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Service Manual 17
Installation
Flaring Work
Main cause for refrigerant leakage is due to defect in
the flaring work. Carry out correct flaring work using the
following procedure.
the flaring work. Carry out correct flaring work using the
following procedure.
Cut the pipes and the cable.
• Use the piping kit accessory or pipes purchased
locally.
• Measure the distance between the indoor and the
outdoor unit.
• Cut the pipes a little longer than the measured
distance.
• Cut the cable 1.5m longer than the pipe length.
Burr removal
• Completely remove all burrs from the cut cross
section of pipe/tube.
• Put the end of the copper tube/pipe in a downward
direction as you remove burrs in order to avoid
dropping burrs into the tubing.
dropping burrs into the tubing.
Putting nut on
• Remove flare nuts attached to indoor and outdoor
unit, then put them on pipe/tube having completed
burr removal.
(not possible to put them on after flaring work)
burr removal.
(not possible to put them on after flaring work)
Flaring work
• Firmly hold copper pipe in a die in the dimension
shown in the table above.
• Carry out flaring work using flaring tool as shown
below.
Check
• Compare the flared work with figure below.
• If flare is noted to be defective, cut off the flared
section and re-flare it.
Copper
pipe
90
°
Slanted Uneven Rough
Bar
Copper pipe
Clamp handle
Red arrow mark
Cone
Yoke
Handle
Bar
"A"
Inclined
Inside is shiny without scratches
Smooth all round
Even length
all round
Surface
damaged
Cracked Uneven
thickness
= Improper flaring =
Pipe
Reamer
Point down
Flare nut
Copper tube
mm
inch
mm
Ø6.35
1/4
0~0.5
Ø9.52
3/8
0~0.5
Ø12.7
1/2
0~0.5
Ø15.88
5/8
0~1.0
Ø19.05
3/4
1.0~1.3
Outside diameter
A
18 Room Air Conditioner
Installation
Connection of Piping Indoor
• Preparing the indoor unit's piping and drain hose
for installation through the wall.
• Remove the plastic tubing retainer(see illustration
below) and pull the tubing and drain hose away
from chassis.
from chassis.
• Replace the plastic tubing holder in the original
position.
For right rear piping
1. Route the indoor tubing and the drain hose in
the direction of rear right.
2. Insert the connecting cable into the indoor unit
from the outdoor unit through the piping hole.
• Do not connect the cable to the indoor unit.
• Make a small loop with the cable for easy
connection later.
3. Tape the tubing, drain hose, and the connecting
cable. Be sure that the drain hose is located at
the lowest side of the bundle. Locating at the
upper side can cause drain pan to overflow
inside the unit.
the lowest side of the bundle. Locating at the
upper side can cause drain pan to overflow
inside the unit.
If the drain hose is routed inside the
room, insulate the hose with an insula-
tion material* so that dripping from
"sweating"(condensation) will not dam-
age furniture or floors.
room, insulate the hose with an insula-
tion material* so that dripping from
"sweating"(condensation) will not dam-
age furniture or floors.
*Foamed polyethylene or equivalent is recom-
mended.
4. Indoor unit installation
• Hook the indoor unit onto the upper portion of the
installation plate.(Engage the two hooks of the rear
top of the indoor unit with the upper edge of the
installation plate.) Ensure that the hooks are prop-
erly seated on the installation plate by moving it
left and right.
top of the indoor unit with the upper edge of the
installation plate.) Ensure that the hooks are prop-
erly seated on the installation plate by moving it
left and right.
Press the lower left and right sides of the unit against the
installation plate until the hooks engage into their
slots(clicking sound).
installation plate until the hooks engage into their
slots(clicking sound).
4. Connecting the pipings to the indoor unit and
drain hose to drain pipe.
• Align the center of the pipes and sufficiently tight-
en the flare nut by hand.
NOTICE
CAUTION:
When
install, make sure
that the remaining
that the remaining
parts must be removed
clearly so as not to dam-
age the piping and drain
hose, especially power
cord and connecting cable.
clearly so as not to dam-
age the piping and drain
hose, especially power
cord and connecting cable.
Tubing holder
Connecting
cable
cable
Loop
Gas side
piping
piping
Liquid side
piping
piping
Drain hose
Drain hose
Connecting
cable
Indoor unit tubing
Flare nut
Pipes
Drain hose
Service Manual 19
Installation
• Tighten the flare nut with a wrench.
• When extending the drain hose at the indoor unit,
install the drain pipe.
5. Wrap the insulation material around the con-
necting portion.
• Overlap the connection pipe insulation material
and the indoor unit pipe insulation material. Bind
them together with vinyl tape so that there is no
gap.
them together with vinyl tape so that there is no
gap.
• Wrap the area which accommodates the rear pip-
ing housing section with vinyl tape.
• Bundle the piping and drain hose together by
wrapping them with vinyl tape for enough to cover
where they fit into the rear piping housing section.
where they fit into the rear piping housing section.
For left rear piping
1. Route the indoor tubing and the drain hose to
the required piping hole position.
2. Insert the piping, drain hose, and the connecting
cable into the piping hole.
mm
inch
kg.m
Ø6.35
1/4
1.8
Ø9.52
3/8
4.2
Ø12.7
1/2
5.5
Ø15.88
5/8
6.6
Ø19.05
3/4
6.6
Outside diameter
Torque
Wrench
Indoor unit tubing
Open-end wrench (fixed)
Connection pipe
Flare nut
Vinyl tape(narrow)
Adhesive
Drain pipe
Indoor unit drain hose
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection
pipe
pipe
Connecting cable
Vinyl tape
(wide)
(wide)
Wrap with vinyl tape
Indoor
unit pipe
unit pipe
Pipe
Drain hose
Connecting
cable
Drain pipe
Connecting cable
20 Room Air Conditioner
Installation
3. Insert the connecting cable into the indoor unit.
• Don't connect the cable to the indoor unit.
• Make a small loop with the cable for easy connec-
tion later.
4. Tape the drain hose and the connecting cable.
• Connecting cable
5. Indoor unit installation
• Hang the indoor unit from the hooks at the top of
the installation plate.
• Insert the spacer etc. between the indoor unit and
the installation plate and separate the bottom of
the indoor unit from the wall.
the indoor unit from the wall.
6. Connecting the pipings to the indoor unit and
the drain hose to drain pipe.
• Align the center of the pipes and sufficiently tight-
en the flare nut by hand.
• Tighten the flare nut with a wrench.
• When extending the drain hose at the indoor unit,
install the drain pipe.
7. Wrap the insulation material around the con-
necting portion.
• Overlap the connection pipe heat insulation and
the indoor unit pipe heat insulation material. Bind
them together with vinyl tape so that there is no
gap.
them together with vinyl tape so that there is no
gap.
• Wrap the area which accommodates the rear pip-
ing housing section with vinyl tape.
mm
inch
kg.m
Ø6.35
1/4
1.8
Ø9.52
3/8
4.2
Ø12.7
1/2
5.5
Ø15.88
5/8
6.6
Ø19.05
3/4
6.6
Outside diameter
Torque
Vinyl tape
Adhesive
Drain hose
Indoor unit drain hose
(narrow)
Plastic bands
Insulation material
Vinyl tape(narrow)
Connection
pipe
pipe
Connecting cable
Indoor
unit piping
unit piping
Pipe
Vinyl tape
(wide)
(wide)
Wrap with vinyl tape
Installation plate
Spacer
Indoor unit
8cm
Indoor unit tubing
Flare nut
Pipes
Wrench
Indoor unit tubing
Connection pipe
Flare nut
Open-end wrench (fixed)
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