similar tool to cut out the part of the rear cover indicated by the marked area in the figure below, to match the positions of the tubes. Then draw out the tubing.

Fig. 3-105

Fig. 3-106

3-28. Installing the Drain Piping

 Prepare standard PVC pipe for the drain and connect it to the

indoor unit drain pipe with the supplied hose clamps to prevent water leaks.

(1) Drain hose connection

 The drain hose is connected below the refrigerant tubing.

(2) Installing the drain hose

 To install the drain hose, first place 1 of the 2 hose bands over the

unit drain port and the other hose band over the hard PVC pipe (not supplied). Then connect both ends of the supplied drain hose.

 On the unit drain side, grasp the hose band with pliers and insert

the drain hose all the way to the base.

 If other commercially available hose bands are used, the drain

hose may become pinched or wrinkled and there is danger of water leakage. Therefore be sure to use the supplied hose bands. When sliding the hose bands, be careful to avoid scratching the drain hose.

 Do not use adhesive when connecting the supplied drain hose to

the drain port (either on the main unit or the PVC pipe).

 Wrap the hose with the supplied drain hose insulation and use the

4 twist ties so that the hose is insulated with no gaps.

 Connect the drain piping so that it slopes downward from the unit

to the outside. (Fig. 3-107)

3-26. Duct for Fresh Air

There is a duct connection port (knock-out hole) at the rightrear of the top panel of the indoor unit for drawing in fresh air. If it is necessary to draw in fresh air, remove the cover by opening the hole and connecting the duct to the indoor unit through the connection port. (Fig. 3-104)

3-27. Shaping the Tubing

 The positions of the refrigerant tubing connections are

shown in the figure below. (The tubing can be routed in 3 directions.)

* When routing the tubing out through the top or right sides,

knock out the appropriate parts in the top panel and cut notches in the side panel as shown in Fig. 3-89.

* When routing the tubing out through the top, the optional

L-shape tubing kit is required.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 49

Rear outlet port

Inter-unit control wiring

", knock-out, use rubber grommet)

(ø1-3/16

Outside air intake duct connection port (ø3-15/16

", knock-out)

Powe r supply outlet

", knock-out)

(ø1-3/16

Rear tubing hole

Left-side drain hose outlet port

Rear cover

Donward gradient

Min. 1/100

Good

Not good

CAUTION

Page 50

Fig. 3-108

 Never allow traps to occur in the course of the piping.  Insulate any piping inside the room to prevent drip-

ping.

 After the drain piping, pour water into the drain pan to

check that the water drains smoothly.

 If the drain hose is to be raised, use the optional drain

up kit. The drain hose can be raised 23-5/8" above the top of the main unit. (For details, refer to the manual of the optional part.)

* If the drain hose is

routed through the left side, refer to Fig. 3-105, and follow the procedure above to install the hose. Re-attach the rubber stopper that was earlier removed onto the right side. The rubber stopper can be inserted easily by using a screwdriver or similar tool to press the stopper into the drain port on the main unit. Press the stopper into the main unit drain port as far as it will go.

Check local electrical codes and regulations before wiring. Also, check any specified instruction or limitations.

How to carry out power supply wiring

(1) Wiring connection ports The power inlet ports are located at the rear and top. The remote controller wiring inlet ports are located at the rear and top (for use with the wired remote controller). For details, refer to Fig. 3-104. For the method used to insert the wiring, refer to the figure below. (Fig. 3-109)

When removing the fastening bracket from the cover of the electrical component box, use caution to avoid dropping the bracket.

(2) How to carry out wiring

 Open the knock-out hole on the rear or top of the

main unit. Attach the supplied rubber grommet and pull the power wiring into the main unit.

 Feed the wiring into the wiring inlet port on the

electrical component box. Connect the wiring to the terminal plate and fasten in place with the supplied clamp.

 Perform electrical and grounding work in

accordance with the package A/C power specifications, and following local electrical codes and regulations.

Fig. 3-109

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 50

Screwdriver

Drain port

Rubber stopper

Tw ist tie (4 ties, supplied)

Unit drain port

13/64

63/64 63/64

Unit drain pan

CAUTION

13/64

Hard PVC pipe (equivalent to VP-20) (Field supply)

Drain hose (supplied)

Hose band (2 bands, supplied)

Position to fasten hose bands

Drain hose insulation (supplied)

5-33/64

CAUTION

Inter-unit control wiring

ø1-9/32 knock-out

Eyelet (supplied)

Powe supply outlet

Page 51

 Wall-Mounted Type (K Type)

3-29. Removing the Rear Panel from the Unit

(1) Remove the set screws used to fasten the rear panel to the

indoor unit during transportation.

(2) Press up on the frame at the 2 locations shown by the arrows

in the figure at right, and remove the rear panel.

Tubing can be extended in 4 directions as shown in Fig. 3-111. Select the direction which will provide the shortest run to the outdoor unit.

3-30. Selecting and Making a Hole

(1) Remove the rear panel from the indoor unit and place it on

the wall at the location selected. Fix the rear panel and hook the unit onto it temporarily. Make sure the unit is horizontal using a carpenter’s level or tape measure to measure down from the ceiling.

(2) Determine which notch of the rear panel should be used.

(Fig. 3-112)

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

behind the determined location. 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 attach-

ment, make a hole (dia. 3-5/32") in the wall. (Fig. 3-113)

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

outside edge and cut the PVC pipe at a slight angle 15/64" shorter than the thickness of the wall. (Fig. 3-114)

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

side only) and insert in the wall. (Fig. 3-115)

The hole should be made at a slight downward gradient to the outside.

Fig. 3-110

Fig. 3-111

Fig. 3-112

Fig. 3-113

Fig. 3-114

Avoid areas where electrical wiring or conduits are located.

3-31. Installing the Rear Panel onto the Wall

Confirm that the wall is strong enough to support the unit. See either Item a) or b) below depending on the wall type.

a) If the Wall is Wooden

(1) Attach the rear panel to the wall with the 10 screws provided. (Fig. 3-116)

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

Fig. 3-116

Fig. 3-115

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 51

NOTE

Screws used during transportation

Press

Remove the rear panel

Left tubing

Center of left rear tubing hole

Tubing hole diameter ø3-5/32

Left-rear tubing

Indoor side

Right-rear tubing (recommended)

Center of right rear tubing hole

Outdoor side

ht tubin

NOTE

CAUTION

Plastic cover

INSIDE

Wall

PVC pipe (locally purchased)

Cut at slight angle

OUTSIDE

PVC pipe

Slight angle

Page 52

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

important so that the unit is correctly installed. (Fig. 3-117)

(3) Make sure the panel 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" dia. holes in the wall. Insert Rawl plugs for appropriate mounting screws. (Fig. 3-118)

3-32. Removing the Grille to Install the Indoor Unit

In principle, with this model wiring can be completed without removing the grille. However, if it is necessary to change the settings on the PCB, follow the procedure below.

Removing the grille

(1) Lift up on both sides of the air-intake grille to open it.

(Fig. 3-119)

(2) Remove the filter. (Fig. 3-119)

(3) Adjust the flap so that it is horizontal. (Fig. 3-120)

(4) Open the installation screw covers below the grille

(3 locations). (Fig. 3-120)

(5) Remove the screws. (Fig. 3-120)

(6) Remove the grille. (Fig. 3-121)

Attaching the grille

(1) Close the flap.

(2) Keep the grille installation tabs aligned with the top portion of

the grille, and reinstall the lower portion of the grille. Fit the installation tabs into the grooves and press the lower portion of the grille back into its original position to install it.

(3) Press on the installation tabs to completely close the grille.

Check that the grille and frame are fitted tightly together.

3-33. Preparing the Tubing

(1) Arrangement of tubing by directions

a) Right or left tubing

The corner of the right or left frame should be cut with a hack saw or similar. (Fig. 3-122)

b) Right-rear or left-rear tubing

In this case, the corners of the frame do not need to be cut.

(2) Be sure to insulate the part of the drain hose that is

run indoors, and the refrigerant tubing. If these are not insulated, condensation may result in dripping and damage to walls and furniture. The flare nuts on the 24-type (only) are large; therefore, use the supplied insulation material.

Fig. 3-117

Fig. 3-118

Fig. 3-119

Fig. 3-120

Fig. 3-121

Fig. 3-123

Fig. 3-122

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 52

Filter

Flap

Open the

3/16" dia. hole

Rawl plug

Intake grille

rille

Right tubing outlet

When left and right side tubin

Installation screw cover

Remove the grille

Installation tabs

Frame

Installation tabs

Page 53

(3) To mount the indoor unit on the rear panel.

1. When installing the indoor unit, position the indoor unit onto the installation tabs on the upper part of the rear panel. (Fig. 3-123)

2. Press on the air outlet to hold it in place, and press the lower part of the indoor unit until a “click” sound is heard and the indoor unit is securely fastened to the installation tabs on the lower side of the rear panel. (Fig. 3-124)

Raising the clamp to lift up the indoor unit will facilitate this work. (Fig. 3-125)

To remove the indoor unit, press up on the 2 locations ( marks) on the lower part of the unit frame to disconnect the installation tabs. Refer to Section 3-1. “Removing the Rear Panel from the Unit” (Fig. 3-110). Then lift up the indoor unit to remove it.

3-34. Shaping the Tubing

Right-rear tubing

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

(Fig. 3-126)

(2) After performing a leak test, wrap both the refrigerant tubing and

drain hose together with insulating tape. The drain hose should be positioned below the refrigerant tubes, and should be given sufficient space so that no strong tension is applied to it.

(3) 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.

Left or left-rear tubing

(1) Pass the tubing and drain hose into the rear of the indoor unit.

Provide sufficient length for the connections to be made. Next, bend the tubing with a pipe bender, and connect them.

(2) After performing a leak test, wrap the refrigerant tubing and drain

hose together with insulating tape, as shown in the figure at right. (Fig. 3-128) Then fit the tubing into the tubing storage space in the rear of the indoor unit and clamp in place.

(3) Adjust the indoor unit so that it is securely installed onto the rear

panel.

3-35. Installing the Drain Hose

a) The drain hose should be slanted downward to the

outside. (Fig. 3-129) b) Never form a trap in the course of the hose. c) If the drain hose will run in the room, insulate the hose* so that

chilled condensation will not damage furniture or floors.

* Foamed polyethylene or its equivalent is recommended.

Fig. 3-124

Fig. 3-125

Fig. 3-126

Fig. 3-129

Fig. 3-127

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

Fig. 3-128

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 53

Rear panel tab

Press

Clamp

Insulating

tape

Refrigerant

tubing

Plastic cover

Insulating tape

Drain hose

Indoor and outdoor unit connection wiring

Insulation

Refrigerant tubing

Rear panel

Inter-unit wiring

Indoor unit

WARNING

Slant

Refrigerant tubing

Page 54

3-36. When Using Wireless Remote Controller Instead Of Wired Remote Controller

When the wireless remote controller is to be used, slide the switch on the indoor unit control PCB.

• If this setting is not made, an alarm will occur. (The operation lamp on the display blinks.)

• This setting is not necessary if both the wired remote controller and wireless remote controller are used.

• The location of the switch varies depending on the type of PCB used. Check the model name before making the setting.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 54

KHX0752 / 0952 / 1252 / 1852

CR-KR74GXH56A-0

Setting at time of factory shipment

Slide No. 3 on SW101 from ON OFF.

KHX2452

CR-KR254GXH56A-0

Setting at time of factory shipment

Slide No. 3 on SW101 from ON OFF.

Page 55

4. HOW TO INSTALL THE OUTDOOR UNIT

4-1. Transporting

When transporting the unit, have it delivered as close to the installation site as

possible without unpacking. Use a hook for suspending the unit. (Fig. 4-1)

 When hoisting the outdoor unit, pass ropes or straps under the bottom plate

as shown in the figure at right. When hoisting, the angle between the rope

and top panel must be 70° or greater so that the rope does not come into

contact with the fan guard.

(Use 2 lengths of rope 25 ft. long or longer.)

 When passing the ropes through the square holes of the bottom plate:

Place the rope in the outer edge of the square holes.

 Use protective panels or padding at all locations where the rope contacts the

outer casing or other parts to prevent scratching. In particular, use protective

material (such as cloth or cardboard) to prevent the edges of the top panel

from being scratched.

 Be careful of the fan.

There is danger of injury if the fan starts to turn during inspection. Be sure to

turn OFF the remote power switch before beginning inspection.

4-2. Installing the Outdoor Unit

(1) Use anchor bolts (M12 or 15/32") or similar to securely anchor the unit in

place. (Fig. 4-2)

(2) Be sure the rubber vibration insulator and platform extend to the inside of the

legs. In addition, the washers used to anchor the unit from the top must be

larger than the installation anchor holes. (Figs. 4-2 and 4-3)

Fig. 4-1

Fig. 4-2

Fig. 4-3

Unit: in.

The vibration insulator, base, or platform must be large enough to bear the full surface of the base plate legs.

Unit: in.

Top view

Fig. 4-4

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 55

CAUTION

(Positions where anchor bolts are fastened)

Installation anchor hole (4 – 19/32 × 25/32 oval holes)

36-7/32 (Installation hole pitch)

37-13/32 (Maximum dimensions)

35-3/64 (Ceiling panel dimensions)

31-7/64 (Installation hole pitch)

35-3/64 (Ceiling panel dimensions)

Plate leg

Anchor bolts

Washer

25/32

3-29/64

Vibration insulator

1-31/32

(3-15/16)

(Detailed view of legs)

Base

Surface where

installation anchor

brackets are

installed

31/32 1-

4 – 19/32 25/32 hole

19/32

1-33/64

35-3/64 (Ceiling panel dimensions) 35-3/64 (Ceiling panel dimensions)

31-7/64 (Installation hole pitch) 31-7/64 (Installation hole pitch)

74-1/64 (Ceiling panel dimensions)

70-5/64 (Installation hole pitch)

35-3/64 (Ceiling panel dimensions)

36-7/32 (Installation hole pitch)

37-13/32 (Maximum dimensions)

Page 56

Fig. 4-6

Fig. 4-5

4-3. Routing the Tubing

 The tubing can be routed out either from the front or from the bottom. (Fig. 4-6)

 The connecting valve is contained inside the unit. Therefore, remove the front panel. (Fig. 4-6)

(1) If the tubing is routed out from the front, use cutting pliers or a similar tool to cut out the tubing outlet slit (part indicated

by ) from the tubing cover. (Figs. 4-5 and 4-6)

(2) If the tubing is routed out from the bottom, remove the

slit part ( ).

 Use a drill bit approximately 13/64 dia. to create holes at

the 4 slit hole indentations (openings).

 Punch out the slit part ( ).

 Be careful not to damage the base plate.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 56

Remove 2 screws

Front

Tubing cover

Bottom

Remove 11 panel screws from front panel

Use cutting pliers or similar tool to cut cover out

Indentation (4 locations)

Slit hole

Page 57

4-4. Prepare the Tubing

 Material: Use C1220 phosphorous deoxidized copper as described in JIS H3300, “Copper and Copper Alloy Seamless Pipes

and Tubes.” (For tubes that are ø7/8"

(ø22.22 mm) or larger, use 1/2H material or H material. For all others use O material.)

 Tubing size

Use the tubing size indicated in the table below.

 When cutting the tubing, use a tube cutter, and be sure to remove any burrs.

(The same applies to distribution tubing (optional).)

 When bending the tubes, bend each tube using a radius that is at least 4 times the outer diameter of the tube.

When bending, use sufficient care to avoid crushing or damaging the tube

 For flaring, use a flare tool, and be sure that flaring is performed correctly.

Use sufficient caution during preparation of the tubing. Seal the tube ends by means of caps or taping to prevent dust, moisture, or other foreign substances from entering the tubes.

Refrigerant tubing (Existing tubing can be used.)

4-5. Connect the Tubing

 Use the supplied connector tubing. (See figure below.)

14053 type (16 hp)

09053 type (10 hp)

Tubing size (in. (mm))

Material O Material 1/2H • H

ø1/4" (ø6.35) t1/32" (0.8) ø7/8" (ø22.22) t5/128" (1.0)

ø3/8" (ø9.52) t1/32" (0.8) ø1" (ø25.4) t5/128" (1.0)

ø1/2" (ø12.7) t1/32" (0.8) ø1-1/8" (ø28.58) t5/128" (1.0)

ø5/8" (ø15.88) t5/128" (1.0) ø1-1/4" (ø31.75) t3/64" (1.1)

ø3/4" (ø19.05) over t5/128" (1.0) ø1-1/2" (ø38.1) over t3/64" (1.15)

ø1-5/8" (ø41.28) over t3/64" (1.20)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 57

CAUTION

Refrigerant tubing

Gas tubing

Liquid tubing

Balance tube

Connection method Supplied parts used?

Brazing

Flare connection

Ye s (ø3/4" ø7/8")

Refrigerant tubing

Gas tubing

Liquid tubing

Balance tube

Connection method Supplied parts used?

Brazing

Flare connection

Ye s (ø1

ø1-1/8")

Page 58

 Precautions for brazing

Be sure to replace the air inside the tube with nitrogen to prevent oxide film from forming during the brazing process. Be sure to use a damp cloth or other means to cool the valve unit during brazing.

1. Be sure to use nitrogen. (Oxygen, CO2, and CFC must not be used.)

2. Use a pressure-reducing valve on the nitrogen tank.

3. Do not use agents intended to prevent the formation of oxide film. They will adversely affect the refrigeration oil, and may cause equipment failure.

4. The balance tube is not used if only 1 outdoor unit is installed. Use the unit in the same conditions as when it was shipped from the factory.

Refrigerant tube port

 Use caulking, putty, or a similar material to fill any gaps at the

refrigerant tube port ( ) in order to prevent rainwater, dust or

foreign substances from entering the unit.

* Perform this work even if the tubing is routed out in a downward

direction.

 Tighten each cap as specified below.

Tightening torque for each cap

Tubing routed out

through the front side

Tubing routed out

through the bottom

Work method

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 58

Cap tightening torque

Service port cap (width 19/32", 43/64")

Valve cap (width 55/64", 15/16")

60 – 100 lbs

170 – 220 lbs

in. (70 – 120 kgf

in. (200 – 250 kgf

Bottom

Tubing cover

cm)

* Be careful of the cap sizes. The sizes of the service port cap and valve cap on the 14053 type liquid tube valves are different from other valve caps.

cm)

plate

Service port cap

Valve cap (width 55/64)

Service port cap (width 19/32)

Flare nut (ø1/4)

(width 19/32)

Valve cap (width 55/64)

Flare nut (ø3/8)

Do not apply a monkey wrench to the hexagonal part.

Do not use two monkey wrenches when removing or installing the balance tube flare nut. In particular, do not apply a monkey wrench to the hexagonal part at the top of the valve. (If force is applied to this part, gas leakage will occur.)

(0905 Type) (1405 Type)

Valve cap (width 55/64)

Service port cap (width 19/32)

Flare nut (ø1/4)

Use two monkey wrenches, as shown in the figure, when removing the liquid tube valve flare nut.

Service port cap (width 43/64)

Valve cap (width 15/16)

Valve cap (width 55/64)

Flare nut (ø3/8)

1. Do not apply a wrench to the valve cap when removing or installing the flare nuts. Doing so may damage the valve.

2. If the valve cap is left off for a long period of time, refrigerant leakage will occur. Therefore, do not leave the valve cap off.

3. Applying refrigerant oil to the flare surface can be effective in preventing g oil which is suitable for the refrigerant that is used in the system. (This unit utilizes R410A refrigerant, and the refrigerant oil is ether oil (synthetic oil). However, hub oil (synthetic oil) can also be used.)

as leakage, however be sure to use a refrigerant

Valve cap (width 55/64)

Service port cap (width 19/32)

Field-supply tube

Brazing locations

Remote valve

Ta pi ng

Pressure-reducing valve (regulator)

Nitrogen

CAUTION

Page 59

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, please refer to 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 damaged, it

must be replaced by a repair shop appointed by the

manufacturer, because special purpose tools are

required.

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

* With ring-type wire terminal.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 59

Outdoor unit

Type

(A) Power supply

Wire size Max. length

CHDX09053 64 ft. 60 A

CHDX14053 100 ft. 80 A

AWG #8

AWG #4

Time delay fuse or

circuit capacity

Indoor unit

Type

A, X, T, U

(B) Power supply

AWG #14

Max. 492 ft.

Max. 426 ft.

Max. 196 ft.

Time delay fuse or

circuit capacity

15 A

Control wiring

(D) Remote control wiring (E) Control wiring for group control

indoor units) control wiring

AWG #18 (0.75 mm

) AWG #18 (0.75 mm2) AWG #18 (0.75 mm2)

Use shielded wiring*Use shielded wiring Use shielded wiring

Max. 3,280 ft.

Max. 1,640 ft.

NOTE

Max. 1,640 ft. (Total)

(F) Inter-outdoor unit control wiring

AWG #18 (0.75 mm

)

Use shielded wiring

Max. 1,640 ft.

Page 60

5-3. Wiring System Diagram

(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

diagram.

(2) The basic connection diagram of the indoor unit shows

the 7P terminal board, so the terminal boards in your

equipment may differ from the diagram.

(3) Refrigerant Circuit (R.C.) address should be set before

turning the power on.

(4) Regarding the R.C. address setting, refer to page 74.

Address setting can be executed by remote controller

automatically. Refer to page 74 – 78.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 60

Power supply 208 / 230V, 1ø, ~60Hz

Remote controller

Power supply 208 / 230V, 1ø, ~60Hz

Remote controller

Power supply 208 / 230V, 1ø, ~60Hz

WHT BLK

Group control:

L1 L2

Ground

L1 L2

Ground

L1 L2

Ground

Indoor unit (No. 1)

Indoor unit (No. 2)

Indoor unit (No. 3)

Ground

Outdoor unit INV unit

Power supply

208 / 230V, 3ø, ~60Hz

Ground

Inter-outdoor-unit control wiring

Outdoor unit INV unit

L1 L2 L3

Ground

Power supply 208 / 230V, 3ø, ~60Hz

Ground

Power supply 208 / 230V, 1ø, ~60Hz

Remote controller

WHT BLK

L1 L2

Ground

NOTE

Indoor unit (No. n)

Ground

1(L1) 2(L2)

Power supply

7P terminal board

Inter-unit

control wiring

X, A, U, D, T Type

5P terminal board

123 45

1(L1)2(L2)

Power

supply

U1 U2

Inter-unit

control wiring

K Type

Remote

controller

Page 61

(1) When linking outdoor units in a network (S-net link system), disconnect the terminal extended from the short plug

(CN003, 2P Black, location: right bottom on the outdoor main control PCB) from all outdoor units except any one

of the outdoor units. (When shipping: In shorted condition.)

Otherwise the communication of S-net link system is not performed. For a system without link (no connection

wiring between outdoor units), do not remove the short plug.

(2) Do not install the inter-unit control wiring in a way that forms a loop. (Fig. 5-1)

Fig. 5-1

Fig. 5-2

Fig. 5-3

(3) Do not install inter-unit control wiring such as star branch

wiring. Star branch wiring causes mis-address setting.

(4) If branching the inter-unit control wiring, the number of branch points should be 16 or fewer.

(Branches less than 3.3 ft. are not included in the total branch number.) (Fig. 5-3)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 61

CAUTION

Outdoor unit Outdoor unit Outdoor unit

Prohibited

Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit

Outdoor unit Indoor unit Indoor unit Indoor unit

Indoor unit Indoor unit Indoor unit

Branch point

Prohibited

Outdoor unit

Indoor unit

Outdoor unit Outdoor unit Outdoor unit

Branch point

16 or fewer

Indoor unit Indoor unit Indoor unit Indoor unit

more than 3.3 ft.

Indoor unit

more than 3.3 ft.

Indoor unit

less than 3.3 ft.

Indoor unit

Indoor unit Indoor unit Indoor unit

Page 62

Fig. 5-4

Fig. 5-5

Fig. 5-6

(5) Use shielded wires for inter-unit control wiring (c)

and ground the shield on both sides, otherwise

misoperation from noise may occur. (Fig. 5-4)

Connect wiring as shown in Section “5-3. Wiring

System Diagram.”

Loose wiring may cause the

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 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.

How to connect wiring to the terminal

 For stranded wiring

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

insulation to expose the stranded wiring about 3/8 in.

and tightly twist the wire ends. (Fig. 5-5)

(2) Using a Phillips head screwdriver, remove the terminal

screw(s) on the terminal plate.

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

clamp each stripped wire end with a ring pressure

terminal.

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

tighten the removed terminal screw using a screwdriver.

(Fig. 5-6)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 62

Shielded wire

WARNING

Ground

Strip 3/8 in.

Ground

Stranded wire

Ring pressure terminal

Special washer

Wire

Screw

Ring pressure terminal

Terminal plate

Screw and Special washer

Ring pressure

terminal

Wire

Page 63

6. HOW TO PROCESS TUBING

The liquid tubing side is connected by a flare nut, and the

gas tubing side is connected by brazing.

6-1. Connecting the Refrigerant Tubing

Use of the Flaring Method

Many of 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. 1 – 2 ft. longer

than the tubing length you estimate.

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

reamer or file. This process is important and should be

done carefully to make a good flare. (Fig. 6-1)

When reaming, hold the tube end downward and be sure

that no copper scraps fall into the tube. (Fig. 6-2)

(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 copper tube with a flare

tool.* (Fig. 6-3)

(*Use “RIGID

” or equivalent.)

A good flare should have the following characteristics:

 inside surface is glossy and smooth

 edge is smooth

 tapered sides are of uniform length

Fig. 6-1

Fig. 6-2

Fig. 6-3

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 63

Deburring

NOTE

Before

After

Copper tubing

Reamer

NOTE

Flare nut

Copper tubing

Flare tool

Page 64

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. 6-4)

(3) For proper connection, align the union tube and flare

tube straight with each other, then screw in the flare nut

lightly at first to obtain a smooth match. (Fig. 6-5)

 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.

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.

6-2. 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

connections, or when tightening them after connecting

the tubing, be sure to use 2 monkey wrenches or

spanners as shown. (Fig. 6-6)

If the flare nuts are over-tightened, the flare may be

damaged, which could result refrigerant leakage and

cause in injury or asphyxiation to room occupants.

 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.

Fig. 6-4

Fig. 6-5

Fig. 6-6

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

monkey wrench with a nominal handle length of 7-7/8 in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 64

Apply refrigerant lubricant here and here

Union

To rq ue wrench

Flare nut

Indoor unit

Tube diameter

ø1/4" (ø6.35 mm)

ø3/8" (ø9.52 mm)

ø1/2" (ø12.7 mm)

ø5/8" (ø15.88 mm)

ø3/4" (ø19.05 mm)

Outdoor unit

Tightening torque, approximate

120 – 160 lbs

(140 – 180 kgf

300 – 360 lbs

(340 – 420 kgf

430 – 530 lbs

(490 – 610 kgf

590 – 710 lbs

(680 – 820 kgf

870 – 1040 lbs

inch cm)

(1000 – 1200 kgf

inch

cm)

Spanner

Tube thickness

1/32" (0.8 mm)

5/128" (1.0 mm)

over 5/128" (1.0 mm)

Page 65

Fig. 6-8

Fig. 6-7

6-3. 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 25/64 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.

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 sup-

plied black insulation tape. Finally, fasten the insulator at both

ends with the supplied vinyl clamps. (Fig. 6-8)

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,

never try to bend it into a narrow

curve because it can cause the

tube to break or crack.

Never grasp the drain or refrigerant connecting outlets when moving the unit.

Three tubes arranged together

Two tubes arranged together

If the exterior of the outdoor unit

valves has been finished with a

square duct covering, make sure

you allow sufficient space to use

the valves and to allow the panels

to be attached and removed.

Fig. 6-9

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 65

CAUTION

Liquid tubing

Insulation

Cosmetic (finishing) tape

Liquid tubing

Insulation

Sealer (supplied)

Unit side insulator

Flare nut

Drain insulator and clamp. Large (supplied)

Packing clamp. Small hose band

pplied)

(su

Insulation tape (white)

Vinyl clamps (supplied)

Refrigerant tubing and insulator (not supplied)

Drain pipe and insulator (not supplied)

Seal

(supplied)

Flare insulator

The procedure used for installing the insulator for both gas and liquid tubes is the same.

Gas tubing

Balance tubing

Flare insulator (supplied)

Tube insulator (not supplied) Heat resistant 248°F or above

Insulation tape

Vinyl clamp

Page 66

Fig. 6-10

Fig. 6-11

6-4. 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 the 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 ft. (Fig. 6-10)

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.

6-5. 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. 6-11)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 66

NOTE

Apply putty here

Insulated tubes

Tubing

Clamp

Drain hose

Page 67

Fig. 7-1

Fig. 7-2

Fig. 7-3

7. AIR PURGING

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

Check that each tube (both liquid and gas tubes) between the

indoor and outdoor units have been properly connected and all

wiring for the test run has been completed. Remove 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.

Leak test

(1) With the service valves on the outdoor unit closed, remove the

5/16" 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.

(3) Pressurize the system to no more than 469 psig (33 kgf/cm

with dry nitrogen gas and close the cylinder valve when the

gauge reading reaches 469 psig (33 kgf/cm

G). Then, test for

leaks with liquid soap.

To avoid nitrogen entering the

refrigerant system in a liquid state, the

top of the cylinder must be higher than

the bottom when you pressurize the

system. Usually, the cylinder is used in

a vertical standing position.

Use a manifold valve for air purging.

If it is not available, use a stop valve

for this purpose. The “Hi” knob of

the manifold valve must always be

kept closed.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 67

Manifold gauge

Vacuum pump

Outlet Inlet

CAUTION

Pressure gauge

Gas tube

Liquid tube

Manifold valve

Lo Hi

Cylinder valve

Open

Charge hose

Nitrogen gas cylinder (In vertical standing position)

Outdoor unit

Balance tube

Page 68

Fig. 7-4

(4) Do a leak test of all joints of the tubing (both indoor and

outdoor) and both gas and liquid service valves. Bub-

bles indicate a leak. Wipe off the soap with a clean cloth

after a leak test.

(5) After the system is found to be free of leaks, relieve the

nitrogen pressure by loosening the charge hose con-

nector at the nitrogen cylinder. When the system pres-

sure is reduced to normal, disconnect the hose from the

cylinder.

Evacuation

(1) Attach the charge hose end described in the preceding

steps to the vacuum pump to evacuate the tubing and

indoor unit. Confirm that the “Lo” knob of the manifold

valve is open. Then, run the vacuum pump. The opera-

tion time for evacuation varies with the tubing length and

capacity of the pump. The following table shows the

amount of time for evacuation:

Required time for evacuation

when 30 gal/h vacuum pump is used

If tubing length is If tubing length is

less than 49 ft. longer than 49 ft.

45 min. or more 90 min. or more

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 68

Manifold valve

Pressure gauge

Gas tube

Liquid tube

Lo Hi

Open

Vac uum pump

Outdoor unit

Open

Balance tube

Page 69

Fig. 7-5

Fig. 7-6

The required time in the above table is calculated based on the

assumption that the ideal (or target) vacuum condition is less

than –14.7 psig (–755 mmHg, 5 Torr).

(2) When the desired vacuum is reached, close the “Lo” knob of

the manifold valve and turn off the vacuum pump. Please

confirm that the gauge pressure is under –14.7 psig

(–755 mmHg, 5 Torr) after 4 to 5 minutes of vacuum pump

operation.

Charging additional refrigerant

 Charging additional refrigerant (calculated from the liquid

tube length as shown in Section “1-8. Additional Refrigerant

Charge”) using the liquid tube service valve. (Fig. 7-5)

 Use a balance to measure the refrigerant accurately.

 If the additional refrigerant charge amount cannot be charged

at once, charge the remaining refrigerant in liquid form by

using the gas tube service valve with the system in cooling

operation mode at the time of test run. (Fig. 7-6)

Finishing the job

(1) With a hex wrench, turn the liquid tube service valve stem

counter-clockwise to fully open the valve.

(2) Turn the gas tube service valve stem counter-clockwise to

fully open the valve.

(3) Loosen the charge hose connected to the gas tube service

port (5/16") slightly to release the pressure, then remove the

hose.

(4) Replace the 1/4 in. flare nut and its bonnet on the gas tube

service port and fasten the flare nut securely with an

adjustable wrench or box wrench. This process is very

important to prevent gas from leaking from the system.

(5) Replace the valve caps at both gas and liquid service valves

and fasten them securely.

This completes air purging with a vacuum pump. The air condi-

tioner is now ready for a test run.

Use a cylinder designed for use

with R410A respectively.

To avoid gas from leaking when

removing the charge hose, make

sure the stem of the gas tube is

turned all the way out (“BACK

SEAT” position).

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 69

Manifold valve

NOTE

CAUTION

Pressure gauge

Gas tube

Liquid tube

Balance tube

Lo Hi

Open

Valve

Liquid

R410A

Outdoor unit

Gas tube

Liquid tube

Balance tube

Open

Outdoor unit

Open

Page 70

8. TEST RUN

8-1. Preparing for Test Run

 Before attempting to start the air conditioner, check

the following.

(1) All loose matter is removed from the cabinet especially

steel filings, bits of wire, and clips.

(2) The control wiring is correctly connected and all

electrical connections are tight.

(3) The protective spacers for the compressor used for

transportation have been removed. If not, remove them

now.

(4) The transportation pads for the indoor fan have been

removed. If not, remove them now.

(5) The power has been connected to the unit for at least 5

hours before starting the compressor. The bottom of the

compressor should be warm to the touch and the

crankcase heater around the feet of the compressor

should be hot to the touch.

(Fig. 8-1)

(6) Both the gas and liquid tube service valves are open. If

not, open them now. (Fig. 8-2)

(7) Request that the customer be present for the trial run.

Explain the contents of the instruction manual, then have

the customer actually operate the system.

(8) Be sure to give the instruction manual and warranty

certificate to the customer.

(9) When replacing the control PCB, be sure to make all the

same settings on the new PCB as were in use before

replacement.

The existing EEP ROM is not changed, and is

connected to the new control PCB.

Fig. 8-1

Fig. 8-2

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 70

(Power must be turned ON at least 5 hours before attempting test run)

Power mains switch

Balance tube

Liquid tube

Gas tube

Page 71

Items to Check Before the Test Run

1. Turn the remote power switch on at least 5 hours before the test, in order to energize the crank case heater.

2. After performing the leak inspection, applying vacuum, and performing refrigerant charge for the tubing which is connected on-site, fully open the outdoor unit service valve. However if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valve fully closed.

3. When replacing the control PCB, be sure that the settings on the new PCB match those on the old PCB.

4. Use caution when making the settings. If there are duplicated system addresses, or if the settings for the Nos. of the indoor units are not consistent, an alarm will occur and the system will not start.

5. These settings are not made on the indoor unit PCB.

8-2. Test Run Procedure

Fig. 8-3

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 71

Recheck the items to check before the test run.

Unit No. setting switch

(S007)

Unit No. setting switch

(S006)

Unit No. setting switch

(S004 and S005)

(Check the link wiring.)

Unit No. setti

(S002 and S003)

Refer to Fig. 8-4

ng switch

Have the outdoor sub units been connected?

YES

Set the unit address.

Set the No. of outdoor units.

Set the No. of indoor units.

Are the inter-unit control wires

connected to more than 1 refrigerant

system?

YES

Set the system address.

When multiple outdoor main units exist, disconnect the terminals

extended from the shor ted plugs (CN003) at all outdoor main unit

Alternatively, move the sockets to the OPEN side.

PCBs except for 1.

Is it possible to turn ON the power only

for the 1 refrigerant system where the

test run will be performed?

YES

The unit with the unit

No. set to 1 is the main unit. All other units are sub units.

CASE 1

Note: It is not necessar y to remove the socket

that is used to short-circuit the terminal plugs from the outdoor sub unit PCBs.

CASE 2

Turn ON the indoor and

outdoor unit power for that

refrigerant system only.

CASE 3BCASE 3A

Is it OK to start the compressors?

Turn ON the indoor and

(CN101) on the outdoor main unit PCB.

tdoor unit power.

Short-circuit the mode change pin

At the same time, short-circuit the

automatic address pin (CN100) for 1

second or longer, then release it.

*3 *3

Start indoor and outdoor unit

cooling operation.

LED 1 and 2 blink alternately.

Are LEDs 1 and 2 on the

outdoor unit PCB OFF?

Check that test run preparation is OK.

(Do not allow the short-circuited pins to remain short-circuited.)

Will automatic address setting be

performed in Heating mode?

YES

Is it OK to start the compressors?

Turn ON the indoor and

outdoor unit power.

Short-circuit the automatic address

pin (CN100) on the outdoor main

unit PCB for 1 second or longer,

then release it.

Start indoor and outdoor unit

heating operation.

LED 1 and 2 blink alternately.

YES

Make necessary

corrections

Turn OFF the indoor and

outdoor unit power.

Check the alarm

contents.

*2 A minimum of 5 hours must have passed after the

power was turned ON to the ou

*3 All indoor units operate in all refrigerant systems

where the power is ON.

Make necessary corrections.

Turn OFF the indoor and

outdoor unit power.

Check the alarm contents.

Refer to “Table of Self-Diagnostic Functions and Description of Alarm Displays.”

Short-circuit the automatic address pin (CN100)

on the outdoor main unit PCB for 1 second or

LED 1 and 2 blink alternately

release it.

longer, then

(about 2 or 3 minutes).

Are LEDs 1 and 2 on the

outdoor unit PCB OFF?

YES

tdoor unit.

Set the wired remote controller for test run.

Refer to the remote

controller test-run

settings.

Does system operate?

YES

Return remote control to normal mode

End test run.

Check and make corrections according to

“Table of Self-Diagnostic F

unctions.”

Page 72

8-3. Main Outdoor Unit PCB Setting

Fig. 8-4

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 72

CN100

CN101

CN003

S003

S002 S004 S005 S006 S007

Page 73

The sub unit control PCB contains the same switches as the main unit control PCB for No. of indoor units, No. of outdoor units, and system address. However it is not necessary to set these switches.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 73

● Examples of the No. of indoor units settings (S005, S004)

No. of indoor units

1 unit (factory setting)

11 units

21 units

31 units

40 units

Indoor unit setting (S005)

(3P DIP switch, blue)

10 20 30

All OFF

1 ON

2 ON

3 ON

1 & 3 ON

● Examples of refrigerant circuit (R.C.) address settings (required when link wiring is used) (S003, S002)

System address (S003)

System address No.

System 1 (factory setting)

System 11

System 21

System 30

(2P DIP switch, blue)

Both OFF

1 & 2 ON

1 ON

2 ON

OFF

10 20

Indoor unit setting (S004)

(Rotary switch, red)

System address (S002)

(Rotary switch, black)

OFF

Set to 1

Set to 0

Set to 1

Set to 0

● Examples of the No. of outdoor units settings (S006)

No. of outdoor units

1 unit (factory setting)

2 units

3 units

4 units

Outdoor unit setting (S006)

(3P DIP switch, blue)

1 ON

2 ON

1 & 2 ON

3 ON

OFF

● Address setting of main outdoor unit (S007)

Unit No. setting

Unit No. 1 (main unit)

(factory setting)

Address setting of outdoor unit (S007)

(3P DIP switch, blue)

21ON3

OFF

● Address setting of sub outdoor unit

Unit No. setting

Unit No. 2 (sub unit)

(factory setting)

Unit No. 3 (sub unit)

Unit No. 4 (sub unit)

Address setting of outdoor unit (S007)

(3P DIP switch, blue)

2 ON

1 & 2 ON

3 ON

21ON3

OFF

Page 74

(1) Automatic Address Setting from the Outdoor Unit

1. To set the number of outdoor units, on the outdoor main unit control PCB set the No. of outdoor units DIP switch (S006) to

(3 units), and set the unit No. DIP switch (S007) to (unit No. 1 – main outdoor unit).

2. On the No. 2 (sub) unit control PCB, set the unit No. switch (S007) to (unit No. 2).

On the No. 3 (sub) unit control PCB, set the unit No. switch (S007) to (unit No. 3).

8-4. Auto Address Setting

Basic wiring diagram: Example (1)

Case 1

Fig. 8-5

3. On the outdoor main unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the DIP switch

(S003) is set to “0.” (These are the settings at the time of factory shipment.)

4. To set the number of indoor units that are connected to the outdoor unit to 10, on the outdoor main unit control PCB set the No. of

indoor units DIP switch (S005) to “1,” and set the rotary switch (S004) to “0.”

5. Turn ON the power to the indoor and outdoor units.

6. On the outdoor main unit control PCB, short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

↓

(Communication for automatic address setting begins.)

↓

(Automatic address setting is completed when LEDs 1 and 2 on the outdoor main unit control PCB turn OFF.)

↓

7. Operation from the remote controllers is now possible.

* To perform automatic address setting from the remote controller, perform steps 1 to 5, then use the remote controller and com-

plete automatic address setting.

 Refer to “Automatic Address Setting from the Remote Controller.”

* To cancel, again short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

The LED that indicates that automatic address setting is in progress turns OFF and the process is stopped. Be sure to perform automatic address setting again.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 74

• If link wiring is not used (The inter-unit control wires are not connected to multiple refrigerant systems.)

Indoor unit addresses can be set without operating the compressors.

No. 1 (main outdoor unit) settings

System address

(system 1 setting)

(S003)(S002) ON

No. of outdoor units (3 units

setting)

Outdoor Unit

OFF

(S006) (S007)

OFF

No. of indoor units

(10 units setting)

(S004)

(S005)

1ON3

Unit number setting (Unit No. 1)

Unit

No. 1

(Main)

OFF

Unit

number setting

(Unit No. 2)

Leave the socket that is used to short-circuit the terminal plug. (CN003)

Outdoor main/sub control wiring

Inter-unit control wiring

No. 2 (sub unit)

settings

(S007)

123

Unit No. 2 (Sub)

OFF

Outdoor main/sub control wiring

Unit

number setting

(Unit No. 3)

No. 3 (sub unit)

settings

(S007)

Unit No. 3 (Sub)

OFF

Indoor Unit

1-1

1-2 1-3

1-10

Remote controller

OFF

cross-over wiring

OFF

Page 75

Basic wiring diagram: Example (2)

Fig. 8-6

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 75

No. 1 Refrigerant circuit

System address

(system 1 setting)

No. of outdoor units (3 units setting)

• If link wiring is used

No. 1 (main outdoor unit) settings

No. of indoor units

(13 units setting)

(S003)(S002)

(S006)

Outdoor unit

system 1

Indoor unit

OFF

(S004)

(S005)

Unit

number setting

(unit No. 1)

OFF

(S007)

Unit

No. 1

(Main)

1-1 1-2

Remote

controller

Unit

number

OFF

setting (unit No. 2)

Leave the socket that is used to short-circuit the terminal plug. (CN003)

Inter-unit control wiring

* When multiple outdoor main units exist, remove the socket that

is used to short-circuit the terminal plug (CN003) from all outdoor main unit PCBs except for one unit.

Alternatively, move the sockets to the “OPEN” side.

No. 2 (sub unit)

settings

(S007)

123

Unit No. 2 (Sub)

OFF

Outdoor main/sub

Unit

number setting

(unit No. 3)

No. 3 (sub unit)

settings

(S007)

Unit No. 3 (Sub)

OFF

control wiring

1-3 1-13

Remote controller communication wiring

No. 2 Refrigerant circuit

No. of outdoor

units (2 units setting)

No. 1 (main unit) settings

System address

(system 2 setting)

(S003)(S002)

(S006)

123

Outdoor unit

system 2

No. of indoor units (9

OFF

Unit

number setting

(unit No. 1)

OFF

units setting)

(S004)

(S005)

1ON3

Unit

No. 1

(Main)

OFF

(S007)

OFF

Move the socket to the “OPEN” side (CN003).

Unit

number setting

(unit No. 2)

Inter-unit control wiring

To other system link wiring

Indoor unit

Remote

controller

2-1 2-2 2-9

Remote controller cross-over wiring

Make settings as appropriate for the cases listed below.

(Refer to the instructions on the following pages.)

• Indoor and outdoor unit power can be turned ON for each system separately.

• Indoor and outdoor unit power cannot be turned ON for each system separately.

Automatic address setting in Heating mode

Automatic address setting in Cooling mode

No. 2 (sub unit) settings

(S007)

123

OFF

Unit No. 2 (Sub)

Outdoor main

Case 2

Case 3A

Case 3B

/sub control wiring

Page 76

Automatic Address Setting (no compressor operation)

 Indoor and outdoor unit power can be turned ON for each system separately.

Indoor unit addresses can be set without operating the compressors.

Automatic Address Setting from Outdoor Unit

1. On the No. 1 (main) unit control PCB, set the unit No. switch (S007) to (unit No. 1).

On the No. 2 (sub) unit control PCB, set the unit No. switch (S007) to (unit No. 2).

On the No. 3 (sub) unit control PCB, set the unit No. switch (S007) to (unit No. 3).

2. To set the number of outdoor units on the outdoor main unit control PCB, set the No. of outdoor units DIP switch (S006) to

(3 units).

3. On the outdoor main unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the DIP

switch (S003) is set to “0” . (These are the settings at the time of factory shipment.)

4. To set the number of indoor units that are connected to the outdoor unit to 13, on the outdoor main unit control PCB set the

No. of indoor units DIP switch (S005) to “1” , and set the rotary switch (S004) to “3.”

5. Turn on power to all indoor and outdoor units in the system.

6. Short-circuit the automatic address pin at the outdoor main unit (CN100) for 1 second or longer, then release it.

↓

(Communication for automatic address setting begins.)

↓

(Automatic address setting is completed when LEDs 1 and 2 on the outdoor main unit control PCB turn OFF.)

↓

7. Next turn the power ON only for the indoor and outdoor units of the next (different) system. Repeat steps 1 – 5 in the same

way to complete automatic address settings for all systems.

↓

8. Operation from the remote controllers is now possible.

* To perform automatic address setting from the remote controller, perform steps 1 – 5, then use the remote controller and

complete automatic address setting.

 Refer to “Automatic Address Setting from Remote Controller.”

Case 2

* To cancel, again short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

The LED that indicates automatic address setting is in progress turns OFF and the process is stopped. Be sure to perform automatic address setting again.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 76

OFF

Page 77

Automatic Address Setting in Heating Mode

 Indoor and outdoor unit power cannot be turned ON for each system separately.

In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating.

Therefore perform this process only after completing all refrigerant tubing work.

Automatic Address Setting from Outdoor Unit

1. Perform steps 1 – 4 in the same way as for .

5. Turn the indoor and outdoor unit power ON at all systems.

↓

6. To perform automatic address setting in , on the outdoor main unit control PCB in the refrigerant system

where you wish to set the addresses, short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

(Be sure to perform this process for one system at a time. Automatic address settings cannot be performed for more than

one system at the same time.)

↓

(Communication for automatic address setting begins, the compressors turn ON, and automatic address setting in

Heating mode begins.)

(All indoor units operate.)

↓

(Automatic address setting is completed when the compressors stop and LEDs 1 and 2 on the main unit control PCB turn

OFF.)

7. At the outdoor main unit in the next (different) system, short-circuit the automatic address pin (CN100) for 1 second or

longer, then release it.

↓

(Repeat the same steps to complete automatic address setting for all units.)

↓

8. Operation from the remote controllers is now possible.

* To perform automatic address setting from the remote controller, perform steps 1 – 5, then use the remote controller and

complete automatic address setting.

 Refer to “Automatic Address Setting from Remote Controller.”

Heating mode

Case 2

Case 3A

* To cancel, again short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

The LED that indicates automatic address setting is in progress turns OFF and the process is stopped. Be sure to perform automatic address setting again.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 77

Page 78

Automatic Address Setting in Cooling Mode

 Indoor and outdoor unit power cannot be turned ON for each system separately.

In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating.

Therefore perform this process only after completing all refrigerant tubing work.

Automatic address setting can be performed during Cooling operation.

Automatic Address Setting from Outdoor Unit

1. Perform steps 1 – 4 in the same way as for .

5. Turn the indoor and outdoor unit power ON at all systems.

↓

6. To perform automatic address setting in , on the outdoor main unit control PCB in the refrigerant system where

you wish to set the addresses, short-circuit the mode change 2P pin (CN101). At the same time, short-circuit the automatic

address pin (CN100) for 1 second or longer, then release it. (Be sure to perform this process for one system at a time. Automatic

address settings cannot be performed for more than one system at the same time.)

↓

(Communication for automatic address setting begins, the compressors turn ON, and automatic address setting in Cooling

mode begins.)

(All indoor units operate.)

↓

(Automatic address setting is completed when the compressors stop and LEDs 1 and 2 on the outdoor main unit control PCB

turn OFF.)

7. At the outdoor main unit in the next (different) system, short-circuit the automatic address pin (CN100) for 1 second or longer,

then release it.

↓

(Repeat the same steps to complete automatic address setting for all units.)

↓

8. Operation from the remote controllers is now possible.

* Automatic address setting in Cooling mode cannot be done from the remote controller.

Automatic Address Setting* from the Remote Controller

Selecting each refrigerant system individually for automatic address setting

---Automatic address setting for each system: Item code “A1”

1. Press the remote controller timer time button and button at the same time.

(Press and hold for 4 seconds or longer.)

2. Next, press either the temperature setting or button.

(Check that the item code is “A1.”)

3. Use either the or button to set the system No. to perform automatic

address setting.

4. Then press the button.

(Automatic address setting for one refrigerant system begins.)

(When automatic address setting for one system is completed, the system returns to

normal stopped status.) <Approximately 4 – 5 minutes is required.>

(During automatic address setting, “NOW SETTING” is displayed on the remote con-

troller. This message disappears when automatic address setting is completed.)

5. Repeat the same steps to perform automatic address setting for each successive system.

Cooling mode

Case 2

Case 3B

* To cancel, again short-circuit the automatic address pin (CN100) for 1 second or longer, then release it.

The LED that indicates automatic address setting is in progress turns OFF and the process is stopped. Be sure to perform automatic address setting again.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 78

Page 79

Display during automatic address setting

 On outdoor main unit PCB

* When automatic address setting has been successfully completed, both LEDs 1 and 2 turn OFF.

* LED 1 is D72. LED 2 is D75.

* If automatic address setting is not completed successfully, refer to the table below and correct the problem. Then perform

automatic address setting again.

 Display details of LEDs 1 and 2 on the outdoor unit control PCB

 Remote controller display

* Do not short-circuit the automatic address setting pin (CN100) again while automatic address set-

ting is in progress. Doing so will cancel the setting operation and will cause LEDs 1 and 2 to turn

OFF.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 79

LED

Blink alternately

( : ON : Blinking : OFF)

LED 1 LED 2

After the power is turned ON (and automatic address setting is not in progress), no communication with the indoor units in that system is possible.

After the power is turned ON (and automatic address setting is not in progress), 1 or more indoor units are confirmed in that system; however, the number of indoor units does not match the number that was set.

Alternating

Simultaneous

Alternating

Automatic address setting is in progress.

Automatic address setting completed.

At time of automatic address setting, the number of indoor units did not match the number that was set. “ ” (when indoor units are operating) indication appears on the display.

Refer to “Table of Self-Diagnostic Functions and Description of Alarm Displays.”

Display meaning

Note: “ ” indicates that the solenoid is fused or that there is a CT detection current failure (current is detected when the

compressor is OFF).

is blinking

Page 80

Request concerning recording the indoor/outdoor unit combination Nos.

After automatic address setting has been completed, be sure to record them for future reference.

List the outdoor main unit system address and the addresses of the indoor units in that system in an easily visible location (next to

the nameplate), using a permanent marking pen or similar means that cannot be abraded easily.

Example: (Outdoor) 1 – (Indoor) 1-1, 1-2, 1-3… (Outdoor) 2 – (Indoor) 2-1, 2-2, 2-3…

These numbers are necessary for later maintenance. Please be sure to indicate them.

Checking the indoor unit addresses

Use the remote controller to check the indoor unit address.

1. Press and hold the button and button for 4 seconds or longer (simple settings mode).

2. The address is displayed for the indoor unit that is connected to the remote controller.

(Only the address of the indoor unit that is connected to the remote controller can be checked.)

3. Press the button again to return to normal remote controller mode.

1. Press and hold the button and button for 4 seconds or longer (simple settings mode).

2. “ALL” is displayed on the remote controller.

3. Next, press the button.

4. The address is displayed for 1 of the indoor units which is connected to the remote controller. Check that the fan of that indoor

unit starts and that air is discharged.

5. Press the button again and check the address of each indoor unit in sequence.

6. Press the button again to return to normal remote controller mode.

8-5. Remote Controller Test Run Settings

1. Press the remote controller button for 4 seconds or longer. Then press the button.

 “TEST RUN” appears on the LCD display while the test run is in progress.

 The temperature cannot be adjusted when in Test Run mode.

(This mode places a heavy load on the machines. Therefore use it only when performing the test run.)

2. The test run can be performed using the HEAT, COOL, or FAN operation modes.

Note: The outdoor units will not operate for approximately 3 minutes after the power is turned ON and after operation is

stopped.

3. If correct operation is not possible, a code is displayed on the remote controller LCD display.

(Refer to “Table of Self-Diagnostic Functions” and correct the problem.)

4. After the test run is completed, press the button again. Check that “TEST RUN” disappears from the LCD display.

(To prevent continuous test runs, this remote controller includes a timer function that cancels the test run after 60 minutes.)

* If the test run is performed using the wired remote controller, operation is possible even if the cassette-type ceiling panel has not

been installed. (“P09” display does not occur.)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 80

Number changes to indicate which indoor unit is currently selected.

Page 81

 This outdoor unit cannot

collect more than the rated

refrigerant amount as shown

by the nameplate on the back.

 If the amount of refrigerant is

more than that recommended,

do not conduct pump down. In

this case use another

refrigerant collecting system.

8-6. Caution for Pump Down

Pump down means refrigerant gas in the system is returned

to the outdoor unit. Pump down is used when the unit is to

be moved, or before servicing the refrigerant circuit.

(Refer to the Service Manual)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 81

CAUTION

Page 82

8-7. Meaning of Alarm Messages

Table of Self-Diagnostics Functions and Description of Alarm Displays

Alarm messages are indicated by the blinking of LED 1 and 2 (D72, D75) on the outdoor unit PCB. They are also displayed on

the wired remote controller.

 Viewing the LED 1 and 2 (D72 and D75) alarm displays

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 82

LED 1

Alternating

( : Blinking)

LED 2

Alarm display LED 1 blinks M times, then LED 2 blinks N times. The cycle then repeats. M = 2: P alarm 3: H alarm 4: E alarm 5: F alarm 6: L alarm N = Alarm No.

Example: LED 1 blinks 2 times, then LED 2 blinks 17 times. The cycle then repeats.

Alarm is "P17."

Connect the outdoor maintenance remote controller to the RC socket on the outdoor main unit control PCB (3P, b l ue), and check the Alarm Messages on the remote controller 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).

Indoor unit is detecting error signal from main outdoor unit.

Improper setting of indoor unit or remote controller.

During auto address setting,

number of connected units does not correspond to number set.

When turning on the power supply, number of connected units does number set.

(Except R.C. address is “0.”)

Indoor unit communication error of group control wiring.

Improper setting.

not correspond to

Error in receivi (Signal from main indoor unit in case of group control) Ex: Auto address is not completed.

Error in transmitting serial communication signal.

Error in receiving serial communication signal. When turning on the power supply, the number of connected

indoor units does n

address is “0.”)

Error of the main outdoor unit in receiving serial communication signal from the indoor unit.

Indoor unit address setting is duplicated.

Remote controller address connector (RCU. ADR) is duplicated. (Duplication of main remote controller)

Starting auto address setting is prohibited. This alarm message shows that the auto address connector CN100

is shorted while other RC line is executing auto address operation. Error in auto address setting. (Number of connected indoor units

is less than the number set.) Error in auto address

is more than the number set.)

No indoor unit is connected during auto address setting.

Main outdoor unit is detecting error signal from sub outdoor unit.

Error of outdoor unit address setting.

The number of connected main and sub outdoor units do not correspond to the number set at main outdoor unit PCB.

Error of sub outdoor unit in receiving serial communication signal from main outdoor unit.

Error of main indoor un

from sub indoor units. This alarm message shows when an indoor unit for multiple-use

is not connected to the outdoor unit.

Duplication of main indoor unit address setting in group control.

Duplication of outdoor R.C. address setting.

There are 2 or more indoor unit controllers that have operation mode priority in refrigerant circuit.

Group control wiring is connected to individual control indoor unit.

Indoor unit address is not set.

Capacity code of indoor unit is not set.

Capacity code of outdoor unit is not set.

Mis-matched connection of outdoor units that have different kinds of refrigerant.

4-way valve operation failure

Alarm contents

ng serial communication signal.

ot correspond to the number set. (Except R.C.

setting. (N umber of connected indoor units

it in receiving serial communication signal

Priority set remote

Non-priority set remote

controller

Alarm

message

<E01>

<E02>

<<E03>>

<E06>

<<E09>>

<L03>

<<L09>>

Continued

E04

E08

E12

E15

E16

E20

E24

E25

E26

E29

E18

L02

L04

L05

L06

L07

L08

L10

L17

L18

Page 83

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 83

Possible cause of malfunction

Activation of protective device

Thermistor fault

EEP ROM on indoor unit PCB failure

Protective device for compressor is activated

Protective device in indoor unit is activated.

Protective device in outdoor unit is activated.

Indoor thermistor is either open or damaged.

Outdoor thermistor is either open or damaged.

Protective device for compressor No. 1 is activated.

Protective device for compressor No. 2 is activated.

Protective device for compressor No. 3 is activated.

Low oil level.

Oil sensor fault. (Disconnection, etc.)

Thermal protector in indoor unit fan motor is activated.

Improper wiring connections of ceiling panel. Float switch is activated.

Operation of protective function of fan inverter.

Compressor thermal protector is activated. Power supply voltage is unusual. (The voltage is more than 260 V or less than 160 V between L1 and L2 phase.)

Incorrect discharge temperature. (Comp. No. 1)

High pressure switch i

s activated.

Negative (defective) phase.

sensor (detects low oxygen level) activated

Compressor running failure resulting from missing phase i

n the

compressor wiring, etc. (Start failure not caused by IPM or no gas.)

Incorrect discharge temperature. (Comp. No. 2)

Compressor 3 discharge temp. failure

Outdoor unit fan motor is unusual.

Overcurrent at time of compressor runs more than 80Hz (DCCT secondary current or ACCT primary current is detected at a time other than when IPM has tripped.)

IPM trip (IPM current or temperature)

Inverter for compressor is unusual. (DC compressor does not operate.)

Indoor coil temp. sensor (E1)

Indoor coil temp. sensor (E2) Indoor coil temp. sensor (E3) Indoor suction air (room) temp. sensor (TA)

Indoor discharge air temp. sensor (BL)

Comp. No. 1 discharge gas temp. sens

or (DISCH1)

Comp. No. 2 discharge gas temp. sensor (DISCH2)

Outdoor No. 1 coil gas temp. sensor Outdoor No. 1 coil liquid temp. sensor

(EXG1)

(EXL1) Outdoor air temp. sensor (AIR TEMP) Compressor intake port temperature sensor (RDT)

High pressure sensor. Negative (defective) N phase.

Low-pressure sensor failure

Compressor 3 discharge temp. sensor failure (DISCH3)

Outdoor No. 2 coil gas temp. sensor (EXG2)

Outdoor No. 2 coil liquid temp. sensor (EXL2)

EEP ROM on the main or sub outdoor unit PCB has failed. Current is not detected when comp. No. 1 is ON.

Discharge gas temperature of the comp. No. 1 is not detected. Te mp . s

ensor is not seated at the sensor holder.

Overload current is detected.

Lock current is detected.

Current is

not detected when comp. No. 2 is ON.

Discharge gas temperature of comp. No. 2 is not detected.

Compressor No. 3 current trouble (overcurrent) Compressor No. 3 current trouble (locked) Compressor No. 3 CT sensor disconnected or short circuit

Compressor No. 3 discharge temp. s

ensor disconnected

Low pressure switch is activated.

Comp. No. 1 oil sensor Comp. No. 2 oil sensor Oil sensor (connection) failure

Alarm

message

<<P01>>

<<P09>>

<<P10>>

P12

P02

P03 P04

P05 P14

P16

P17

P18 P22

P26

H31

P29

<<F01>>

<<F02>> <<F03>>

<<F10>>

<<F11>>

F04 F05

F06 F07

F08 F12 F16

F17

F22

F23

F24

F29

F31 H03

H05

H11 H12 H13 H15

H21 H22

H23

H25 H06

H07 H08 H27

H28

Continued

Page 84

1. Alarm messages in << >> do not affect other indoor unit operations.

2. Alarm messages in < > sometimes affect other indoor unit operations depending on the fault.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 84

Alarm messages displayed on system controller

Serial communication errors

Mis-setting

Activation of protective device

Error in transmitting serial communication signal

Error in receiving serial communication signal

Protective device of sub indoor unit in group control is activated.

Indoor or main outdoor unit is not operating correctly. Mis-wiring of control wiring between indoor unit, main outdoor unit

and system controller.

Indoor or main outdoor unit is not operating correctly. Mis-wiring of control wiring between indoor unit, main outdoor unit and system controller. CN1 is not connected properly.

When using wireless remote controller or system controller, in order to check the alarm message in detail, connect wired remote controller to indoor unit temporarily.

NOTE

C05

C06

P30

Page 85

1. Use a screwdriver to remove the bolt screw on each side for the two latches. (Be sure to

reattach the two bolt screws after cleaning.)

2. Press on the two latches of the air intake grille with your thumbs in the direction of the

arrow to open the grille.

3. Open the air intake grille downward.

9. APPENDIX

9-1. 4-Way Air Discharge Semi-Concealed Type (X Type)

 NAME OF PARTS

 CARE AND CLEANING

1. For safety, be sure to turn the air conditioner off and also to disconnect the power before cleaning.

2. Do not pour water on the indoor unit to clean it. This will damage the internal components and cause an electric shock hazard.

1. Never use solvents or harsh chemicals when cleaning the indoor unit. Do not wipe plastic parts using very hot water.

2. Some metal edges and the fins are sharp and may cause injury if handled improperly; be especially careful when you clean these parts.

3. The internal coil and other components of the outdoor unit must be cleaned every year. Consult your dealer or service center.

Air intake and outlet side Clean the air intake and outlet side of the indoor unit with a vacuum cleaner brush, or wipe them

(Indoor unit) with a clean, soft cloth.

If these parts are stained, use a clean cloth moistened with a mild liquid detergent. When cleaning the air outlet side, be careful not to force the vanes out of place.

Air filter

The air filter collects dust and other particles from the air and should be cleaned at regular intervals as indicated in the table below or when the filter indication ( ) on the display of the remote control unit (wired type) shows that the filter needs cleaning. If the filter gets blocked, the efficiency of the air conditioner drops greatly.

1. Remove the air filter from the air intake grille.

2. Use a vacuum cleaner to remove light dust. If there is sticky dust on the filter, wash the fil-

ter in lukewarm, soapy water, rinse it in clean water, and dry it.

Type Period

X 6 months

The frequency with which the filter should be cleaned depends on the environment in which the unit is used.

 When cleaning the air filter, never remove the safety chain. If it is necessary to remove it

for servicing and maintenance inside, be sure to reinstall the safety chain securely (hook on the grille side) after the work.

 When the filter has been removed, rotating parts (such as the fan), electrically charged

areas, etc. will be exposed in the unit’s opening. Bear in mind the dangers that these parts and areas pose, and proceed with the work carefully.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 85

X type (4-WAY)

WARNING

CAUTION

Water drain

Ceiling panel (optional)

Air outlet (4 locations)

Air intake grille (air intake)

NOTE

CAUTION

Page 86

4. Remove the air filter attached to the air intake grille.

Care: After a prolonged idle period

Care: Before a prolonged idle period

Check the indoor and outdoor unit air intakes and outlets for blockage; if there is a blockage, remove it.

• Operate the fan for half a day to dry out the inside.

• Disconnect the power supply and also turn off the circuit breaker.

• Clean the air filter and replace it in its original position.

• Outdoor unit internal components must be checked and cleaned periodically. Contact your local dealer for this service.

1. Certain metal edges and the condenser fins are sharp and may cause injury if handled improperly; special care should be taken when you clean these parts.

2. Periodically check the outdoor unit to see if the air outlet or air intake is clogged with dirt or soot.

3. The internal coil and other components of the outdoor unit must also be cleaned periodically. Consult your dealer or service center.

 TROUBLESHOOTING

If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or a service center.

 Tips for Energy Saving

Avoid

• Do not block the air intake and outlet of the unit. If either is obstructed, the unit will not work well, and may be damaged.

• Do not let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls and ceiling of the room are warmed by the sun, it will take longer to cool the room.

• Always try to keep the air filter clean. (Refer to “Care and Cleaning.”) A clogged filter will impair the performance of the unit.

• To prevent conditioned air from escaping, keep windows, doors and any other openings closed.

Should the power fail while the unit is running

If the power supply for this unit is temporarily cut off, the unit will automatically resume operation once power is restored using the same settings before the power was interrupted.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 86

Latch

Air intake grille

Bolt screws

Safety chain

Air filter

CAUTION

Air conditioner does not run at all 1. Power failure. 1.

Tro uble

Compressor runs but soon stops 1. Obstruction in front of condenser coil 1. Remove obstruction

oor cooling (or heating)

performance

2. Leakage circuit breaker has

3. Li ne voltage is too low.

4. Operation button is turned off.

5. The wired remote control unit or malfunctioning.

(

The inspection mark and the

H, L, P in

the LCD of the wired

1. Dirty or clogged air filter.

2. Heat source or many people in

3. Doors and/or windows are open.

4. Obstacle near air intake or air

5. Thermostat is set too high for (or too low for heating).

6. (Defrosting system does not work.)

Possible Cause

tripped.

heat pump is

letters E, F,

combination with numbers

remote control unit.)

room.

discharge port.

cooling

appear

Remedy

After a power outage, press ON/ OFF operation button

on the

2. Contact service center.

3. Co nsult your electrician or dealer.

4. Press the button again.

5. Consult your dealer.

1. Clean air filter to improve the

2. Eliminate heat source if possible.

3. Shut them to keep the heat (or

4. Remove it to ensure good airflow.

5. Set the temperature lower (or

6. (Consult your dealer.)

wired remote control unit.

airflow.

cold) out.

higher).

NOTE

Page 87

9-2. 1-Way Air Discharge Semi-Concealed Type (A Type)

 NAME OF PARTS

 CARE AND CLEANING

1. For safety, be sure to turn the air conditioner off and also to disconnect the power before cleaning.

2. Do not pour water on the indoor unit to clean it. This will damage the internal components and cause an electric shock hazard.

1. Never use solvents or harsh chemicals when cleaning the indoor unit. Do not wipe plastic parts using very hot water.

2. Some metal edges and the fins are sharp and may cause injury if handled improperly; be especially careful when you clean these parts.

3. The internal coil and other components of the outdoor unit must be cleaned every year. Consult your dealer or service center.

Air intake and outlet side Clean the air intake and outlet side of the indoor unit with a vacuum cleaner brush, or wipe them

(Indoor unit) with a clean, soft cloth.

If these parts are stained, use a clean cloth moistened with a mild liquid detergent. When cleaning the air outlet side, be careful not to force the vanes out of place.

1. Remove the air filter from the air intake grille.

2. Use a vacuum cleaner to remove light dust. If there is sticky dust on the filter,

wash the filter in lukewarm, soapy water, rinse it in clean water, and dry it.

Type A

Period 2 weeks

The frequency with which the filter should be cleaned depends on the environment in which the unit is used.

Air filter

<How to remove the filter> 1-way air discharge semi-concealed type (A):

1. Take hold of the finger-hold on the air intake grille and press it to

the rear, and the grille will open downward.

2. Take hold of the finger-hold on the air filter, pull it toward you.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 87

SEMI-CONCEALED

A type (1-WAY)

Wa ter dra i n

Air outlet

Air intake

Ceiling panel (optional)

WARNING

CAUTION

NOTE

Air filter finger-hold

Air intake grill

Air filter

Slide

Latch

Air filter finger-hold

*Take hold of the finger-hold on the air filter, pull it toward you.

Hook

Screw

Page 88

Care: After a prolonged idle period

Care: Before a prolonged idle period

Check the indoor and outdoor unit air intakes and outlets for blockage; if there is a blockage, remove it.

• Operate the fan for half a day to dry out the inside.

• Disconnect the power supply and also turn off the circuit breaker.

• Clean the air filter and replace it in its original position.

• Outdoor unit internal components must be checked and cleaned periodically. Contact your local dealer for this service.

1. Certain metal edges and the condenser fins are sharp and may cause injury if handled improperly; special care should be taken when you clean these parts.

2. Periodically check the outdoor unit to see if the air outlet or air intake is clogged with dirt or soot.

3. The internal coil and other components of the outdoor unit must also be cleaned periodically. Consult your dealer or service center.

Outdoor unit

 TROUBLESHOOTING

If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or a service center.

 Tips for Energy Saving

Avoid

• Do not block the air intake and outlet of the unit. If either is obstructed, the unit will not work well, and may be damaged.

• Do not let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls and ceiling of the room are warmed by the sun, it will take longer to cool the room.

• Always try to keep the air filter clean. (Refer to “Care and Cleaning.”) A clogged filter will impair the performance of the unit.

• To prevent conditioned air from escaping, keep windows, doors and any other openings closed.

Should the power fail while the unit is running

If the power supply for this unit is temporarily cut off, the unit will automatically resume operation once power is restored using the same settings before the power was interrupted.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 88

CAUTION

Tro uble

Air conditioner does not run at all 1. Power failure. 1.

Compressor runs but soon stops 1. Obstruction in front of condenser coil 1. Remove obstruction

oor cooling (or heating)

performance

2. Leakage circuit breaker has

3. Li ne voltage is too low.

4. Operation button is turned off.

5. The wired remote control unit or malfunctioning.

(

The inspection mark and the

H, L, P in

the LCD of the wired

1. Dirty or clogged air filter.

2. Heat source or many people in

3. Doors and/or windows are open.

4. Obstacle near air intake or air

5. Thermostat is set too high for (or too low for heating).

6. (Defrosting system does not work.)

Possible Cause

tripped.

heat pump is

letters E, F,

combination with numbers

remote control unit.)

room.

discharge port.

cooling

appear

Remedy

After a power outage, press ON/ OFF operation button

on the

2. Contact service center.

3. Co nsult your electrician or dealer.

4. Press the button again.

5. Consult your dealer.

1. Clean air filter to improve the

2. Eliminate heat source if possible.

3. Shut them to keep the heat (or

4. Remove it to ensure good airflow.

5. Set the temperature lower (or

6. (Consult your dealer.)

wired remote control unit.

airflow.

cold) out.

higher).

NOTE

Page 89

9-3. Concealed Duct (High-Static Pressure) Type (U, D Type)

 NAME OF PARTS

 CARE AND CLEANING

1. For safety, be sure to turn the air conditioner off and also to disconnect the power before cleaning.

2. Do not pour water on the indoor unit to clean it. This will damage the internal components and cause an electric shock hazard.

1. Never use solvents or harsh chemicals when cleaning the indoor unit. Do not wipe plastic parts using very hot water.

2. Some metal edges and the fins are sharp and may cause injury if handled improperly; be especially careful when you clean these parts.

3. The internal coil and other components of the outdoor unit must be cleaned every year. Consult your dealer or service center.

Air intake and outlet side Clean the air intake and outlet side of the indoor unit with a vacuum cleaner brush, or wipe them

(Indoor unit) with a clean, soft cloth.

If these parts are stained, use a clean cloth moistened with a mild liquid detergent. When cleaning the air outlet side, be careful not to force the vanes out of place.

1. Remove the air filter from the air intake grille.

2. Use a vacuum cleaner to remove light dust. If there is sticky dust on the filter, wash the filter in lukewarm, soapy water,

rinse it in clean water, and dry it.

Type Period

U, D* (Depends on filter

specifications)

The frequency with which the filter should be cleaned depends on the environment in which the unit is used.

*Concealed duct type (U, D):

An air filter is not provided with this air conditioner at the time of shipment. To get clean air and to extend the service life of the air conditioner, an air filter must be installed in the air intake. For installation and cleaning the air filter, consult your dealer or service center.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 89

CONCEALED DUCT

U type (standard static pressure

)

Flexible duct (optional)

Air outlet grille (optional)

WARNING

Water d rain

Canvas duct (optional)

Air intake grille (air intake) (optional)

CONCEALED DUCT

D type (high static pressure)

Air intake sideduct flange (rear)

Water drain

Electrical box

Air outlet side duct flange

CAUTION

NOTE

Page 90

 TROUBLESHOOTING

If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or a service center.

 Tips for Energy Saving

Avoid

• Do not block the air intake and outlet of the unit. If either is obstructed, the unit will not work well, and may be damaged.

• Do not let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls and ceiling of the room are warmed by the sun, it will take longer to cool the room.

• Always try to keep the air filter clean. (Refer to “Care and Cleaning.”) A clogged filter will impair the performance of the unit.

• To prevent conditioned air from escaping, keep windows, doors and any other openings closed.

Should the power fail while the unit is running

If the power supply for this unit is temporarily cut off, the unit will automatically resume operation once power is restored using the same settings before the power was interrupted.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 90

Tro uble

Air conditioner does not run at all 1. Power failure. 1.

2. Leakage circuit breaker has

3. Li ne voltage is too low.

Compressor runs but soon stops 1. Obstruction in front of condenser coil 1. Remove obstruction

oor cooling (or heating)

performance

4. Operation button is turned off.

5. The wired remote control unit or malfunctioning.

(

The inspection mark and the

H, L, P in

the LCD of the wired

1. Dirty or clogged air filter.

2. Heat source or many people in

3. Doors and/or windows are open.

4. Obstacle near air intake or air

5. Thermostat is set too high for (or too low for heating).

6. (Defrosting system does not work.)

Possible Cause

tripped.

heat pump is

letters E, F,

combination with numbers

remote control unit.)

room.

discharge port.

cooling

appear

Remedy

After a power outage, press ON/ OFF operation button

on the

2. Contact service center.

3. Co nsult your electrician or dealer.

4. Press the button again.

5. Consult your dealer.

1. Clean air filter to improve the

2. Eliminate heat source if possible.

3. Shut them to keep the heat (or

4. Remove it to ensure good airflow.

5. Set the temperature lower (or

6. (Consult your dealer.)

wired remote control unit.

airflow.

cold) out.

higher).

NOTE

Page 91

1. Take hold of the finger-hold on

the air intake grille and press it to the rear, and the grille will open downward.

2. Take hold of the finger-hold on

the air filter, pull it toward you.

9-4. Ceiling-Mounted Type (T Type)

 NAME OF PARTS

 CARE AND CLEANING

1. For safety, be sure to turn the air conditioner off and also to disconnect the power before cleaning.

2. Do not pour water on the indoor unit to clean it. This will damage the internal components and cause an electric shock hazard.

1. Never use solvents or harsh chemicals when cleaning the indoor unit. Do not wipe plastic

parts using very hot water.

2. Some metal edges and the fins are sharp and may cause injury if handled improperly; be

especially careful when you clean these parts.

3. The internal coil and other components of the outdoor unit must be cleaned every year.

Consult your dealer or service center.

Air intake and outlet side Clean the air intake and outlet side of the indoor unit with a vacuum cleaner brush, or wipe them

(Indoor unit) with a clean, soft cloth.

If these parts are stained, use a clean cloth moistened with a mild liquid detergent. When cleaning the air outlet side, be careful not to force the vanes out of place.

Air filter

Type Period

T 2 weeks

The frequency with which the filter should be cleaned depends on the environment in which the unit is used.

1. Remove the air filter from the air intake

grille.

2. Use a vacuum cleaner to remove light

dust. If there is sticky dust on the filter, wash the filter in lukewarm, soapy water, rinse it in clean water, and dry it.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 91

T ty

CEILING-MOUNTED

Air outlet

Water dra in

(Drain pipe can be connected to either the left or right side.)

Air intake grille (air intake)

WARNING

CAUTION

NOTE

Air intake grill finger-hold

Screw

Air filter

Hook

Screw

Air filter finger-hold * Take hold of the finger-hold on the air filter, pull it toward you.

Latch

Air filter finger-hold

Air intake grill

Slide

Page 92

Care: After a prolonged idle period

Care: Before a prolonged idle period

Check the indoor and outdoor unit air intakes and outlets for blockage; if there is a blockage, remove it.

• Operate the fan for half a day to dry out the inside.

• Disconnect the power supply and also turn off the circuit breaker.

• Clean the air filter and replace it in its original position.

• Outdoor unit internal components must be checked and cleaned periodically. Contact your local dealer for this service.

1. Certain metal edges and the condenser fins are sharp and may cause injury if handled improperly; special care should be taken when you clean these parts.

2. Periodically check the outdoor unit to see if the air outlet or air intake is clogged with dirt or soot.

3. The internal coil and other components of the outdoor unit must also be cleaned periodically. Consult your dealer or service center.

 TROUBLESHOOTING

If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or a service center.

 Tips for Energy Saving

Avoid

• Do not block the air intake and outlet of the unit. If either is obstructed, the unit will not work well, and may be damaged.

• Do not let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls and ceiling of the room are warmed by the sun, it will take longer to cool the room.

• Always try to keep the air filter clean. (Refer to “Care and Cleaning.”) A clogged filter will impair the performance of the unit.

• To prevent conditioned air from escaping, keep windows, doors and any other openings closed.

Should the power fail while the unit is running

If the power supply for this unit is temporarily cut off, the unit will automatically resume operation once power is restored using the same settings before the power was interrupted.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 92

CAUTION

Tro uble

Air conditioner does not run at all 1. Power failure. 1.

Compressor runs but soon stops 1. Obstruction in front of condenser coil 1. Remove obstruction

oor cooling (or heating)

performance

2. Leakage circuit breaker has

3. Li ne voltage is too low.

4. Operation button is turned off.

5. The wired remote control unit or malfunctioning.

(

The inspection mark and the

H, L, P in

the LCD of the wired

1. Dirty or clogged air filter.

2. Heat source or many people in

3. Doors and/or windows are open.

4. Obstacle near air intake or air

5. Thermostat is set too high for (or too low for heating).

6. (Defrosting system does not work.)

Possible Cause

tripped.

heat pump is

letters E, F,

combination with numbers

remote control unit.)

room.

discharge port.

cooling

appear

Remedy

After a power outage, press ON/ OFF operation button

on the

2. Contact service center.

3. Co nsult your electrician or dealer.

4. Press the button again.

5. Consult your dealer.

1. Clean air filter to improve the

2. Eliminate heat source if possible.

3. Shut them to keep the heat (or

4. Remove it to ensure good airflow.

5. Set the temperature lower (or

6. (Consult your dealer.)

wired remote control unit.

airflow.

cold) out.

higher).

NOTE

Page 93

1. Move the flap on the air outlet grille to its lowest position with the remote control unit.

2. The filter is disengaged by pushing the tab up gently. Hold the air filter by the tab at the bottom,

and pull downward.

When replacing the filter, make sure that the FRONT mark is facing you. Push it up until you hear it click back into position.

9-5. Wall-Mounted Type (K Type)

 NAME OF PARTS

 CARE AND CLEANING

Air intake and outlet side Clean the air intake and outlet side of the indoor unit with a vacuum cleaner brush, or wipe them

(Indoor unit) with a clean, soft cloth.

If these parts are stained, use a clean cloth moistened with a mild liquid detergent. When cleaning the air outlet side, be careful not to force the vanes out of place.

Air filter

1. Remove the air filter from the air intake grille.

2. Use a vacuum cleaner to remove light dust. If there is sticky dust on the filter, wash the filter in

lukewarm, soapy water, rinse it in clean water, and dry it.

Type Period

K 2 weeks

The frequency with which the filter should be cleaned depends on the environment in which the unit is used.

1. For safety, be sure to turn the air conditioner off and also to disconnect the power before cleaning.

2. Do not pour water on the indoor unit to clean it. This will damage the internal components and cause an electric shock hazard.

1. Never use solvents or harsh chemicals when cleaning the indoor unit. Do not wipe plastic parts using very hot water.

2. Some meta l edges and the fins are sharp and may cause injury if handled improperly; be especially careful when you clean these parts.

3. The internal coil and other components of the outdoor unit must be cleaned every year. Consult your dealer or service center.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 93

K Type (Wall-Mounted)

WARNING

Air intake

Air outlet

CAUTION

NOTE

Air intake grille

Air filter

Page 94

Care: After a prolonged idle period

Care: Before a prolonged idle period

Check the indoor and outdoor unit air intakes and outlets for blockage; if there is a blockage, remove it.

• Operate the fan for half a day to dry out the inside.

• Disconnect the power supply and also turn off the circuit breaker.

• Clean the air filter and replace it in its original position.

• Outdoor unit internal components must be checked and cleaned periodically. Contact your local dealer for this service.

 TROUBLESHOOTING

If your air conditioner does not work properly, first check the following points before requesting service. If it still does not work properly, contact your dealer or a service center.

 Tips for Energy Saving

Avoid

• Do not block the air intake and outlet of the unit. If either is obstructed, the unit will not work well, and may be damaged.

• Do not let direct sunlight into the room. Use sunshades, blinds or curtains. If the walls and ceiling of the room are warmed by the sun, it will take longer to cool the room.

• Always try to keep the air filter clean. (Refer to “Care and Cleaning.”) A clogged filter will impair the performance of the unit.

• To prevent conditioned air from escaping, keep windows, doors and any other openings closed.

Should the power fail while the unit is running

If the power supply for this unit is temporarily cut off, the unit will automatically resume operation once power is restored using the same settings before the power was interrupted.

1. Certain metal edges and the condenser fins are sharp and may cause injury if handled improperly; special care should be taken when you clean these parts.

2. Periodically check the outdoor unit to see if the air outlet or air intake is clogged with dirt or soot.

3. The internal coil and other components of the outdoor unit must also be cleaned periodically. Consult your dealer or service center.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 94

CAUTION

Tro uble

Air conditioner does not run at all 1. Power failure. 1.

Compressor runs but soon stops 1. Obstruction in front of condenser coil 1. Remove obstruction

oor cooling (or heating)

performance

2. Leakage circuit breaker has

3. Li ne voltage is too low.

4. Operation button is turned off.

5. The wired remote control unit or malfunctioning.

(

The inspection mark and the

H, L, P in

the LCD of the wired

1. Dirty or clogged air filter.

2. Heat source or many people in

3. Doors and/or windows are open.

4. Obstacle near air intake or air

5. Thermostat is set too high for (or too low for heating).

6. (Defrosting system does not work.)

Possible Cause

tripped.

heat pump is

letters E, F,

combination with numbers

remote control unit.)

room.

discharge port.

cooling

appear

Remedy

After a power outage, press ON/ OFF operation button

on the

2. Contact service center.

3. Co nsult your electrician or dealer.

4. Press the button again.

5. Consult your dealer.

1. Clean air filter to improve the

2. Eliminate heat source if possible.

3. Shut them to keep the heat (or

4. Remove it to ensure good airflow.

5. Set the temperature lower (or

6. (Consult your dealer.)

wired remote control unit.

airflow.

cold) out.

higher).

NOTE

Page 95

Page 96

Sanyo R410A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual