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05-424 KS0971-1271 12/13/05 1:27 PM Page a
INSTALLATION INSTRUCTIONS
COOL/DRY Model
– Inverter Split System Air Conditioner –
This air conditioner uses the new refrigerant R410A.
Contents
Model Combinations
Page
Combine indoor and outdoor units only as listed
IMPORTANT!
below.
Please Read Before Starting .................................. 2
Indoor Unit Outdoor Unit
1. GENERAL .......................................................... 3
KS0971 C0971
1-1. Tools Required for Installation (not s
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05-424 KS0971-1271 12/13/05 1:27 PM Page 2 IMPORTANT! Please Read Before Starting This air conditioning system meets strict safety and operating When Installing… standards. As the installer or service person, it is an important …In a Ceiling or Wall part of your job to install or service the system so it operates Make sure the ceiling/wall is strong enough to hold the safely and efficiently. unit’s weight. It may be necessary to construct a strong For safe installation and trouble-free oper
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05-424 KS0971-1271 12/13/05 1:27 PM Page 3 1. General 6. Sabre saw or key hole saw This booklet briefly outlines where and how to install the 7. Hacksaw air conditioning system. Please read over the entire set 8. Core bits of instructions for the indoor and outdoor units and make 9. Hammer sure all accessory parts listed are with the system before 10. Drill beginning. 11. Tube cutter 1-1. Tools Required for Installation (not supplied) 12. Tube flaring tool 1. Standard screwdriver 13. Torque
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05-424 KS0971-1271 12/13/05 1:27 PM Page 4 1-5. Additional Materials Required for Installation Indoor unit 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 Drain hose 2. Installation Site Selection Outside drainage 2-1. Indoor Unit Fig. 1 To prevent abnormal heat genera- WARNING tion and the possibility of fire, do not place obstacles, enclosures 6" (15
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About 16" (40 cm) 05-424 KS0971-1271 12/13/05 1:27 PM Page 5 2-2. Outdoor Unit NO Exhaust fan AVOID: Hot air heat sources, exhaust fans, etc. (Fig. 4) Heat source damp, humid or uneven locations. Outdoor unit DO: choose a place as cool as possible. choose a place that is well ventilated. allow enough room around the unit for air intake/ Fig. 4 exhaust and possible maintenance. (Fig. 5a) provide a solid base (level concrete pad, concrete Obstacle above block, 4" ¥ 1'4" (10 ¥ 40 cm
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05-424 KS0971-1271 12/13/05 1:27 PM Page 6 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 marks on the frame cover and disen- gage the stationary tabs from the frame. (Fig. 7) Set screw only for transportation (3) Remove the rear panel. Fig. 6 NOTE Tubing can be extended in 5 directions as shown in Fig. Rear panel 8. Select the direction you need providing the shortest run to the
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05-424 KS0971-1271 12/13/05 1:27 PM Page 7 (4) Using a sabre saw, key hole saw or hole-cutting drill NOTE attachment, cut a hole in the wall. See Table 4 and Hole should be made at a slight downward slant to the Fig. 10. outdoor side. Table 4 Indoor Outdoor side side Hole Dia. 2-9/16" (65 mm) (5) Measure the thickness of the wall from the inside edge to the outside edge and cut PVC pipe at a Fig. 10 slight angle 1/4" (6 mm) shorter than the thickness of the wall. (Fig. 11) PVC pipe (Locally p
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05-424 KS0971-1271 12/13/05 1:27 PM Page 8 Grille Air intake grille 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 need- ed, follow the steps as given below. Be sure to wear work gloves CAUTION during installation to avoid being Fig. 16a cut by the sharp aluminum fins of the heat exchanger. How to remove the grille (1) Grasp both ends of the air intake grille, and remove it by
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05-424 KS0971-1271 12/13/05 1:27 PM Page 9 3-5. Shape the Indoor Side Tubing (1) Arrangement of tubing by direction Frame a) Right or left tubing Cut out the corner of the right/left frame with a Left tubing hacksaw or the like. (Figs. 20 and 21) outlet 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: Fig. 20 Hang the 2 mounting slots of the unit on the upper tabs of the rear panel. (Fig. 22) Frame 3-6.
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05-424 KS0971-1271 12/13/05 1:27 PM Page 10 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 electrical codes. Carefully observe these regulations when carrying out the installation. Table 5 lists recommended wire lengths and diameters for power supply systems. NOTE Refer to the wiring system diagram (Fig. 23) for the meaning of (A), (B), and (C) in Table 5. Refer to your local
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05-424 KS0971-1271 12/13/05 1:28 PM Page 11 3-8. Wiring Instructions for Inter-unit Connections Rear Wall (1) Insert the inter-unit wiring (according to local codes) panel into the through-the-wall PVC pipe. Run the wiring Plastic toward the indoor side allowing approx. 10" (25 cm) cover to extend from the wall face. (Fig. 24) (2) Grasp both ends of the air intake grille, and remove Wiring it by opening towards the front and pulling towards you. 10" (3) Remove the screw on the right side cov
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05-424 KS0971-1271 12/13/05 1:28 PM Page 12 Loose wiring may cause the WARNING terminal to overheat or result in unit malfunction. A fire hazard may also exist. There- fore, be sure all wiring is tightly connected. When connecting each power wire to the corresponding terminal, follow the instructions “How to connect wiring to the terminal” and fasten the wire securely tight with 9/32" the fixing screw of the terminal plate. (7 mm)(ACTUAL STRIP SIZE) SIZE How to connect wiring to the terminal
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05-424 KS0971-1271 12/13/05 1:28 PM Page 13 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) Push NOTE For tubing, choose either the right or left tubing direction Fig. 33 and follow the steps below. This work can be made easi- er by placing pa
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05-424 KS0971-1271 12/13/05 1:28 PM Page 14 Left-side tubing Rear panel (1) Lead the tubing and drain hose through the wall, Hole in wall allowing sufficient length for connection. Then bend the tubing using a tube bender to make the attach- ment. (Fig. 38) Wide tube Bent part (2) Switch the drain hose and drain cap. Narrow tube Fig. 38 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,
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05-424 KS0971-1271 12/13/05 1:28 PM Page 15 To unmount indoor unit Press the 2 marks 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) Push * F
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05-424 KS0971-1271 12/13/05 1:28 PM Page 16 4. How to Install the Outdoor Unit First refer to Section 2. Installation Site Selection. 4-1. Wiring Instructions for the Outdoor Unit Lock nut Cabinet Regulations on wire size differ from locality to locality. For field wiring requirements, please refer to your local elec- trical codes. Make sure that the installation fully complies with all local and national regulations. Terminal (1) Remove access panel “C”. (Fig. 46) block (2) Connect the int
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05-424 KS0971-1271 12/13/05 1:28 PM Page 17 Deburring 5. Refrigerant Tubing Before After 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 Fig. 47 tube cutter. It is recommended
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05-424 KS0971-1271 12/13/05 1:28 PM Page 18 5-4. Connecting Tubing between Indoor and Torque wrench Outdoor Units a) Tightly connect the indoor side refrigerant tubing exten- Spanner ded from the wall with the outdoor side tubing. (Fig. 52) Indoor unit b) To fasten the flare nuts, apply specified torque as: Table 6 Outdoor unit Tube Dia. Tightening Torque Fig. 52 1/4" (6.35 mm) Approx. 120 – 160 lbs·in (140 – 180 kgf·cm) 3/8" (9.52 mm) Approx. 300 – 360 lbs·in (340 – 420 kgf·cm) 1/2" (12.70
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05-424 KS0971-1271 12/13/05 1:28 PM Page 19 6. Air Purging Indoor unit Air and moisture remaining in the refrigerant system have undesirable effects as indicated below. Therefore, they must be purged completely. pressure in the system rises operating current rises cooling (or heating) efficiency drops Outdoor unit moisture in the air may freeze and block capillary tubing water may lead to corrosion of parts in the refrigerant system Air Purging with a Vacuum Pump (for Test Run) (
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05-424 KS0971-1271 12/13/05 1:28 PM Page 20 (5) With the vacuum pump still running, close the “Lo” knob of the manifold valve. Then stop the vacuum pump. 90° (1/4 turn) Narrow tube (6) With the accessory hex wrench, turn the valve stem on the narrow tube service valve counter-clockwise Hex wrench by 90 degrees (1/4 turn) for 10 seconds, and then turn the stem clockwise to close it again. (Fig. 58) Wide tube Be sure to completely insert CAUTION the hex wrench before attempting to turn the valv
