Airwell CCD User manual

English
Installation manual
Indoor unit cassette type - ССD / KCD / DCC
AIR CONDITIONER
CASSETTE
ENGLISH

10. REFRIGERANT TUBING..............................................................................................18
11. PANEL INSTALLING....................................................................................................20
...............................................................................................................22FINAL TASKS
12.
1
Indoor unit cassette type
14
16

ENGLISH
1. REQUIRED TOOLS FOR INSTALLATION WORK
2. SAFETY PRECAUTIONS
Installation should be in accordance with local and national electrical and building fire safety
regulations or codes.
WARNING
2
Indoor unit cassette type

Indoor unit cassette type
10)
11) Carry out drainage piping as mentioned in installation instructions. If drainage is not perfect,
water may enter the room and damage the furniture.
12) For appliances with supplementary heaters, the minimum clearance from the appliance to
combustible is 50cm other wise, it will cause fire.
Selection of the installation location.
Select an installation location which is rigid and strong enough to support or hold the unit, also
for easy maintenance and repair.
1)
Power supply connection to the room air conditioner.
Connect the power supply cord of the room air conditioner to the mains using one of the
following method.
Power supply point shall be the place where there is ease for access for the power
disconnection in case of emergency.
In some countries, permanent connection of this room air conditioner to the power supply is
prohibited.
2)
Do not release refrigerant.
Do not release refrigerant during piping work for installation, reinstallation and during repairing
a refrigeration parts. Take care of the liquid refrigerant. it may cause frostbite.
3)
4) Installation work. It may need two people to carry out the installation work.
Do not install this appliance inalaundry room or other location where water may drip from the
ceiling, etc.
5)
The temperature of refrigerant circuit will be high, please keep the interconnection cable away
from the copper tube.
6)
ATTENTION
3
Do notinstalltheunit:insuchplacesabove,there isariskofunitcatchingfire.
a) at placeswhereleakage of flammablegasmayoccur, or oilorvapor or other
flammablesubstancesareintheair
b) abovecookers,specially in kitchens
c) closetoheatingdeviceswhereunitsareexposed to hightemperatures.
Important information for the used refrigerant
This product has the fluorinated gas which is listed in Kyoto protocol.
It is forbidden to release to air.
Refrigerant type: R410a Volume of GWP: 2088; tonnes CO2 equivalent
GWP=Global Warming Potential
Attention:
1) The fluorinated greenhouse gases are contained in non-hermetically sealed equipment.
2) Installs, services, maintains, repairs, checks for leaks or decommissions equipment and product
recycling should be carried out by natural persons that hold relevant certificates.
3) For equipment that contains fluorinated greenhouse gases in quantities of 5 tonnes of CO 2
equivalent or more, but of less than 50 tonnes of CO 2 equivalent: the leakage check should be
performed at least every 12 months; or where a leakage detection system is installed, at least every
24 months.

Indoor unit cassette type
ENGLISH
3. INSTALLATION/SERVICE TOOLS (Only for R410A product)
Gauge manifold
New tools for
R410A
New tools for R410A
Applicable to R22 model Changes
Charge hose
Electronic balance
for refrigerant
charging
Torque wrench
(nominal dia. 1/2,
5/8)
Flare tool
(clutch type)
Gauge for
projection
adjustment
As the working pressure is high, it is impossible to
measure the working pressure using conventional
gauges. In order to prevent any other refrigerant from
being charged, the port diameters have been changed.
In order to increase pressure resisting strength, hose
materials and port sizes have been changed (to 1/2
UNF 20 threads per inch). When purchasingacharge
hose, be sure to confirm the port size.
As working pressure is high and gasification speed is
fast, it is difficult to read the indicated value by means
of charging cylinder, as air bubbles occur.
The size of opposing flare nuts have been increased.
Incidentally, a common wrench is used for nominal
diameters 1/4 and 3/8.
By increasing the clamp bar's receiving hole size,
strength of spring in the tool has been improved.
New Refrigerant Air Conditioner Installation
THIS AIR CONDITIONERADOPTS THENEWHFC REFRIGERANT (R410A) WHICH DOES
NOT DESTROYOZONELAYER. R410A refrigerant is apt to be affected by impurities such as
water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx.
1.6 times of refrigerant R22. Accompanied with the adoption of the new refrigerant, the
refrigeration machine oil has also been changed. Therefore, during installation work, be sure that
water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type
refrigerant R410A air conditioner circuit.
To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of
charging port on main unit and installation tools are different from those used for the conventional
refrigerant units. Accordingly, special tools are required for the new refrigerant (R410A) units. For
connecting pipes, use new and clean piping materials with high pressure fittings made for R410A
only, so that water and/or dust does not enter. Moreover, do not use the existing piping because
there are some problems with pressure fittings and possible impurities in existing piping.
Changes in the product and components
In air conditioners using R410A, in order to prevent any other refrigerant from being accidentally
charged, the service port diameter size of the outdoor unit control valve (3 way valve) has been
changed. (1/2 UNF 20 threads per inch)
In order to increase the pressure resisting strength of the refrigerant piping, flare processing
diameter and opposing flare nuts sizes have been changed. (for copper pipes with nominal
dimensions 1/2 and 5/8)
CAUTION
Used when flare is made by using conventional flare
tool.
4

Indoor unit cassette type
Vacuum pump
adapter
Gas leakage
detector
Connected to conventionalvacuumpump. It is
necessary to use an adapter to prevent vacuum pump
oil from flowing back into the charge hose. The charge
hose connecting part has two ports -- one for
conventional refrigerant (7/16 UNF 20 threads per inch)
and one for R410A. If the vacuum pump oil (mineral)
mixes with R410A a sludge may occur and damage
the equipment.
Incidentally, the "refrigerant cylinder" comes with the refrigerant designation (R410A) and
protector coating in the U.S's ARI specified rose color (ARI color code: PMS 507).
Also, the "charge port and packing for refrigerant cylinder" requires 1/2 UNF 20 threads per inch
corresponding to the charge hose's port size.
Exclusive for HFC refrigerant.
4. ACCESSORIES
5
Remote control
with batteries
No. Accessories part Qty. No. Accessories part Qty.
1
1
1
6or4 2
Remote control
bracket
(optional)
1
Screws
dowels
Outdoor
unit drain
connector
1
Power input
cable (Optional)
Installation carton
board
(optional)
Unit support(optional)
Twin-wire cable(optional)
1
1
Manual package
9
8
1
7
2
3
4
6
5

Indoor unit cassette type
ENGLISH
5. ACCESSORIES
6. LOCATION OF THE INDOOR AND OUTDOOR UNITS
Note: Decoration panel is separated from unit when packaging, select proper panel for
different installation situation.
Panel
Thisairconditionerhastheoptional2-way/3-wayairdischargingaccording to
installationlocation.Usesealingmaterial in accessorypartstosealtherelatedair
outlets.
4-way direction (Default)
Air flow direction (example)
3-way direction 2-way direction
Indoor unit
Do not install the cassette in a room where gasses, acids or inflammable products are stored,
in order to avoid damage to the aluminum and copper evaporators and the internal plastic
parts.
1.
Do not install the cassette inaworkshop orakitchen. Oil vapor attracted by the treated air
could form deposits on the cassette evaporators and modify their performance or damage the
cassette's internal plastic parts.
2.
3. Do not install the cassette in a laundry, or a room where steam is produced.
The appliance must be positioned so that the plug is accessible.
4.
5. Installing the cassette will be easier with the use of a fork lift truck. Use the packing base by
placing it between the cassette and the truck forks.
6. It is recommended to install the cassette, as far as possible, in the centre of the room, in order
to optimize treated air distribution.
7. For the chosen location, check that the distribution grilles can be removed and that there is
sufficient space available for maintenance and repairs.
6

Indoor unit cassette type
1. The location must allow easy servicing and provide good air circulation as shown in fig 4.
2. The unit may be suspended from a wall by a bracket (Optional) or located inafree standing posi-
tion on the floor (preferably slightly elevated).
3. If the unit is suspended, ensure that the bracket is firmly connected and the wall is strong enough
to withstand vibrations.
4. Unit location should not disturb neighbors with noise or exhaust air stream.
5. Place the mounting pads under the unit legs.
6. Refer to figure 4 for allowed installation distances.
When the unit is installed on a wall, install the drain connector hose and drain plug as shown in
fig1 and fig2.
1. Bottom of outdoor unit
2. Drain connector
Fig.1
Drain installation
Example
Fig.2
7
Fig 2
Fig 1
1
2
Outdoor unit

Indoor unit cassette type
ENGLISH
Fig.3
Fig.4
8
CAPACITY
(KBtu/h) TUBE OD: LIQUID - GAS (Inch) A- L.MAX (m) B - H.MAX (m)
LENGTH OF
PRECHARGE
(m)
ADDITIONAL
CHARGE
(g/m)
12 1/4"-3/8" 25 10 5 15
18 1/4"-1/2" 30 20 5 15
24 3/8"-5/8" 30 20 5 30
30/36 3/8"-5/8" 50 25 5 30
42/48 3/8"-5/8" 65 30 5 30
MAXIMUMPIPE LENGTH & HEIGHT (TYPE INVERTER)

Indoor unit cassette type
7. INSTALLATION OF THE INDOOR UNIT
Deciding ceiling opening size
1. Gird ceiling installation situation (60x60 standard ceiling):
Because this unit is a mini-cassette, there is no need to make an opening cut on the ceiling,
just remove one piece of ceiling panel.
2. Hard ceiling installation situation:
Create the ceiling opening required for installation, below shows the relationship of the ceiling
opening to unit and the panel (Fig 5)
Fig.5
9
880mm
A
H
600mm
A
H
Model 09-18 Model 24-48
CAPACITY
(KBtu/h)
A H
09-18 270mm >280mm
24-36 245mm >275mm
42-48 287mm >317mm
INVERTER
Ground
OutletOutlet
>2300
Inlet
>1000
>1000
>1000
>1000

Indoor unit cassette type
ENGLISH
Installing the indoor unit
1. Useinstallation template (supplied with the panel) when deciding the suspension bolt position.Fig.6
and Fig. 7 show the dimensions relationship.
Fig.6
Fig.7
2. Tubing and wiring must be prepared beforehand inside the ceiling when suspending the unit.
10
(Unit: mm)
780
840
950
680
840
950
523
570
647
(Unit: mm)
545
570
647
Bolt M6X12
Central hole
Installation
paper board
Body

Indoor unit cassette type
Ouer 1 mm5
10-1 mm2
Fig.8
Supplied bolt Full-scale installation diagram
(Supplied with the unit)
Nuts and washers
(Use for upper and lower)
Suspension bolt Suspension hook
2 nuts
10 12 mm
Fig.9
11
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 15mm as shown in Fig.8
3.
In order to prevent a possible looseness, it is recommended to use 3 hexagonal nuts (Prepared
on site) and2washers (accessory) for each suspension bolt. Pay attention that2nuts will be
used in the lower side.(Fig.9)
4.
Adjust the distance between the unit and the ceiling bottom to 10~12mm. Tighten all the nuts
on the suspending bolts.(Fig.9)
5.

Indoor unit cassette type
ENGLISH
Duct installation
1. Side openings are provided for installing separate ducts for outside air intake and treated air
distribution to an adjacent room.
2. Use a punch to remove the knock-down openings on the casing. Use a knife to make the
suitable opening on the polystyrene behind the casing.
TAKE CARE not to damage the heat exchanger coil located behind the openings.
Fig.10
12
Fresh air
Fresh air intake ( 75)
Ø65mm Ø75mm
MODLE (09-18)
3. Plug the gaps between the ducts and the opening edge with anti-condensation insulation.
IF THEABOVEINSTRUCTIONS ARE NOT FOLLOWED,CONDENSATEFLOWS WILL
BUILD UP.
6. Distributing air to an adjacent room requires the corresponding panel air outlets to be sealed by
using the sealing material.
7. A decoration grille must be fitted in the partition between the air conditioned room (where the c-
assette is installed) and the adjacent room.
Use material which can withstand a continuous operating temperature of 60 . The ducts can
be of the flexible type with a spring core or of corrugated aluminum, covered inside with an
insulating material (12 to 25 mm thick glass fiber).
4.
When the installation is finished, all the surfaces of the non-insulated ducts must be covered
with anti-condensation insulation material (6mm thick expanded polystyrene or expanded
neoprene). Fireproofing classification: M1.
5.
Model 09/12/18:

Indoor unit cassette type
13
80mm
80mm
Ø75mm
MODLE (24-48)
Model 24~48
INVERTER : 24-48: A=160mm; B=95mm
NOTE
Fig.11

Indoor unit cassette type
ENGLISH
14
8. CONDENSATE HOSE CONNECTION
Drain hose connection
1. Use standard hard PVC pipefor the drain pipe.
2. Use the drain hose (Prepared on site)to change the direction.
Fig.12
Caution!
1. Do not raise the drain pipe higher than 0.75m, or else there will be water leak risk.
2. Make sure the drain pipe has a downward gradient (no less than 1/100) and there are no
water traps (Fig.13).
3. To hold the drain pipe, space bracket every 1 to 1.5m.(Fig.13)
Ceiling
Bracket
Drain hose
(Prepared on site)
Clamp (Prepared on site) 1/100 gradient or more
Fig.13
0.75m
1 1.5m
Insert the drain hose until it connects the drain port very well, and then secure it tightly with
the hose clamp(Prepared on site)( Fig.12)
3.
After checking the drainage, wrap the drain hose with the insulation and clamp.
(Prepared on site)( Fig.12)
4.
Connected by hose connector
(Prepared on site)
Hard PVC pipe
Drainhose (Accessory)
Drain clamp (Accessory)
Insulatio(Accessory)
Drain port
OD:31.2mm(Model 24-48)
OD:25mm(Model 09-18)
Hard PVC pipe

Indoor unit cassette type
15
1 mm00
Plastic container for water intake
Fig.14
Caution!
Finish the drainage work.
During this operation, the fan will start working. So pay attention to the rotating fan.
After checking the drainage, make sure that heat insulation is wrapped around the indoor drain
pipe to avoid any dew condensation. (The material should have M1 fireproofing classification)
After wiring and drain piping are completed, check the drainage according to the following
procedure. If necessary, prepare a bucket and cloth to catch and wipe up the water spilled
out.
1.
Check the drainage
Connect the AC 220V~240V power to the terminal blocks (L, N terminals) inside the
electrical box.
2.
Operate the unit in cooling mode. Check the drainage through the transparent drain port to
see if any drain leakage happens.
4.
3. Slowly inject about 1,000 cc of water into the drain pan.(Fig.14)
5. When the check is finished, do not forget to cut off the power input.

ENGLISH
16
9. ELECTRICAL CONNECTION BETWEEN INDOOR AND OUTDOOR UNIT
Electrical requirements
Electrical wiring and connections should be made by qualified electricians and in accordance
with local electrical codes and regulation. The air conditioner units must be grounded.
The air conditioner unit must be connected to an adequate power outlet from a separate branch
circuit protected by a time delay circuit breaker, as specified on unit's nameplate.
Voltage should not vary beyond ±10% of the rated voltage.
1. To connect the indoor unit to the outdoor unit uses the following electrical cables(page16).
2. Prepare the cable ends for the power input and for the cables between outdoor and indoor
units as shown in figure 15a and 15b respectively.
Notes: The wire color code can be selected by the installer.
Fig.15a Fig.15b
Cablebetween indoor and outdoor units
Fig.15 A. OUTDOOR B. INDOOR
Power input cable
3. Connect the cable ends to the terminals of the indoor and outdoor units, as shown in fig 16.
4. Secure the multiple wire power cable with the cable clamps.
Indoor unit cassette type

Indoor unit cassette type
17
INVERTER TYPE
Capacity 18K 24K 30K 36/42K(1Ph)
Power supply
Fuse Rating (ODU/IDU) 16A/10A 20A / 10A 30A / 10A 30A / 10A
1- Power Cable (ODU)
3 x 2.5mm
2
3 x 2.5mm
2
3 x 2.5mm
2
3 x 4.0mm
2
2- Power Cable (IDU)
3 x 1.0mm
2
3 x 1.0mm
2
3 x 1.0mm
2
3 x 1.0mm
2
3- Interconnecting Cable 2 x 0.5mm22 x 0.5mm22 x 0.5mm22 x 0.5mm2
Indoor &Outdoor
Capacity 48k(1Ph) 36K(3Ph) 48K(3Ph)
Power supply
Fuse Rating (ODU/IDU) 40A / 10A 25A / 10A 25A / 10A
1- Power Cable (ODU)
3 x 4.0mm
2
5 x 2.5mm
2
5 x 2.5mm
2
2- Power Cable (IDU)
3 x 1.0mm
2
3 x 1.0mm
2
3 x 1.0mm
2
3- Interconnecting Cable
2 x 0.5mm
2
2 x 0.5mm
2
2 x 0.5mm
2
Indoor & Outdoor
Capacity
Power supply
Fuse Rating
1- Power Cable (ODU)
2- Interconnecting Cable
12K
Outdoor
3 x 1.5mm2
16A
4 x 1.0mm2
OUTDOOR UNIT
24/30/36/42/48 KBtu/h (1Ph) 36/48 KBtu/h (3Ph)
INDOOR UNIT
L N
L
(3) (*)
(* - Optional) (* - Optional)
(1)
(230V ~ 50Hz)
N
(1)L (2)N
S1 S2
S1 S2
(2)
(1)
(230V ~ 50Hz)
(2)
(230V ~ 50Hz)
OUTDOOR UNIT
18 KBtu/h
INDOOR UNIT
(* - Optional)
OUTDOOR UNIT
INDOOR UNIT
L1 L2
L
(3)
(*)
(400V 3N~ 50Hz)
N
(1)L (2)N
S1 S2
S1 S2
L3 N
ENGLISH
INVERTER TYPE
S1
S2
N(B)
L(B)
L
N
L N
(3)
(*)
(1)
(230V ~ 50Hz)
S1 S2
(2)
(230V ~ 50Hz)
1L 2N S L N
L N S
(1)
(230V ~ 50Hz)

Indoor unit cassette type
18
10. REFRIGERANT TUBING
Connect the indoor to the outdoor unit
The indoor unit contains a small quantity of nitrogen. Do not unscrew the nuts from the unit is
supplied with sufficient refrigerant charge (R410A). Refer to outdoor unit nameplate.
Caution!
When unscrewing the
valve caps, do not stand
in front of them or the
spindles at any time, as
the system is under
pressure.
Fig.17
1. Indoor unit
2. Liquid tube (small dia.)
3. Suction tube (large dia.)
4. Plugs
5. Flare nuts
6. Tubing between units
7. Suction tube
8. Liquid tube
9. Outdoor unit
10. Flare nuts
11. Suction valve (large)
12. Liquid valve (small)
Fig.17
Fig.18
Fig.19
Fig.18
1.Wrench
2.Torque wrench
3.Union
Fig.19
To prevent refrigerant
leakage, coat the flared
surface with refrigeration oil
Fig.20
Fig.20
1.Suction valve
2.Service port
3.Liquid valve
4.Union
Tightening torques of
unions and valve caps:
TUBE SIZE
Liquid line 1/4”
Suction line 3/8”
Suction line 1/2”
Suction line 5/8”
TORQUE
15-20 N.M.
30-35 N.M
50-54N.M.
75-78N.M.
1
2
3
4
5
6
7
8
9
10
11
12
To prevent crushing, bend tubes using a bending tool.
NOTE: Use R410A refrigerant type copper tubing only.
1. Open the valve cover.
Use tubing diameter that corresponds to the tubing diameter of the indoor and outdoor units.
Note that the liquid and suction tubes have different diameters. (See tube size, torque
tightening table.)
2.
Place flare nuts on tube ends before preparing them withaflaring tool. Use the flare nuts
that are mounted on the supplied outdoor and indoor units.
3.
Connect the all ends of the tubing to the indoor and outdoor units. Notice the sign. All ends
should correspond one by one.
4.
Insulate each tube separately, and their unions, with at least6mm thick of insulation. Wrap
the refrigerant tubing, drain hose and electric cables together withavinyl tape (UV
protected).
5.

Fig.21
Note
For additional charge of
various tubing lengths,
refer to outdoor unit
nameplate.
1. Charging set
2. Vacuum pump
3. Outdoor unit
4. Service port
5. Cap
6. Suction valve
7. Service port *
8. Cap
9. Liquid valve
10. Indoor unit
11. Suction flare connection
12. Liquid flare connection
* In some models only
19
Do the vacuum of the refrigeration tubes and the indoor unit
After connecting the unions of the indoor and outdoor units, purge the air from the tubes and
indoor unit as follows:
Connect the charging hoses withapush pin to the low side of the charging set and the
service port of the suction valve. Be sure to connect the end of the charging hose with the
push pin to the service port.
1.
2. Connect the center hose of the charging set to a vacuum pump.
Turn on the power switch of the vacuum pump, turn off the high side switch and make sure
that the needle in the needle in the gauge moves from 0 MPa (0cm Hg) to -0.1MPa (-76cm
Hg). Let the pump run for fifteen minutes.
3.
Close the valve of the low side of the charging set and turn off the vacuum pump. Note that
the needle in the gauge should not move after approximately five minutes.
4.
Not any problem for five minutes, turn on the power switch of the vacuum pump and open
the valve of the low side of the charging set.
5.
Disconnect the charging hose from the vacuum pump and from the service ports of the
suction valve.
6.
7. Tighten the service port caps of suction valve.
8. Redo 1 to 7 for other indoor units.
9. Remove the valve caps from all valves, and open them usingahexagonal Allen wrench.
10.Remount valve caps from all of the valves.
11.Check for gas leaks from all the connecting position.
Test with electronic leak detector or with a sponge immersed with soapy water for bubbles.
Indoor unit cassette type