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24 Room Air Conditioner
Installation
Checking the Drainage
Form the Piping
1. To remove the front panel from the indoor unit.
• Set the air direction louvers up-and-down to the
position(horizontally) by hand.
• Remove the securing screws that retain the front
panel. Pull the lower left and right sides of the
grille toward you and lift it off.
grille toward you and lift it off.
2. To check the drainage.
• Pour a glass of water on the evaporator.
• Ensure the water flows through the drain hose of
the indoor unit without any leakage and goes out
the drain exit.
the drain exit.
3. Drain piping
• The drain hose should point downward for easy
drain flow.
• Do not make drain piping.
1. Form the piping by wrapping the connecting
portion of the indoor unit with insulation materi-
al and secure it with two kinds of vinyl tapes.
al and secure it with two kinds of vinyl tapes.
• If you want to connect an additional drain hose,
the end of the drain outlet should be routed above
the ground. Secure the drain hose appropriately.
the ground. Secure the drain hose appropriately.
2. In cases where the outdoor unit is installed
below the indoor unit perform the following.
• Tape the piping, drain hose and connecting cable
from down to up.
• Secure the tapped piping along the exterior wall
using saddle or equivalent.
3. In cases where the Outdoor unit is installed
above the Indoor unit perform the following.
• Tape the piping and connecting cable from down
to up.
• Secure the taped piping along the exterior wall.
Form a trap to prevent water entering the room.
• Fix the piping onto the wall by saddle or equiva-
lent.
Pull the right and
the left side.
the left side.
Taping
Drain
hose
hose
Pipings
Connecting
cable
cable
Trap is required to prevent water
from entering into electrical parts.
from entering into electrical parts.
Seal small openings
around pipings with a
gum type sealer.
around pipings with a
gum type sealer.
Seal a small opening
around the pipings
with gum type sealer.
around the pipings
with gum type sealer.
Trap
Trap
Downward slope
Do not raise
Accumulated
drain water
drain water
Tip of drain hose
dipped in water
dipped in water
Air
Waving
Water
leakage
leakage
Water
leakage
leakage
Ditch
Less than
50mm gap
50mm gap
Water
leakage
leakage
Service Manual 25
Installation
CAUTION:
To avoid nitrogen entering the
refrigerant system in a liquid state, the top of
the cylinder must be higher than its bottom when you
pressurize the system. Usually, the cylinder is used
in a vertical standing position.
pressurize the system. Usually, the cylinder is used
in a vertical standing position.
Air and moisture remaining in the refrigerant system
have undesirable effects as indicated below.
have undesirable effects as indicated below.
• Pressure in the system rises.
• Operating current rises.
• Cooling(or heating) efficiency drops.
• Moisture in the refrigerant circuit may freeze and
block capillary tubing.
• Water may lead to corrosion of parts in the refrig-
eration system.
Therefore, the indoor unit and tubing between the
indoor and outdoor unit must be leak tested and
evacuated to remove any noncondensables and
moisture from the system.
indoor and outdoor unit must be leak tested and
evacuated to remove any noncondensables and
moisture from the system.
1. Preparation
• Check that each tube(both liquid and gas side
tubes) between the indoor and outdoor units have
been properly connected and all wiring for the test
run has been completed. Remove the service
valve caps from both the gas and the liquid side on
the outdoor unit. Note that both the liquid and the
gas side service valves on the outdoor unit are
kept closed at this stage.
been properly connected and all wiring for the test
run has been completed. Remove the service
valve caps from both the gas and the liquid side on
the outdoor unit. Note that both the liquid and the
gas side service valves on the outdoor unit are
kept closed at this stage.
2. Leak test
• Connect the manifold valve(with pressure gauges)
and dry nitrogen gas cylinder to this service port
with charge hoses.
with charge hoses.
• Pressurize the system to no more than 150
P.S.I.G. with dry nitrogen gas and close the cylin-
der valve when the gauge reading reached 150
P.S.I.G. Next, test for leaks with liquid soap.
der valve when the gauge reading reached 150
P.S.I.G. Next, test for leaks with liquid soap.
• Do a leak test of all joints of the tubing(both indoor
and outdoor) and both gas and liquid side service
valves.
Bubbles indicate a leak. Be sure to wipe off the
soap with a clean cloth.
valves.
Bubbles indicate a leak. Be sure to wipe off the
soap with a clean cloth.
• After the system is found to be free of leaks,
relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
Lo
Hi
Indoor unit
Outdoor unit
Manifold valve
Charge hose
Nitrogen gas
cylinder(in vertical
standing position)
cylinder(in vertical
standing position)
Pressure
gauge
gauge
CAUTION:
Be sure to use a manifold valve
for air purging. If it is not available, use a stop
valve for this purpose. The "Hi" knob of the manifold
valve must always be kept close.
valve must always be kept close.
Air Purging
Air Purging with Vacuum Pump
26 Room Air Conditioner
Installation
3. Evacuation
• Connect the charge hose end described in the pre-
ceding steps to the vacuum pump to evacuate the
tubing and indoor unit.
Confirm the "Lo" knob of the manifold valve is
open. Then, run the vacuum pump.
The operation time for evacuation varies with tub-
ing length and capacity of the pump. The following
table shows the time required for evacuation.
tubing and indoor unit.
Confirm the "Lo" knob of the manifold valve is
open. Then, run the vacuum pump.
The operation time for evacuation varies with tub-
ing length and capacity of the pump. The following
table shows the time required for evacuation.
• When the desired vacuum is reached, close the
"Lo" knob of the manifold valve and stop the vacu-
um pump.
um pump.
4. Finishing the job
• With a service valve wrench, turn the valve stem of
liquid side valve counter-clockwise to fully open
the valve.
the valve.
• Turn the valve stem of gas side valve counter-
clockwise to fully open the valve.
• Loosen the charge hose connected to the gas side
service port slightly to release the pressure, then
remove the hose.
remove the hose.
• Replace the flare nut and its bonnet on the gas
side service port and fasten the flare nut securely
with an adjustable wrench. This process is very
important to prevent leakage from the system.
with an adjustable wrench. This process is very
important to prevent leakage from the system.
• Replace the valve caps at both gas and liquid side
service valves and fasten them tight.
This completes air purging with a vacuum pump.
The air conditioner is now ready to test run.
The air conditioner is now ready to test run.
(1) Remove the caps from the 2-way and 3-way
valves.
(2) Remove the service-port cap from the 3-way valve.
(3) To open the 2-way valve turn the valve stem coun-
(3) To open the 2-way valve turn the valve stem coun-
terclockwise approximately 90°, wait for about 2~3
sec, and close it.
sec, and close it.
(4) Apply a soap water or a liquid neutral detergent on
the indoor unit connection or outdoor unit connec-
tions by a soft brush to check for leakage of the
connecting points of the piping.
tions by a soft brush to check for leakage of the
connecting points of the piping.
(5) If bubbles come out, the pipes have leakage.
Soap water method
Required time for evacuation when 30 gal/h vacuum pump is
used
10 min. or more
15 min. or more
If tubing length is less than 10m
(33 ft)
if tubing length is longer than 10m
(33 ft)
Gas side
Liquid side
Cap
Hexagonal wrench
2-way valve
(Open)
3-way valve
(Close)
Indoor unit
Outdoor unit
Lo
Hi
Manifold valve
Vacuum pump
Pressure
gauge
gauge
Open
Close
Service Manual 27
Installation
Test Running
1. Check that all tubing and wiring have been properly
connected.
2. Check that the gas and liquid side service valves are
fully open.
Prepare remote control
1. Remove the battery cover
by pulling it according to the
arrow direction.
arrow direction.
2. Insert new batteries making
sure that the (+) and (–) of
battery are installed correctly.
battery are installed correctly.
3. Reattach the cover by
pushing it back into position.
• Use 2 AAA(1.5volt) batteries. Do not use
rechargeable batteries.
• Remove the batteries from the remote
control if the system is not going to be
used for a long time.
used for a long time.
Settlement of outdoor unit
• Anchor the outdoor unit with a bolt and
nut(ø10mm) tightly and horizontally on a concrete
or rigid mount.
or rigid mount.
• When installing on the wall, roof or rooftop, anchor
the mounting base securely with a nail or wire
assuming the influence of wind and earthquake.
assuming the influence of wind and earthquake.
• In the case when the vibration of the unit is con-
veyed to the hose, secure the unit with an anti-
vibration bushing.
vibration bushing.
Evaluation of the performance
Operate unit for 15~20 minutes, then check the system
refrigerant charge:
1. Measure the pressure of the gas side service valve.
2. Measure the temperature of the intake and discharge
refrigerant charge:
1. Measure the pressure of the gas side service valve.
2. Measure the temperature of the intake and discharge
of air.
3. Ensure the difference between the intake tempera-
ture and the discharge is more than 8°C(46°F)
(Cooling) or (Heating).
(Cooling) or (Heating).
4. For reference; the gas side pressure of optimum
condition is as below.(Cooling)
If the actual pressure is higher than shown,
the system is most likely over-charged, and
charge should be removed. If the actual pres-
sure are lower than shown, the system is
most likely undercharged, and charge should
be added.
the system is most likely over-charged, and
charge should be removed. If the actual pres-
sure are lower than shown, the system is
most likely undercharged, and charge should
be added.
The air conditioner is now ready for use.
NOTICE
NOTICE
Bolt
Tubing connection
Discharge
temperature
Discharge air
Intake temperature
R-22
35°C (95°F)
4~5kg/cm
2
G(56.8~71.0 P.S.I.G.)
R-410A
35°C (95°F)
8.5~9.5kg/cm
2
G(120~135 P.S.I.G.)
Outside ambient
TEMP.
Refrigerant
The pressure of the gas side
service valve.
This is performed when the unit is to be relocated
or the refrigerant circuit is serviced.
Pump Down means collecting all refrigerant in the
outdoor unit without loss in refrigerant gas.
or the refrigerant circuit is serviced.
Pump Down means collecting all refrigerant in the
outdoor unit without loss in refrigerant gas.
CAUTION:
Be sure to perform Pump Down procedure with the
unit cooling mode.
Be sure to perform Pump Down procedure with the
unit cooling mode.
Pump Down Procedure
1. Connect a low-pressure gauge manifold hose to
1. Connect a low-pressure gauge manifold hose to
the charge port on the gas side service valve.
2. Open the gas side service valve halfway and purge
the air from the manifold hose using the refrigerant
gas.
gas.
3. Close the liquid side service valve(all the way in).
4. Turn on the unit's operating switch and start the
4. Turn on the unit's operating switch and start the
cooling operation.
5. When the low-pressure gauge reading becomes 1
to 0.5kg/cm2 G(14.2 to 7.1 P.S.I.G.), fully close the
gas side valve stem and then quickly turn off the
unit. At that time, Pump Down has been completed
and all refrigerant gas will have been collected in
the outdoor unit.
gas side valve stem and then quickly turn off the
unit. At that time, Pump Down has been completed
and all refrigerant gas will have been collected in
the outdoor unit.
PUMP DOWN
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