Technibel MCAF188R5I User manual

Français
English
85264190272000 03/2006
Contents Page
IMPORTANT!
Please Read Before Starting .................................. 2
1. GENERAL .......................................................... 3
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Optional Copper Tubing Kit
1-4. Type of Copper Tube and Insulation Material
1-5. Additional Materials Required for Installation
2. INSTALLATION SITE SELECTION ................... 4
2-1. Indoor Unit
2-2. Outdoor Unit
3. HOW TO INSTALL THE INDOOR UNIT ............. 6
3-1. Remove the Rear Panel from the Unit
3-2. Make a Hole
3-3. Install the Rear Panel on the Wall
3-4. Remove the Grille to Install the Indoor Unit
3-5. Shape the Indoor Side Tubing
3-6. Wiring Instructions
3-7. Recommended Wire Length and Diameter
3-8. Wiring Instructions for Inter-unit Connections
3-9. Mounting
3-10. Drain Hose
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 16
4-1. Wiring Instructions for the Outdoor Unit
5. REFRIGERANT TUBING.................................. 17
5-1. Use of the Flaring Method
5-2. Flaring Procedure with a Flare Tool
5-3. Caution before Connecting Tubes Tightly
5-4. Connecting Tubing between Indoor and
Outdoor Units
5-5. Insulation of Refrigerant Tubing
5-6. Taping the Tubes
5-7. Finishing the Installation
6. AIR PURGING................................................... 19
IAir Purging with a Vacuum Pump (for Test Run)
IBasic Functions of the Service Valves
IPump Down
Model Combinations
Combine indoor and outdoor units only as listed
below.
Indoor Unit Outdoor Unit
MCAF188R5I GRF186R5I
MCAF248R5I GRF246R5I
Power Source:
50 Hz, single-phase, 220 – 240 VAC
INSTALLATION INSTRUCTIONS
– Split system air conditioner –
COOL/DRY/HEAT Model
This air conditioner uses the new refrigerant R410A.
Be sure to read the yellow instruction sheet
attached to the outdoor unit for models using the
new refrigerant R410A.
The illustrations are based on the typical appearance
of a standard model. Consequently, the shape may
differ from that of the air conditioner that you are
installing.
NOTE
7. REMOTE CONTROL UNIT INSTALLATION
POSITION ......................................................... 23
7-1. Mounting on a Wall
8. ADDRESS SWITCH.......................................... 24
8-1. Address Setting of the Remote
Control Unit
9. ELECTRIC WIRING SYSTEM........................... 25
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IMPORTANT!
Please Read Before Starting
This air conditioning system meets strict safety and operat-
ing 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:
GCarefully read this instruction booklet before beginning.
GFollow each installation or repair step exactly as
shown.
GObserve all local, state, and national electrical codes.
GPay 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 tub-
ing 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 fin-
gers.
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 pre-
vents 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)
•Position the outdoor unit in a protected location
where snow will not blow into it.
•Install the outdoor unit on a raised platform that is
higher than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
• 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.
Others
• 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 upon completing installation that no refrigerant
gas is leaking. If escaped gas comes in contact with a
stove, gas water heater, electric room heater or other
heat source, it can produce dangerously toxic gas.
WARNING
WARNING
CAUTION
CAUTION
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1. General
This booklet briefly outlines where and how to install
the air conditioning system. Please read over the
entire set of instructions for the indoor and outdoor
units and make sure all accessory parts listed are with
the system before beginning.
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)
1-2. Accessories Supplied with Unit
Table 1
1-3. Optional Copper Tubing Kit
Copper tubing for connecting the outdoor unit to the
indoor unit is available in kits which contain the narrow
and wide tubing, fittings and insulation. Consult your
nearest sales outlet or A/C workshop.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately
from a local source, you will need:
1. Deoxidized annealed copper tube for refrigerant
tubing as detailed in Table 2.
Cut each tube to the appropriate lengths +30 cm
to 40 cm to dampen vibration between units.
Table 2
2. Foamed polyethylene insulation for the specified
copper tubes as required to precise length of tub-
ing. Wall thickness of the insulation should be not
less than 8 mm.
3. Use insulated copper wire for field wiring. Wire
size varies with the total length of wiring. Refer to
3-6. Wiring Instructions for details.
PartsFigure Q’ty
1
1
1
4
2
AAA alkaline
battery
Remote
control unit
Remote control
unit holder
PartsFigure Q’ty
Tapping screw
Clamp
Tapping screw
Truss-head
Phillips
4 30 mm
Truss-head
Phillips
4 16 mm 2
8
Cushion
rubber *
Air cleanfilter
PartsFigure Q’ty
1Drainelbow *
5 GRF246
4 GRF186
*Packed inthe outdoor unit.
Draincap*
2
(1 each)
CAUTION
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions or
limitations.
Model Narrow Tube Wide Tube
Outer Dia. Thickness Outer Dia. Thickness
MCAF186 6.35 mm 0.8 mm 12.70 mm 0.8 mm
MCAF246 6.35 mm 0.8 mm 15.88 mm 1.0 mm
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1-5. Additional Materials Required for Installation
1. Refrigeration (armored) tape
2. Insulated staples or clamps for connecting wire
(See local codes)
3. Putty
4. Refrigeration lubricant
5. Clamps or saddles to secure refrigerant tubing
2. Installation Site Selection
2-1. Indoor Unit
AVOID:
Gdirect sunlight.
Gnearby heat sources that may affect performance of the
unit.
Gareas where leakage of flammable gas may be expected.
Gplaces where large amounts of oil mist exist.
DO:
Gselect an appropriate position from which every corner of
the room can be uniformly cooled. (High on a wall is best.)
Gselect a location that will hold the weight of the unit.
Gselect a location where tubing and drain hose have the
shortest run to the outside. (Fig. 1)
Gallow room for operation and maintenance as well as unre-
stricted air flow around the unit. (Fig. 2)
Ginstall the unit within the maximum elevation difference (H)
above or below the outdoor unit and within a total tubing
length (L) from the outdoor unit as detailed in Table 3 and
Fig. 3a.
GInstall the indoor unit more than 1 meter away from any
antenna or power lines or connecting wires used for televi-
sion, radio, telephone, security system, or intercom. Electrical
noise from any of these sources may affect operation.
Table 3
Drain hose
Indoor unit
Outside drainage
Fig. 1
5 cm
min.
5 cm
min.
15 cm min.
Front View
Fig. 2
INDOOR
UNIT
Tubing length (L)
OUTDOOR
UNIT
Elevation
difference (H)
Fig. 3a
WARNING
To prevent abnormal heat genera-
tion and the possibility of fire, do
not place obstacles, enclosures
and grilles in front of or surround-
ing the air conditioner in a way
that may block air flow.
*If total tubing length becomes 10 to 30 m, charge additional refrigerant (R410A) by 25 g/m.
No additional charge of compressor oil is necessary.
Indoor unit
Floor level
Wall
Minimum height
from floor level
1.5 m
Fig. 3b
For stable operation of the air
conditioner, do not install
wall-mounted type indoor
units less than 1.5 m from
floor level.
CAUTION
Max. Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of
Model Length at Shipment Length (L) Difference (H) Additional Refrigerant
(m) (m) (m) (g/m)*
MCAF186/246 10 30 15 25
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(GRF186)
Air intake Min. 10 cm
Air discharge
Min.
5 cm Min.
40 cm
Valve
side
Min.
25 cm
Min.
2 m
Min.
2 m
Ground
Obstacle
Obstacle above
Air discharge
Min. 10 cm
Air intake
(GRF246)
Air intake Min. 20 cm
Air discharge
Min.
10 cm Min.
50 cm
Valve
side
Min.
25 cm
Min.
2 m
Min.
2 m
Ground
Obstacle
Obstacle above
Air discharge
Min. 20 cm
Air intake
5
English
2-2. Outdoor Unit
AVOID:
Gheat sources, exhaust fans, etc. (Fig. 4)
Gdamp, humid or uneven locations.
DO:
Gposition the outdoor unit in a protected location
where snow will not blow into it.
Gchoose a place as cool as possible.
Gchoose a place that is well ventilated.
Gallow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 5a or 5b)
Gprovide a solid base (level concrete pad, concrete
block, 10 ¥40 cm or 15 ¥40 cm beams or equal), a
minimum of 10 cm or 15 cm above ground level to
reduce humidity and protect the unit against possi-
ble water damage and decreased service life.
(Fig. 5c or 5d)
GInstall cushion rubber under unit’s feet to reduce
vibration and noise. (Fig. 5e)
Guse lug bolts or equal to bolt down unit, reducing
vibration and noise.
GInstall in a location where no antenna of a television
or radio exists within 3 meters.
Outdoor unit
Hot air
Heat source
Exhaust fan
NO
Fig. 4
Fig. 5c
(GRF186)
Air intake
Concrete
or equal
About 10 cm
Min. 10 cm
Anchor bolts
(4 pcs.)
About 40 cm
Fig. 5d
(GRF246)
Air intake
Concrete
or equal
About 15 cm
Min. 15 cm
Anchor bolts
(4 pcs.)
About 40 cm
Fig. 5e
Cushion rubber
Fig. 5a
Fig. 5b
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Set screw only for transportation
Fig. 6
Rear panel
marks
Fig. 7
Left
tubing
Right tubing
Downward tubing
Right-rear
tubing
(recommended)
Left-rear
tubing
Fig. 8
3. How to Install the Indoor Unit
3-1. Remove the Rear Panel from the Unit
(1) Remove and discard the set screw on the rear
panel. (Fig. 6)
(2) Press the 2 LLmarks on the frame cover and dis-
engage the stationary tabs from the frame. (Fig. 7)
(3) Remove the rear panel.
Tubing can be extended in 5 directions as shown in
Fig. 8. Select the direction you need providing the
shortest run to the outside unit.
GWhen left tubing is to be done, switch the drain
hose and drain cap. (For details, refer to “Switching
drain hose and drain cap” on page 14.)
3-2. Make a Hole
(1) Place the rear panel from the indoor unit on the
wall at the location selected. Make sure the panel
is horizontal, using a carpenter’s level or tape mea-
sure to measure down from the ceiling. Wait until
after cutting the hole before attaching the rear
panel to the wall.
(2) Determine which side of the unit you should make
the hole for tubing and wiring. (Fig. 9)
In the case of left-rear tubing, use the measurement
points 60 mm from the edge of the rear panel for pre-
cise placement of the hose outlet. (Fig. 9)
(3) Before making the hole, check carefully that no
studs or pipes are directly run behind the spot to
be cut.
The above precautions are also applicable if tub-
ing goes through the wall in any other location.
NOTE
NOTE
60mm
Fig. 9
CAUTION
Also avoid areas where elec-
trical wiring or conduits are
located.
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Indoorside Outdoorside
Hole should be made at a slight downward slant to the
outdoor side.
NOTE
Fig. 10
Plastic cover
INSIDE OUTSIDE
Wall
Slight
angle
PVC pipe
(Locally purchased)
Fig. 12
PVC pipe (Locally purchased)
Cut at slight angle
Fig. 11
(4) Using a sabre saw, key hole saw or hole-cutting
drill attachment, cut a hole in the wall. See Table 4
and Fig. 10.
Table 4
(5) Measure the thickness of the wall from the inside
edge to the outside edge and cut PVC pipe at a
slight angle 6 mm shorter than the thickness of the
wall. (Fig. 11)
(6) Place the plastic cover over the end of the pipe (for
indoor side only) and insert the pipe in the wall.
(Fig. 12)
3-3. Install the Rear Panel on the Wall
Be sure to confirm that the wall is strong enough to
suspend the unit.
See either Item a) or b) below depending on the wall
type.
a) If Wooden Wall
(1) Attach the rear panel to the wall with the 8 screws
provided. (Fig. 13)
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 5 mm dia. holes in the
panel over the stud locations and then mount the
rear panel.
(2) Double check with a carpenter’s level or tape mea-
sure that the panel is level. This is important to
install the unit properly. (Fig. 14)
(3) Make sure the panel is flush against the wall. Any
space between the wall and unit will cause noise
and vibration.
b) If Block, Brick, Concrete or Similar Type Wall
Make 4.8 mm dia. holes in the wall. Insert rawl plugs
for appropriate mounting screws. (Fig. 15)
Hole Dia. (mm)
80
Fig. 13
Fig. 14
4.8mm dia. hole
Rawl plug
(Locally purchased)
Fig. 15
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3-4. Remove the Grille to Install the Indoor Unit
Basically, these models can be installed and wired
without removing the grille. If access to any internal
part is needed, follow the steps as given below.
How to remove the grille
(1) Grasp both ends of the air intake grille, and
remove it by opening towards the front and pulling
towards you. (Fig. 16a)
(2) Remove the 3 screws. (Fig. 16b)
(3) Remove the screw on the right side cover plate
and open the cover. (Fig. 17a)
(4) Take out the thermistor from the grille. (Fig. 17b)
(5) Press the 3 tabs at the top of the grille and the 3
tabs on the front face to separate the grille from
the frame. (Fig. 18a)
(6) Pull the grill toward you to remove it.
How to replace the grille
(1) When installing the grille, place the bottom of the
grille into the frame first. (Fig. 18b)
Then insert the tabs on the top of the grille and on
the front face into the frame.
(2) Make sure that the grille and frame are firmly fitted
together by engaging the tabs.
(3) Attach the thermistor on the grille. (Fig. 17a)
(4) Close the cover and replace the screw. (Fig. 17a)
(5) Affix the grille with the 3 previously removed
screws. (Fig. 16b)
(6) Install the air intake grille.
(a) Allow the edge of the air intake grille to slide
into the top of the indoor unit, and then insert it
all the way inside. (Fig. 19a)
(b) Press the bottom right and left corners and
center of the air intake grille to attach it to the
indoor unit. (Fig. 19b)
Attach so that the round pins at the top right and left
corners of the air intake grille are inserted into the
grooves at the top right and left of the indoor unit.
NOTE
Air intake grille Grille
Fig. 16a
Fig. 16b
Cover
Thermistor
Fig. 17a
Thermistor
Fig. 17b
Fig. 18a
Tab
Tab
Fig. 18b
Fig. 19b Fig. 19a
Pin
Groove
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3-5. Shape the Indoor Side Tubing
(1) Arrangement of tubing by directions
a) Right or left tubing
Cut out the corner of the right/left frame with a
hacksaw or the like. (Figs. 20 and 21)
b) Right-rear or left-rear tubing
In this case, the corner of the frame need not be
cut.
(2) To mount the indoor unit on the rear panel:
Hang the 2 mounting slots of the unit on the
upper tabs of the rear panel. (Fig. 22)
3-6. Wiring Instructions
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, with a power supply disconnect and cir-
cuit breaker for overcurrent protection provided in
the exclusive line.
(3) To prevent possible hazard due to insulation fail-
ure, the unit must be grounded.
(4) Each wiring connection must be done tightly and 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.
Frame
Right tubing
outlet
Frame
Left tubing
outlet
Fig. 21
Fig. 22
Fig. 20
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3-7. Recommended Wire Length and Diameter
Regulations on wiring diameter differ from locality to locality.
For field wiring requirements, please refer to your local elec-
trical codes. Carefully observe these regulations when carry-
ing out the installation.
Table 5 lists recommended wire lengths and diameters for
power supply systems.
Refer to the wiring system diagram (Fig. 23) for the meaning
of (A), (B) and (C) in Table 5.
Table 5
NOTE
Fig. 23
WIRING SYSTEM DIAGRAM
WARNING
GBe sure to comply with local codes on running the wire
from the indoor unit to the outdoor unit (size of wire
and wiring method, etc.).
GEach wire must be firmly connected.
GNo wire should be allowed to touch refrigerant tubing,
the compressor, or any moving part.
Grounding line
INDOOR
UNIT OUTDOOR UNIT
1
2
3
4
Te r mi nal
1
2
3
N
L
Te r mi nal
Grounding
line
Power supply
L
N
(B)
(C)
(A)4
Single-phase 220–240VAC 50HZ
CAUTION
GBe sure to connect the power supply line to the outdoor
unit as shown in the wiring diagram. The indoor unit
draws its power from the outdoor unit.
GDo not run wiring for antenna, signal, or power lines of
television, radio, stereo, telephone, security system, or
intercom any closer than 1 meter from the power cable
and wires between the indoor and outdoor units. Electri-
cal noise may affect the operation.
GTo avoid the risk of electric shock, each air condi-
tioner unit must be grounded.
GFor the installation of a grounding device, please
observe local electrical codes.
GGrounding is necessary, especially for units using
inverter circuits, in order to release charged electrici-
ty and electrical noise caused by high tension.
Otherwise, electrical shock may occur.
GPlace a dedicated ground more than 2 meters away
from other grounds and do not have it shared with
other electric appliances.
WARNING
Cross-Sectional (A) Power Supply Wiring Length (m) (B) Power Line Fuse or Circuit
Area (mm2) (C) Control Line Breaker Capacity
Model 2.5mm22.5mm2
GRF186 25 30 20A
GRF246 25 30 20A
(m)
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3-8. Wiring Instructions for Inter-unit Connections
(1) Grasp both ends of the air intake grille, and
remove it by opening towards the front and pulling
towards you.
(2) Remove the screw on the right side cover plate
and open the cover. (Fig. 24)
(3) Insert the inter-unit wiring into the through-the-wall
PVC pipe. Lead the power wiring into the room
allowing approx. 25 cm to extend from the wall
face. (Fig. 25)
(4) Route the inter-unit wiring from the back of the
indoor unit and pull it toward the front for connec-
tion. (Fig. 26)
(5) Connect the inter unit wiring to the corresponding
terminals on the terminal plate (Fig. 26) while
referring to the wiring diagram.
(6) Be sure to secure the wiring with the provided
clamp.
When closing the air intake grille, press the bottom
right and left corners and center. (Fig. 27)
Please refer to “How to replace the grille” on page 8
for installing the air intake grille.
NOTE
25 cm
Wiring
Rear
panel
Plastic
cover
Fig. 25
Cover
Fig. 24
Fig. 26
Fig. 27
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When connecting each power wire to the correspond-
ing terminal, follow the instructions “How to connect
wiring to the terminal” and fasten the wire securely
tight with the fixing screw of the terminal plate.
How to connect wiring to the terminal
a) For Indoor Unit
(1) Cut the wire end with a cutting pliers, then strip
the insulation to expose the wire about 7 mm. See
the label (Fig. 28) near the terminal plate.
(2) Using a screwdriver, loosen the terminal screw on
the terminal plate.
(3) Insert the wire and tighten the terminal screw
completely using a screwdriver.
b) For Outdoor Unit
IFor solid core wiring (or F-cable)
(1) Cut the wire end with a cutting pliers, then strip
the insulation to expose the solid wire about 25
mm. (Fig. 29)
(2) Using a screwdriver, remove the terminal screw(s)
on the terminal plate.
(3) Using the pliers, bend the solid wire to form a loop
suitable for the terminal screw.
(4) Shape the loop wire properly, place it on the ter-
minal plate and fix it securely with the removed
terminal screw using a screwdriver.
IFor stranded wiring
(1) Cut the wire end with a cutting pliers, then strip
the insulation to expose the stranded wiring about
10 mm and tightly twist the wire ends. (Figs. 30
and 31)
(2) Using a 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 connec-
tor. (Fig. 30)
(4) Place the ring connector wire, and replace and
tighten the removed terminal screw using a screw-
driver. (Fig. 32)
Solid wire
Loop
Insulation
Strip 25 mm
Fig. 29
STRIP
SIZE
7 mm (ACTUAL
SIZE)
Fig. 28
Stranded wire
Ring
connector
Strip 10 mm
Fig. 30
Screw
Ring connector
Terminal plate
Wire
Special
washer
Fig. 32
Screw and
special washer
Ring
connector
Wire
WARNING
Loose wiring may cause the
terminal to overheat or result
in unit malfunction. A fire
hazard may also exist. There-
fore, be sure all wiring is
tightly connected.
Twist wire ends
Fig. 31
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3-9. Mounting
(1) To install the indoor unit, mount the indoor unit
onto the 2 tabs on the upper part of the rear plate.
(2) Hold down the air discharge outlet and press the
lower part of the indoor unit until it clicks to
securely fasten to the 2 tabs on the lower part of
the rear plate. (Fig. 33)
For tubing, choose either the right or left tubing direc-
tion and follow the steps below. This work can be made
easier by placing padding material (such as styrofoam)
at the rear right side of the indoor unit. (Fig. 34)
IRight-side tubing
(1) Shape the refrigerant tubing so that it can easily
go into the wall hole. (Fig. 35)
(2) Push the wiring, refrigerant tubing, and drain hose
through the hole in the wall. Adjust the indoor unit
so it is securely seated on the rear panel. (Fig. 36)
(3) Carefully bend the tubing (if necessary) to run
along the wall in the direction of the outdoor unit
and then tape as far as the fittings. (See Caution
on page 18.) The drain hose should come straight
down the wall to a point where water runoff won’t
stain the wall.
(4) Connect the refrigerant tubing to the outdoor unit.
(After performing a leak test on the connecting
part, insulate it with the tubing insulation. (Fig. 37))
Also, refer to Section 5-4. Connecting Tubing
between Indoor and Outdoor Units.
(5) Assemble the refrigerant tubing, drain hose, and
inter-unit wiring as shown in Fig. 37.
NOTE
Cover
Refrigerant
tubing
Rear panel
Drain hose
Inter-unit
wiring
Fig. 35
Fig. 36
Fig. 37
Fig. 33
Push
Fig. 34
Insulation
Padding material
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Hole in wall
Bent part
Narrow tube
Wide tube
Rear panel
Fig. 38
Drain cap
Drain hose
Fig. 39
ILeft-side tubing
(1) Lead the tubing and drain hose through the wall,
allowing sufficient length for connection. Then
bend the tubing using a tube bender to make the
attachment. (Fig. 38)
(2) Switch the drain hose and drain cap.
Switching drain hose and drain cap
(a) Locate the drain hose and the drain cap.
(Fig. 39)
(b) Remove the screws fastening the drain hose
on the right side, and pull out the drain hose
to remove it. (Fig. 39)
(c) Apply moderate force to pull off the drain cap
on the left side. (If you cannot pull it off by
hand, use a long-nose pliers.)
(d) Reattach the drain hose to the left side and
the drain cap to the right side. (Fig. 40a)
Drain hose
Slide the drain hose fully onto the drain pan outlet
until the drain hose edge is pushed into the insu-
lation. Check that the screw holes in the drain
bracket and the drain pan outlet are aligned and
securely in contact, then fasten them with the
screw. (After attaching the drain hose, check that
it is attached securely.) (Fig. 40c)
Drain cap
Use a Phillips screwdriver to push the drain cap in
firmly. (If it is difficult to push in, wet the cap with
water first.)
(3) Install the indoor unit on the rear panel.
(4) Connect the tubing and wiring led inside from out-
doors.
(5) After completing a leak test, bundle the tubing
together with armoring tape and store it inside the
tubing storage area at the back of the indoor unit
and hold it with clamps. (Fig. 41)
Fig. 40a
Fig. 40b
Fig. 40c
Fig. 41
Refrigerant tubing
Inter-unit wiring
Screw
Drain hose
Drain pan outlet
Screw hole
Drain bracket
Drain cap
Clamp
Drain hose
Drain hose
Drain bracket
Insulation
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To unmount indoor unit
Press the 2 LLmarks on the lower part of the indoor
unit and unlatch the tabs. Then lift the indoor unit and
unmount. (Fig. 42)
3-10. Drain Hose
a) The drain hose should be slanted downward to
the outdoors. (Fig. 43)
b) Never form a trap in the course of the hose.
c) If the drain hose will run in the room, insulate the
hose with insulation*so that chilled condensation
will not damage furniture or floors. (Fig. 44)
*Foamed polyethylene or its equivalent is recom-
mended.
WARNING
Risk of Electric Shock
Do not supply power to the
unit or operate it until all
tubing and wiring to the
outside unit are completed.
;; ;; ;;
;;;; ;;;; ;;;;
;;
;;
;;
Condensation
Insulation material
(locally purchased)
must be used.
Fig. 44
Push
Fig. 42
;;
;;
;;
;;;;
;;;; ;;;;
Slant
Drain
hose
Indoor
unit
Fig. 43
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4. How to Install the Outdoor Unit
First refer to Section 2. Installation Site Selection.
The drain hole at the bottom of the outdoor unit was
not plugged at the time of factory shipment. If neces-
sary, plug the drain hole with the accessory drain cap
or mount the accessory drain elbow before installing
the outdoor unit. (Fig. 45a or 45b)
4-1. Wiring Instructions for the Outdoor Unit
Regulations on wire size differ from locality to locality.
For field wiring requirements, please refer to your local
electrical codes. Make sure that the installation fully
complies with all local and national regulations.
(1) Remove access panel “C”. (Fig. 46)
(2) Connect the inter-unit wiring and power line
according to the drawing on the panel side.
(3) Be sure to size each wire allowing approx. 10 cm
longer than the required length for wiring. Store
excess wiring inside the cabinet.
(4) When connections are completed, check that all
connections are correct as shown in the wiring
system diagram on panel side.
(5) Be sure to ground the unit according to your local
codes.
NOTE
Accessory
drain cap Accessory
drain cap
Accessory
drain elbow
Outdoor unit
Fig. 45a
Access panel “C”
Fig. 46
CAUTION
When installing in a cold
area where drainage water
may freeze, do not attach the
provided drain cap or drain
elbow to the bottom plate of
the unit.
Accessory
draincap Accessory
draincap
Accessory
drainelbow
Outdoor unit
Fig. 45b
for GRF186
for GRF246
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5. Refrigerant Tubing
5-1. Use of the Flaring Method
Many of the 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.
5-2. 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. 30 –
50 cm 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. 47)
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 48)
(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.*(Figs. 49a and 49b)
(*Use “RIGID” or equivalent.)
A good flare should have the following characteristics:
Ginside surface is glossy and smooth.
Gedge is smooth.
Gtapered sides are of uniform length.
5-3. Caution before Connecting Tubes Tightly
a) Be sure to apply a sealing cap or water-proof tape
to prevent dust or water from getting into the tubes
before they are used.
b) Be sure to apply refrigerant lubricant to the match-
ing surfaces of the flare and union before connect-
ing them together. This is effective for reducing
gas leaks. (Fig. 50)
c) 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. 51)
NOTE
NOTE
Deburring
Before After
Fig. 47
Reamer
Copper
tubing
Fig. 48
Flare tool
Flare nut
Copper
tubing
Fig. 49b
Fig. 49a
Apply refrigerant
lubricant here and here
Fig. 50
Flare nutUnion
Fig. 51
0 0.5 mm
If the special R410A
flare tool is used:
1.2 mm
If the previous flare tool
(clutch-type) is used:
Adjust so that the amount of tube
protrusion is as shown in the figure.
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5-4. Connecting Tubing between Indoor and
Outdoor Units
a) Tightly connect the indoor side refrigerant tubing
extended from the wall with the outdoor side tubing.
(Fig. 52)
b) To fasten the flare nuts, apply specified torque as:
Table 6
5-5. Insulation of Refrigerant Tubing
To prevent heat loss and wet floors due to dripping of
condensation, both tubes must be well insulated
with a proper insulation material. (Fig. 53)
The thickness of the insulation should be a minimum
8 mm. (Fig. 54)
5-6. Taping the Tubes
(1) At this time, the 2 refrigerant tubes (and electrical
wire if local codes permit) should be taped togeth-
er with armoring tape. The drain hose may also be
included and taped together as 1 bundle with the
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. (Fig. 55)
(3) Clamp the tubing bundle to wall, using 1 clamp
approx. every 120 cm.
Do not wind the armoring tape too tightly, since this
will decrease the heat insulation effect. Also, be sure
the condensation drain hose splits away from the bun-
dle and drips clear of the unit and the tubing.
5-7. Finishing the Installation
After finishing insulating and taping over the tubing,
use sealing putty to seal off the hole in the wall to pre-
vent rain and draft from entering. (Fig. 56)
NOTE
IMPORTANT
Indoor unit
Outdoor unit
Spanner
Torque wrench
Fig. 52
Insulation
Min. 8 mm Thickness: min. 8 mm
Fig. 54
Fig. 55
Clamp
Insulated tubes
Apply putty here
Tubing
Fig. 56
CAUTION
After a tube has been insu-
lated, never try to bend it
into a narrow curve, as this
may cause the tube to break
or crack.
Insulation
Fig. 53
Tube Dia. Tightening Torque
6.35 mm 14 – 18 N·m (140 – 180 kgf · cm)
9.52 mm 34 – 42 N·m (340 – 420 kgf · cm)
12.70 mm 49 – 61 N·m (490 – 610 kgf · cm)
15.88 mm 68 – 82 N·m (680 – 820 kgf · cm)
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6. Air Purging
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below. Therefore,
they must be purged completely.
Gpressure in the system rises
Goperating current rises
Gcooling (or heating) efficiency drops
Gmoisture in the air may freeze and block capillary tubing
Gwater may lead to corrosion of parts in the refrigerant
system
IAir Purging with a Vacuum Pump (for Test Run)
(1) Check that each tube (both narrow and wide tubes)
between the indoor and outdoor units have been
properly connected and all wiring for the test run
has been completed. Note that both narrow and
wide tube service valves on the outdoor unit are
kept closed at this stage.
(2) Using an adjustable wrench or box wrench, remove
the valve caps from the service valve on both nar-
row and wide tubes.
(3) Connect a vacuum pump and a manifold valve (with
pressure gauges) to the service port on the wide
tube service valve. (Fig. 57)
(4) With the “Lo” knob of the manifold valve open, run
the vacuum pump. The operation time for the vacu-
um pump varies with tubing length and the capacity
of the pump. The following table shows the amount
of time for evacuation:
Table 7
HiLo
Indoor unit
Outdoor unit
Manifold valve
(Exclusively for R410A)
Pressure
gauge
Vacuum pump
Charging hose
(Exclusively for R410A)
Vacuum pump adapter
(Exclusively for R410A)
(with reverse flow prevention)
Fig. 57
CAUTION
Be sure to use a manifold valve
for air purging. If it is not avail-
able, use a stop valve (field
supply) for this purpose. The
“Hi” knob of the manifold valve
must always be kept closed.
The required time in Table 7 is calculated based on the
assumption that the ideal (or target) vacuum condition
is around 10 mmHg abs.
NOTE
Required time for evacuation when
100 liter/h vacuum pump is used
If tubing length is If tubing length is
less than 10 m more than 10 m
10 min. or more 15 min. or more
CAUTION
The service port on the wide tube
service valve uses a Schrader
core valve to access the refriger-
ant system. The valve core is sim-
ilar to those used in automobile
tires. Therefore, be sure to use a
vacuum hose connector which
has a push-pin inside.
To prevent other refrigerants from being mistakenly
charged to units which use R410A, the size of the
charge port on the service valve is different from the
one for other refrigerant types. For servicing such as
recharging, the specified charging hose, manifold and
vacuum pump adapter (with reverse flow prevention)
for R410A must be used.
NOTE
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(5) With the vacuum pump still running, close the “Lo”
knob of the manifold valve. Then stop the vacuum
pump.
(6) With the hex wrench, turn the valve stem on the
narrow tube service valve counter-clockwise by 90
degrees (1/4 turn) for 10 seconds, and then turn the
stem clockwise to close it again. (Fig. 58)
(7) Leak test all joints at the tubing (both indoor and out-
doors) with soapy water. Bubbles indicate a leak. Tight-
en the joint more when leaks, then check if there is no
leak. Be sure to wipe off the soap with a clean cloth.
(8) With the hex wrench, turn the wide tube service
valve stem counter-clockwise to fully open the valve.
(9) Turn the narrow tube service valve stem counter-
clockwise to fully open the valve.
(10) Loosen the vacuum hose connected to the wide
tube service port slightly to release the pressure.
Then, remove the hose.
(11) Fasten the valve cap on the wide tube service port
securely with an adjustable wrench or box wrench.
Next, mount the valve cap on the service valve and
tighten it to 20 N·m (200 kgf·cm) with a torque
wrench. This process is very important to prevent
gas from leaking from the system.
(12) Test run the air conditioner. (See next page.)
(13) While the air conditioner is running, apply liquid
soap to check for any gas leaks around the service
valves or caps.
(14) If there is no leakage, stop the air conditioner.
(15) Wipe off the soap on the tubing.
This completes air purging with a vacuum pump and the
air conditioner is ready for actual operation.
CAUTION
Be sure to completely insert
the hex wrench before
attempting to turn the valve.
Fig. 58
CAUTION
This may cause the refriger-
ant gas to leak. In order to
avoid this, take off the hose
quickly.
90°(1/4 turn) Narrow tube
Hex wrench
Wide tube
Valve cap
Vacuum hose to manifold valve
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