Worcester waaiu5 User manual

1
2
34
5
Piping
a. Piping length should be 1m or more in order to decrease
vibration propagated from the outdoor unit.
b. If piping length exceeds 10m, add 20g of refrigerant per 1m.
c. When the outdoor unit is placed at a higher level than the
indoor units, provide a trap near the hose’s lead-in port.
Max. piping length A (m) Max. level difference B (m)
860
108
A
125
J
175
115
I
F
E
D
J
E
A
F
I
D
292
45 30
(1) (2)
(3)
(4)
(4)
(1) Process the end of the electrical cable for the indoor side.
• Use a copper cable.(Cross-section area 2mm2or more)
• Use a cable which is not lighter than polychloroprene sheathed flexible
cord (design 245 IEC 57).
(2) Open the open panel by about 70°.
(3) Connect the electrical cable.
• Be very careful not to confuse the terminal connections. Wrong cabling
may damage the internal control circuit.
• The markings on the indoor unit’s terminal board must match with
those of the outdoor unit.
(4) Fix the cable with the accompanying cord holder and the short screw.
(5) Close the open panel.
Mounting the indoor unit
If the wall is 250 mm or thicker, connect the pipes first.
(1) For rear exit piping, pass the auxiliary pipe and the drain
hose through the piping hole, and hook the unit onto the
mounting plate.
(2) Push the unit and apply the bottom hooking points to the
mounting plate's support. (Take this step after cabling be-
tween the indoor and outdoor units.)
(3) Pull the bottom of the unit to check that the unit is fixed in
place.
Detaching the unit from the mounting plate
Push the “ “ marks at the bottom of the indoor unit and
pull the bottom of the unit. When the hooks are released
from the mounting plate, support the bottom of the unit and
lift the unit upwards.
1 2N
LOCATIONS OF INDOOR AND OUTDOOR UNIT
A
B
B
Drain Hose
GREENSOURCE AIR/AIR HEAT PUMP
INSTALLATION MANUAL After installation, be sure to explain to
the customer enough about the system. ENGLISH
Cut-out
Notch
Cut the plate along notch.
MOUNTING PLATE
Indoor
WALL
Outdoor
Cut with a saw.
Cap
(Downward to outdoor
)
5 mm
Sleeve
Length unit: mm
Center of wall hole:
Backward piping
Center of wall hole:
Leftward piping.
Ceiling
Outline of indoor unit
50mm or more
NOTES ON LOCATIONS
Provide as much installation space as
possible for efficient air-conditioning.
OPEN PANEL - OPENING AND CLOSING
OUTDOOR UNIT MOUNTING SCREW HOLES
Drain Cap
Drain Hose
SHORT SCREW 7
CORD HOLDER 8 Electrical cable
Earth wire
Terminal board
Drain Cap
Unit
Piping Holder
Tape
Insert
Hook
Unit
Piping Holder
Unit
1. Insert the top of the piping
holder into the square opening.
Indoor Unit
15 7
(unit size)
(unit size)
MIN.50
MIN.50 MIN.50
Length unit: mm
MIN.50
MIN.200
MIN.100 MIN.200
4
ACCESSORIES
CAUTION
This room air conditioner uses new
refrigerant R410A.
1. Keep any open ends of pipes be sealed
with a cap, etc. until connected with the
equipment.
2. Exercise great care when performing piping
installation so as water, dust, etc. will not
enter into the piping and equipment.
3. Pipes connected to the indoor and outdoor
units must be used new. (This air condi-
tioner using R410A incurs pressure higher
compared with R22, it is necessary to
choose adequate materials.)
4. Use only R410A refrigerant when charging
additional refrigerant to the equipment.
Never add lubricating oil to the equipment
in any case.
5. In order to prevent any other refrigerant
from being charged accidentally, the ser-
vice port diameter of the 3-way valve has
been changed. (1/2” UNF screw)
OPER
INSTALL
4 REMOTE CONTROL
8 CORD HOLDER
1
1 MOUNTING PLATE
2 WALL PLUG
3 LONG SCREW
5 DRY BATTERY
6 SPECIAL SCREW
9 MANUALS
1
8
7
1
2
1
1
1
10 AIR PURIFYING
FILTER 2
WALL PLUG 2
LONG
SCREW 3
MOUNTING
PLATE 1
Drain Hose
Hose holder
Hexagon socket screw key
Drain cap
Drain Hose
Screw
Drain Cap
MIN.70
8mm
40mm
32 mm
6.5
mm
WALL PLUG 2
Carefully read and follow
these instructions for smooth
and trouble-free installation.
ITEMS Q’ty APPLICATION ITEMS Q’ty APPLICATION
To mount the indoor unit
on the wall.
To fix the mounting plate
with the long screws.
To fix the remote control
with the special screw.
To fix the mounting plate
with the wall plugs.
To control remotely.
For the remote control.
AAA batteries.
To mount the remote
control on the wall.
To secure the electrical
cable.
Installation manual
Operation manual
To remove dust and to-
bacco smoke from the air.
Indoor unit
a. Keep the air outlet clear of any obstacle so
that outgoing air flows smoothly in the entire
room.
b. Make a drain hose hole for easy drainage.
c. Provide sufficient space on both sides and
above the unit.
d. The air filters should be easily taken in and
out.
e. Keep TV set, radio and the like 1 m or more
away from the unit and the remote control.
f. Keep the air inlet clear of obstacles that could
block incoming air.
g. The remote control may not function prop-
erly in a room equipped with an electronic
simultaneous-start or rapid-start fluorescent
lighting.
h. Select a location that does not cause loud
operation noise and extreme vibrations.
Outdoor unit
a. Place the outdoor unit on a stable base.
b. Provided sufficient space around the unit. It should also be well
ventilated.
c. The unit should not be exposed to strong wind nor splashed with
rain water.
d. Water drain from the unit should be let out without problem. Lay
a drain hose if required. In cold regions, installation of the drain
pipe is not advisable as freezing could result.
e. Keep TV set, radio and the like 1 m or more away from the unit.
f. Avoid locations exposed to machine oil vapor, salty air (facing the
seashore, for example), hot spring vapor sulfur gas, etc. Such
location can cause breakdown.
g. Also, avoid locations exposed to muddy water (along a road, for
example) or where the unit can be tampered with.
h. Select a location where the outgoing air or operating noise can-
not annoy others.
i. Install the unit on a stable base not to allow louder noise.
j. Keep the air outlet opening free of any obstacle. This could affect
the performance of the unit and create loud noises.
Outdoor Unit Trap
NOTES ON DRAIN HOSE
The drain hose can be connected at either side of the indoor unit.
The unit has been shipped with the drain hose
connected at left (viewed from the back of the unit)
and the drain cap applied at right.
Reposition the drain hose and drain cap as re-
quired.
(1) Remove the fixed screw in the hose holder at
the end of the drain hose.
(2) Hold the end of the drain hose, and pull it out.
(3) Pull out the drain cap.
(4) Reconnect the drain hose to the right and in-
sert the drain cap to the left.
Fully insert the drain hose until it stops and
use the screw that was previously removed
in STEP (1) to secure the hose holder to the
drain pan.
Insert a hexagon socket screw key (4mm di-
agonal) into the drain cap, and press it fully.
Caution:
After replacing, make sure that both the drain
hose and drain cap are firmly inserted.
(2) Drill diameter 6.5mm, depth 32mm
holes and fit the wall plug.
(3) Secure mounting plate and check the
stiffness. Fix mounting plate to wall at 7
points.
(4) Drill a piping hole with 70mm diameter
concrete drill or a hole saw with a 5mm
down ward slant to the outside.
(5) Set the sleeve and caps.
Opening
To open, hold the left
and right bottom cor-
ners of the panel and
lift it up.
1 PLACING THE MOUNTING PLATE AND MAKING A TUBE HOLE Fix the mounting plate horizontally.
(1) Referring to the figure below, mark the location for the wall plugs and the
tube hole. Recommended fixing holes are marked in circle around the
hole.
2 SETTING UP THE INDOOR UNIT
Piping route
For directions 1, 2, 4 and 5, cut out the specific zone
without leaving any sharp edge.
(Keep the cut-out plate for possible future use.)
For left side Piping
(1) Reverse the positions of the drain hose and drain
cap. Refer to NOTES ON DRAIN HOSE.
(2) Connect the pipes and coil tape around the pipes
and electrical cable.
(3) Store the pipes within the back cavity of the unit,
and secure the pipes by attaching the piping
holder. (Refer to steps 1 and 2 as shown on the
right.)
(4) Coil tape around the drain hose together with the
pipes and electrical cable.
(5) Hook the unit onto the mounting plate.
3 CONNECTING THE ELECTRICAL CABLE TO THE INDOOR UNIT
7 SHORT SCREW
To fix the CORD HOLDER.
1
540
299
2. Hook the bottom of piping
holder to the unit.
Taping
INDOOR UNIT OUTDOOR UNIT
WAAIU5 WAAIU5 B166
Closing
To close, press-fit
the arrow-marked
points.
Notch
Cut-out
Cut the plate along
notch.
WORCESTER.indd 1 08.6.18 11:04:25 AM

2
N 1
AIR VENT
(T TUBE JOINT)
Not running wavy.
Not left in water.
To drainage pit
5 CONNECTING THE REFRIGERANT PIPES
Flare body
Flare nut
8 POWER CABLING
9
HANGING THE REMOTE CONTROL
11 EXPLANATION TO CUSTOMER
Loading the batteries
Slide the cover in the direction of the ar-
row.
(1) Open the cover.
(2) Insert the batteries.
(3) Close the cover.
• If after battery replacement the control
fails to function, take out the batteries.
Wait for more than 30 seconds and put
them in again.
10 TEST RUN
No trap allowed.
Not to rise.
Indoor unit
(1) Connect a drain hose.
(2) Tape over the connecting
part.
Drain hose
ø18mm
Connecting the pipes
(1) Tighten the flare nuts by hand
for the first 3-4 turns.
(2) Use two wrenches to tighten up
the pipes.
(3) Wind coating tape around refrig-
erant pipes together with drain
hose and electrical cable for
general.
• Lay the drain hose below the
pipes.
• The thermal insulation should
cover both the GAS and LIQUID
pipes as shown below. As insula-
tion, use polyethylene foam 6 mm
or thicker.
4 CONNECTING THE DRAIN HOSE
6
AIR REMOVAL
Flare nut tightening torque
DETACHING THE FRONT PANEL
YES NO
GAS LIQUID
Insulation Insulation GAS
LIQUID
Insulation
Insulation
GAS
LIQUID
NO
LIQUID
GAS
Insulation
Drain hose
Electrical
cable
No trap allowed.
Flaring the pipe end
(1) Cutting with a pipe cutter
Cut at a right angle.
(2) Deburring
Allow no cuttings in the pipe.
(3) Putting in the flare nut
(4) Flaring
Flare processing dimensions(:A)
differ according to the type of flare
tool.
R410A tool: 0-0.5mm
Conventional tool: 1.0-1.5mm
(5) Checking
To be flared perfectly circular.
Flare nut not missing.
A
Tube size
Liquid side
Gas side
1/4"
3/8"
Torque
16±2N·m (1.6±0.2kgf·m)
38±4N·m (3.8±0.4kgf·m)
Liquid side
Valve shaft cap tightening torque
Pipe size
1/4"
Gas side 3/8"
Width
22mm
Torque
24±3N·m (2.4±0.3kgf·m)
Service port cap tighting torque
Torque
11±1N·m (1.1±0.1kgf·m)
22mm 24±3N·m (2.4±0.3kgf·m)
Lo Hi
2-WAY VALVE
VALVE SHAFT CAP
SERVICE PORT
CAP VACUUM PUMP
HEXAGON
SOCKET SCREW
KEY
3-WAY VALVE
INDOOR UNIT
1 Remove
3 Connect
9 Disconnect
1 Remove
4 Open
4 Operate
6 Turn off
8 Fully Open
7 Fully Open 5 Close
10 Replace
2 Remove
10 Replace
10 Replace
COMPOUND
GAUGE
GAUGE MANIFOLD
VACUUM PUMP
ADAPTER
VALVE SHAFT
CAP
POWER SUPPLY CABLE
Blue
Brown
Green/yellow-striped
POWER SUPPLY
Neutral
Live
Ground
Supply power 220-240V, single-phase
Circuit breaker 10A
For servicing, for example, detach the front panel in the
following steps. Be sure to disconnect the power cord
from the wall outlet or turn off the circuit breaker.
(1) Remove the air filter.
(2) Unscrew the 2 screws of the front panel.
(3) Open the vertical adjustment louvre by hand.
(4) Remove the front panel.
• Slightly open the lower part of the front panel, and extract
the 5 hooks along the upper surface for disassembly.
(5) To set the panel back into position, press-fit it at the bottom
first and then press its top.
(3)
(2)
(4)
(1)
Screw
Vertical adjustment louvre
Air filter
WALL PLUG 2 SPECIAL
SCREW 6
Remote control rear
side
(1) Open the open panel to see the control section.
(2) Start the operation with the remote control.
(3) Press the “AUX” button on the unit for 5 seconds or
more. A beep sound is heard and the OPERATION
lamp starts flashing. Now the system is in the cool-
ing test run mode.
(4) To put the system in the heating test run mode, start
the cooling operation and select the heating mode on
the remote control.
(5) Make sure the system runs well, and press the AUX
button again to stop the operation.
• Explain to the customer how to use and maintain the system,
referring to the operation manual.
• Ask the customer to carefully read the operation manual.
• When the system has been set up, hand the installation manual
to the customer.
IMPORTANT POINTS TO EXPLAIN
Whipping sound :
• The system adjusts itself, by expansion or shrinkage,
according to great temperature fluctuations.
Running liquid sound :
• The refrigerant runs in the system, generating such sound.
(For details, refer to the accompanying operation manual.)
Prepare a dedicated power supply circuit.
For the connections, see below. Earth leakage breaker
• Provide an earth leakage breaker in
order to protect against electric shock
in case of leak.
• Use the current-activated, high-sen-
sitivity, high-speed type breaker with
a rated sensitivity current of below 30
mA and an operating time of below 0.1
second.
• The appliance shall be installed in
accordance with national wiring regu-
lations. Wrong connection can cause
overheating or fire.
• Fit a disconnect switch, having a contact
separation of at least 3mm in all poles,
to the electricity power line.
(1) Fit the special screw to the
wall with the wall plug.
(2) Hang the remote control to the
screw head.
Notes:
• Be sure to lay the drain hose downward for smooth drainflow.
•
Be careful not to allow the drain hose to rise, form a trap or leave its end in water, as shown below.
• Coil thermal insulation around a drain hose extension, if running in the room.
• It is recommended to add an "intermediate air vent" when the drain hose is extended horizontally, or an
"anti-back-flow air vent" when the hose is exposed to high winds on a high-rise building, for example. For
this purpose, employ a "T tube joint" (PVC-made, commercially available) halfway in the hose.
• Use pipes with thickness 0.8mm.
• Connect the pipes for the indoor unit first
and then for the outdoor unit.
• Bend the pipes carefully as not to damage
them.
• Do not over tighten the tubes; it may be
deformed or damaged.
Use a torque wrench, when possible. See
the table below for the flare nut tightening
torque.
Use an adapter for preventing vacuum pump oil from flowing back to the
gauge manifold hose. ON/OFF operation of the vacuum pump should be
made by the adapter switch.
( 1 ) Remove both valve shaft caps of the 2 and 3-way valves.
( 2 ) Remove the service port cap of the 3-way valve.
( 3 ) Connect the gauge manifold hose to the service port and the
vacuum pump.
Be sure that the hose end to be connected to the service port has a
valve core pusher.
( 4 ) Open the gauge manifold valve and operate the vacuum pump for
10-15 minutes.
Make sure the compound gauge reads -76cmHg.
( 5 ) Close the gauge manifold valve.
( 6 ) Turn off the vacuum pump.
( 7 ) Fully open the 2-way valve with hexagon socket screw key. (diago-
nally 4 mm)
Turn all the way up to contact.
( 8 ) Fully open the 3-way valve with hexagon socket screw key. Turn all
the way up to contact.
( 9 ) Disconnect the gauge manifold hose from the service port.
(10) Replace the service port cap and both valve shaft caps tightly.
Notes:
• Use a gauge manifold and hoses exclusive for R410A.
• After air removal, check the tube connections for gas leak using a
leakage detector or soapy water. Regarding leakage detector, use
high-sensitivity type designed specially for R410A.
Pump down
Pump down is adopted in the case of unit removal for re-installation,
abandonment, repair etc.
Pump down is to collect the refrigerant into the outdoor unit by control of
the 2 and 3-way valves and the compressor.
( 1 ) Stop the air conditioner operation.
( 2 ) Remove both valve shaft caps of the 2 and 3-way valves.
( 3 ) Run the air conditioner at cooling test run mode (Refer to 10 TEST
RUN). If pump down is performed at normal cooling operation, the
protection system may engage and stop the operation.
Coating tape
(1) Process the end of the electrical cable for the outdoor unit.
(2)
Remove the control box cover.
(3)
Remove the cable holder and connect the cable.
Be sure that the terminal connections are as specified.
(4) Fix the electrical cable sheath with the cable holder and the screw.
(5) Double-check that the cable is securely in place.
(6) Place the control box cover back in the reverse order.
Caution:
•Use the specified electrical cable. Make sure the cable is secured in place and that
the terminals are free of any excess force from the cable. Otherwise overheating or
fire may result.
•Dress the cable so that the control box cover, the cord holder and cable holder are
not loose. Double-check that the cover is tight in position. Otherwise overheating, fire
or electric shock may result.
• Be sure to put the cable leads deep into the terminal board and tighten up the screws.
Poor contact can cause overheating or fire, or malfunction.
Earth wire
Control box cover
Electrical cable
Terminal board
Cable holder
Screw
7 CONNECTING THE ELECTRICAL CABLE TO THE OUTDOOR UNIT
8mm
40mm
TINS-B166JBRZ
( 4 ) After 5~10 minutes, fully close the 2-way valve by turning the hexagon
socket screw key clockwise.
( 5 ) After 2~3 minutes, immediately close the 3-way valve fully.
( 6 ) Stop the test run operation.
( 7 ) Replace both valve shaft caps tightly.
( 8 ) Disconnect both refrigerant pipes.
Note:
• Do not perform the pump down when at heating mode. The refrigerant
will not be collected.
Installation Manual Greensource air to air 2008/07 en 8 716 115 358
WORCESTER.indd 2 08.6.18 11:04:28 AM