ABU18RULX Installation Manual

Flare tool for R410A, clutch type
0 to 0.5 mm
(0 to 0.0197 in.)
INDOOR UNIT
(1) Install the indoor unit level on a strong wall, floor, ceiling which is not subject to vibration.
(2) The inlet and outlet ports should not be obstructed : the air should be able to blow all over the room.
(3) Install the unit near an electric outlet or special branch circuit.
(4) Do not install the unit where it will be exposed to direct sunlight.
(5) Install the unit where connection to the outdoor unit is easy.
(6) Install the unit where the drain pipe can be easily installed.
(7) Take servicing, etc., into consideration and leave the spaces shown in figure. Also install the unit where the filter can be removed.
••
••
• Floor console
Floor Console/Under Ceiling Dual Type
INSTALLATION INSTRUCTION
SHEET
(PART NO. 9359945031)
For authorized service personnel only.
Contents of change
Pressure is high and cannot be measured with a conventional gauge. To prevent erroneous mixing of other
refrigerants, the diameter of each port has been changed.
It is recommended the gauge with seals –0.1 to 5.3 MPa (–76 cmHg to 53 kgf/cm
2
) for high pressure.
–0.1 to 3.8 MPa (–76 cmHg to 38 kgf/cm
2
) for low pressure.
To increase pressure resistance, the hose material and base size were changed.
A conventional vacuum pump can be used by installing a vacuum pump adapter.
Special gas leakage detector for HFC refrigerant R410A.
Tool name
Gauge manifold
Charge hose
Vacuum pump
Gas leakage detector
Left
Right
30 cm (12") or more 30 cm (12") or more
STANDARD PARTS
The following installation parts are furnished. Use them as required.
INDOOR UNIT ACCESSORIES
Name and Shape
Cover plate (left)
Cover plate (right)
Tapping screw (ø4 × 10)
Installation template
Bracket (left)
Bracket (right)
Anchor bolt (M12)
Spring washer
Special nut
Wall bracket
Tapping screw (ø4 × 20)
Coupler heat insulator
(large)
Coupler heat insulator
(small)
Nylon fastener
Q’ty
1
1
2
1
1
1
4
4
4
2
6
1
1
1
Application
For positioning the indoor
unit
For under ceiling type
For suspending the indoor
unit from ceiling
For suspending the indoor
unit on the wall.
For fixing the wall bracket.
For indoor side pipe joint
(Large pipe)
For indoor side pipe joint
(Small pipe)
For fixing the drain hose
Name and Shape
Drain hose
Insulation (drain hose)
VT wire
Remote control unit
Battery (penlight)
Remote control unit holder
Tapping screw (ø3 × 12)
Q’ty
1
1
1
1
2
1
2
Application
Adhesive type 70 × 230
For fixing the drain hose
L 280 mm
Use for air conditioner
operation
For remote control unit
Use as remote control unit
holder
For remote control unit
holder installation
CONNECTION PIPE
REQUIREMENT
CAUTION
Install heat insulation around both the gas and liquid pipes.
Failure to do so may cause water leaks.
Use heat insulation with heat resistance above 248 °F. (Re-
verse cycle model only)
In addition, if the humidity level at the installation location
of the refrigerant piping is expected to exceed 70%, install
heat insulation around the refrigerant piping. If the expected
humidity level is 70-80%, use heat insulation that is 15 mm
(19/32") or thicker and if the expected humidity exceeds 80%,
use heat insulation that is 20 mm (3/4") or thicker.
If heat insulation is used that is not as thick as specified,
condensation may form on the surface of the insulation.
In addition, use heat insulation with heat conductivity of
0.045 W/(m·K) or less (at 68 °F).
Connect the connection pipes according to “3 CONNECTING THE
PIPING” in this installation instruction sheet.
••
••
• Under ceiling
Right Left
Indoor unit
Ceiling
Ceiling
15 cm (6") or more 30 cm (12") or more
2 cm (3/4") or more
••
••
• Use pipe with water-resistant heat insulation.
••
••
• Use pipe that can withstand a pressure of 4,150 kPa.
14000, 18000 BTU/h 24000 BTU/h
model model
MODEL
Diameter
Liquid
Gas
6.35 mm (1/4 in.) 9.52 mm (3/8 in.)
12.70 mm (1/2 in.) 15.88 mm (5/8 in.)
ELECTRICAL REQUIREMENT
••
••
• Electric wire size:
••
••
• Install all electrical works in accordance to the standard.
••
••
• Install the disconnect device with a contact gap of at least 3 mm (1/8")
in all poles nearby the units. (Both indoor unit and outdoor unit)
••
••
• Install the circuit breaker nearby the units.
Connection cord (mm
2
)
MAX.
MIN.
2.5
1.5
Indoor unit
To outdoor unit
Floor console
This air conditioner uses new refrigerant HFC (R410A).
The basic installation work procedures are the same as conventional refrigerant models.
However, pay careful attention to the following points:
(1) Since the working pressure is 1.6 times higher than that of conventional refrigerant models, some of the piping and instal-
lation and service tools are special. (See the table below.)
Especially, when replacing a conventional refrigerant model with a new refrigerant R410A model, always replace the con-
ventional piping and flare nuts with the R410A piping and flare nuts.
(2) Models that use refrigerant R410A have a different charging port thread diameter to prevent erroneous charging with
conventional refrigerant and for safety. Therefore, check beforehand. [The charging port thread diameter for R410A is 1/2
UNF 20 threads per inch.]
(3) Be more careful that foreign matter (oil, water, etc.) does not enter the piping than with refrigerant models. Also, when
storing the piping, securely seal the openings by pinching, taping, etc.
(4) When charging the refrigerant, take into account the slight change in the composition of the gas and liquid phases, and
always charge from the liquid phase side whose composition is stable.
Special tools for R410A
Copper pipes
It is necessary to use seamless copper pipes and it is desirable that the amount
of residual oil is less than 40 mg/10 m. Do not use copper pipes having a
collapsed, deformed or discolored portion (especially on the interior surface).
Otherwise, the expansion valve or capillary tube may become blocked with
contaminants.
As an air conditioner using R410A incurs pressure higher than when using
conventional refrigerant, it is necessary to choose adequate materials.
Thicknesses of copper pipes used with R410A are as shown in table. Never
use copper pipes thinner than that in the table even when it is available on the
market.
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 danger, 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 and the potential for
product or property damage.
•
Hazel alerting symbols
Electrical
Safety / alert
If Necessary, Get Help
These instructions are all you need for most installation sites and mainte-
nance 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 con-
nection points and a possible fire hazard.
WARNING:
CAUTION:
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 Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the unit’s weight. It
may be necessary to construct a strong wood or metal frame to provide
added support.
...In a Room
Properly insulate any tubing run inside a room to prevent “sweating” that
can cause dripping and water damage to walls and floors.
...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 abnor-
mal 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
•
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.
NOTE:
Depending on the system type, liquid and gas lines may be either narrow
or wide. Therefore, to avoid confusion the refrigerant tubing for your
particular model is specified as either “small” or “large” rather than as
“liquid” or “gas”.
When Servicing
•
Turn the power OFF at the main circuit breaker panel 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.
•
After installation, explain correct operation to the customer, using the
operating manual.
Thickness mm (inch)
R410A
0.80 (0.0315)
0.80 (0.0315)
0.80 (0.0315)
1.00 (0.0394)
Outer diameter
mm (inch)
6.35 (1/4)
9.52 (3/8)
12.7 (1/2)
15.88 (5/8)
Thicknesses of Annealed Copper Pipes
SELECTING THE MOUNTING POSITION
WARNING
Install at a place that can withstand the weight of the indoor and outdoor units and install positively so that the units will not
topple or fall.
CAUTION
(1) Do not install where there is the danger of combustible gas leakage.
(2) Do not install near heat sources.
(3) If children under 10 years old may approach the unit, take preventive measures so that they cannot reach the unit.
Decide the mounting position with the customer as follows:
CAUTION
This installation instruction sheet describes how to the indoor unit only.
To install the outdoor unit, refer to the installation instruction sheet included with the outdoor unit.
OPTIONAL PARTS
The following options are available.
••
••
• WIRED REMOTE CONTROLLER UNIT: UTB-UUB (P/N9075887004)
Indoor unit
To outdoor unit
Under ceiling
100 mm (4")
1
INSTALLATION PROCEDURE
Install the room air conditioner as follows:
PREPARING INDOOR UNIT
INSTALLATION
1. REMOVE THE INTAKE GRILLE
Open the intake grille and remove the three screws.
Remark: The main unit can be wired before the indoor unit is in-
stalled. Select the most appropriate installation order.
Machine screw
Tapping screw
Intake grille
Tapping screw
2
INDOOR UNIT INSTALLATION
A. FLOOR CONSOLE TYPE
1. DRILLING FOR PIPING
Select piping and drain directions.
The piping and drain can be made in three directions as shown below.
The drain hose can be connected to either the left or right side.
Drain hose
(Right side)
Drain hose
(Left side)
When installing set to wall install the accessory wall bracket at the posi-
tion shown in figure, and mount the set to it.
Wall
Outdoor side
6 mm (1/4")
Indoor side
2. INSTALLING THE DRAIN HOSE
Select whether the drain hose will be connected to the left or right side.
Insert the drain hose into the drain pan, then secure the drain hose with a
nylon fastener.
Nylon fastener
Wrap the insulation (drain hose) around the drain hose connection.
Drain pan
Drain hose
Insulation (Drain hose)
Drain pan
Drain hose
Be sure to arrange the drain hose so that it is leveled lower than the drain
hose connecting port of the indoor unit.
CAUTION
Do not install the unit so that the drain hose side is too
high. Height A should be less than 5 mm (3/16").
Arrange the drain
hose lower than
this portion.
Drain hose
B. UNDER CEILING TYPE
Using the installation template, drill holes for piping and anchor bolts (for
holes).
Drain hose
900 mm (35-7/16")
200 mm
(7-7/8" )
Drilling position
for piping
Installation
template
Drilling position
for anchor bolt
Ceiling
Wall
1. DRILLING FOR PIPING
Select piping and drain directions.
CAUTION
Install the drain hose at the rear; it should not be installed
on the top or right side.
When the directions are selected, drill 80 mm (3-1/8") and 50 mm (2") or
150 mm (6") dia. hole on the wall so that the hole is tilted downward to-
ward the outdoor for smooth water flow.
Top
Rear (Install the
drain hose in this
direction.)
Right
Wall
6 mm (1/4")
Indoor side Outdoor side
When the directions are selected, drill a 10 cm (4") dia. hole on the wall so
that the hole is tilted downward toward the outdoor for smooth water flow.
When the pipe is led out from the rear, make a hole in figure, at the posi-
tion shown.
2. DRILLING HOLES FOR ANCHOR BOLTS AND
INSTALLING THE ANCHOR BOLTS
With a concrete drill, drill four 12.7 mm (1/2") dia. holes.
60 to 70 mm
(2-3/8" to 2-3/4")
ø 12.7 mm (1/2")
3. INSTALLING BRACKETS
Install the brackets with nuts, washers and spring washers.
Insert the anchor bolts into the drilled holes, and drive the pins completely
into the anchor bolts with a hammer.
Apply the indoor unit to the brackets.
Spring
washer
Special nut
Bracket
Bracket (Left)
Bracket (Right)
4. INSTALLING INDOOR UNIT
Reset the hex bolts as shown in figure.
Hex bolt
Indoor unit
8 to 13 mm
(5/16" to 1/2")
Bolt
Bracket
Indoor unit
Now, securely tighten the hex bolts in both sides.
5. INSTALLING THE DRAIN HOSE
Select whether the drain hose will be connected to the left or right side.
Insert the drain hose into the drain pan, then secure the drain hose with a
nylon fastener.
Wrap the insulation (drain hose) around the drain hose connection.
Be sure to arrange the drain hose so that it is leveled lower than the drain
hose connecting port of the indoor unit.
Remove the hole cover.
Drain hose
Arrange the drain hose
lower than this portion.
Piping hole
VT wire
hole
Pass the drain hose
through here.
Base (Bottom)
Cut the grille
VT wire
Drain hose
Intake grille
3 4
CONNECTING THE PIPING
WARNING
Do not use the existing piping and flare nuts.
• If the existing materials are used, the pressure inside the
refrigerant cycle will rise and cause breakage, injury, etc.
(Use the special R410A materials.)
CAUTION
(1) Do not use mineral oil on flared part.
Prevent mineral oil from getting into the system as this
would reduce the lifetime of the units.
(2) Never use piping which has been used for previous
installations. Only use parts which are delivered with
the unit.
(3) While welding the pipes, be sure to blow dry nitrogen
gas through them.
4. HEAT INSULATION ON THE PIPE JOINTS
(INDOOR SIDE ONLY)
Put coupler heat insulator on the joints (indoor side only).
Indoor unit
No gap
Coupler heat
insulator
(large)
Coupler heat
insulator (small)
No gap
Coupler heat
insulation
50 cm (20")
24.5 cm
(
9-5/8" )
6.5 cm (2-1/2")
10 cm (4") hole
5 cm (2") hole
12.5 cm (5") 10 cm (4")
6.5 cm (2-1/2")
65.5 cm (26")
53 cm (21")
4.5 cm (1-3/4")
Wall bracket
Side of set
99 cm (39")
OK NO
Be sure to overlap
the insulation
Large pipe Small pipe
- Continued on back -
1. FLARING PROCESSING
(1) Cut the connection pipe to the necessary length with a pipe cutter.
(2) Hold the pipe downward so that cuttings will not enter the pipe and
remove the burrs.
(3) Insert the flare nut (always use the flare nut attached to the indoor
and outdoor units respectively) onto the pipe and perform the flare
processing with a flare tool.
Use the special R410A flare tool, or the conventional flare tool.
When using the conventional flare tool, always use an allowance ad-
justment gauge and secure the A dimension shown in table.
Check if [L] is flared uniformly
and is not cracked or scratched.
Die
A
Pipe
Pipe outside diameter
L
2. BENDING PIPES
(1) When bending the pipe, be careful not to crush it.
(2) To prevent breaking of the pipe, avoid sharp bends. Bend the pipe
with a radius of curvature of 150 mm (6") or over.
(3) If the copper pipe is bend the pipe or pulled to often, it will become
stiff. Do not bend the pipes more than three times at one place.
Pipe outside
diameter
6.35 mm (1/4 in.)
9.52 mm (3/8 in.)
12.7 mm (1/2 in.)
15.88 mm (5/8 in.)
A
Indoor unit side
Optional parts
CAUTION
Be sure to apply the pipe against the port on the indoor
unit correctly. If the centering is improper, the flare nut
cannot be tightened smoothly. If the flare nut is forced to
turn, the threads will be damaged.
(2) Install the outdoor unit wall cap (supplied with the optional installation
set or procured at the site) to the wall hole pipe.
(3) Connect the outdoor unit and indoor unit piping.
(4) After matching the center of the flare surface and tightening the nut
hand tight, tighten the nut to the specified tightening torque with a
torque wrench.
Flare nut tightening torque
Flare nut
6.35 mm (1/4 in.) dia.
9.52 mm (3/8 in.) dia.
12.7 mm (1/2 in.) dia.
15.88 mm (5/8 in.) dia.
Tightening torque
16 to 18 N·m (160 to 180 kgf·cm)
30 to 42 N·m (300 to 420 kgf·cm)
49 to 61 N·m (490 to 610 kgf·cm)
63 to 75 N·m (630 to 750 kgf·cm)
Tighten with two wrenches.
Wrench (fixed)
Flare nut
Connection pipe
Indoor unit
pipe
Torque wrench
To prevent gas leakage,
coat the flare surface with
alkylbenzene oil (HAB).
Do not use mineral oil.
CAUTION
Be sure to connect the large pipe after connecting the small
pipe completely.
Do not remove the cap from the connection pipe before connecting
the pipe.
A. Solid wire
Strip 25 mm (15/16")
Insulation
Loop
B. Strand wire
Strip 10 mm (3/8")
Round
terminal
Wire
Screw with
special washer
Round terminal
Terminal
board
Wire
Screw with
special washer
Round
terminal
A. For solid core wiring
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 25 mm (15/16") of expose the solid wire.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
board.
(3) Using pliers, bend the solid wire to form a loop suitable for the
terminal screw.
(4) Shape the loop wire properly, place it on the terminal board and
tighten securely with the terminal screw using a screwdriver.
B. For strand wiring
(1) Cut the wire end with a wire cutter or wire-cutting pliers, then strip
the insulation to about 10 mm (3/8") of expose the strand wiring.
(2) Using a screwdriver, remove the terminal screw(s) on the terminal
board.
(3) Using a round terminal fastener or pliers, securely clamp a round
terminal to each stripped wire end.
(4) Position the round terminal wire, and replace and tighten the ter-
minal screw using a screwdriver.
HOW TO CONNECT WIRING
TO THE TERMINALS
3. CONNECTION PIPES
(1) Centering the pipe against port on the indoor unit, turn the flare nut
with your hand.
Be sure that the small pipe is completely installed before connecting
the large the pipe.
When drain hose is arranged backward.
Secure the drain hose with the VT wire.
GENERAL
This INSTALLATION INSTRUCTION SHEET briefly outlines where and
how to install the air conditioning system. Please read over the entire set
of instructions for the indoor and outdoor units and make sure all acces-
sory parts listed are with the system before beginning.
9359945031_IM_front.p65 17/11/05, 13:061