Sanyo Automobile Accessories CH2442 User Guide

INSTALLATION INSTRUCTION

— Split System Heat Pump Air Conditioner —

Model Combinations

Combine indoor and outdoor units only as listed below.

Indoor Units and Outdoor Units

Indoor Units Type

4-Way Air Discharge

XH2442

XH3642

XH4242

Semi-Concealed

(PNR-XH2442)

(PNR-XH3642)

(Matching Ceiling Panel)

Wall-Mounted

KH2442

TH2442

UH2442

KH3642

TH3642

UH3642

Ceiling-Mounted

TH4242

CH4242

Concealed-Duct

Outdoor Units

CH3642

CH2442

(WD)

Wired Remote Controller

Wireless Remote Controller

RCS-SH80UG (Optional part )

Built-in type: RCS-SH80UA.WL (Optional part )

External type: RCS-BH80UA.WL (Optional part )

(WL)

Weekly Timer

TM-SH80UG (Optional part )

SHA-KC64UG (Optional part )

System Controller

OPERATING LIMITS

■ Maximum Conditions Cooling

Outdoor temperature : 115°F DB

Room temperature : 71°F WB

■ Minimum Conditions

Heating

65°F WB

80°F DB

Outdoor temperature : 23°F (0°F)* DB / 15°F WB

Room temperature : 57°F WB

59°F DB

* When air discharge chamber is installed.

Units should be installed by licensed contractor according

to local code requirements.

SANYO FISHER COMPANY

In Canada

A DIVISION OF SANYO NORTH

AMERICA CORPORATION

21605 Plummer Street

SANYO Canada Inc.

300 Applewood Crescent

Concord, Ontario

L4K 5C7, Canada

85464359146001 © SANYO 2001

Chatsworth, CA91311

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CONTENTS

Page

3-25. Checking the Drainage

3-26. Increasing the Fan Speed

IMPORTANT

Please Read Before Starting

4. HOW TO INSTALL THE OUTDOOR UNIT ................ 40

1. GENERAL ................................................................... 4

4-1. Removing the Protective Spacer for Transportation

4-2. Installing the Outdoor Unit

1-1. Tools Required for Installation (Not Supplied)

1-2. Accessories Supplied with Unit

4-3. Tubing Direction

1-3. Type of Copper Tube and Insulation Material

1-4. Additional Materials Required for Installation

1-5. Tubing Length

5. ELECTRICAL WIRING ............................................. 41

5-1. General Precautions on Wiring

5-2. Recommended Wire Length and Wire Diameter

for Power Supply System

2. SELECTING THE INSTALLATION SITE .................. 10

Indoor Unit

5-3. Wiring System Diagrams

Outdoor Unit

5-4. How to Connect Wiring to the Terminal

2-1. Air Discharge Chamber for Top Discharge

2-2. Installing the Outdoor Unit in Heavy Snow Areas

2-3. Precautions When Installing in Heavy Snow Areas

2-4. Dimensions of Snow / Wind-proof Ducting and

Refrigerant Tubing Space for Installation

6. HOW TO INSTALL THE WIRED REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 45

6-1. Installation site selection

6-2. Wired Remote Controller Installation

6-3. Basic Wiring Diagram

3. HOW TO INSTALL THE INDOOR UNIT.................... 14

6-4. Wiring System Diagram for Group Control

6-5. Wiring System Diagram for Multiple Remote

Control

■

4-Way Air Discharge Semi-Concealed Type

(XH Type)................................................................... 14

3-1. Suspending the Indoor Unit

6-6. How to Switch the Indoor Temperature Sensor

6-7. Explanation of Alarm Messages

3-2. Preparation for Suspending

3-3. Placing the Unit Inside the Ceiling

3-4. Installing the Drain Piping

7. HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER

(OPTIONAL PART) .................................................... 52

7-1. Wireless Remote Controller Installation

7-2. Room Temperature Sensor Setting

7-3. Address Switches

3-5. Checking the Drainage

3-6. Before Installing the Ceiling Panel

3-7. Installing the Ceiling Panel

3-8. When Removing the Ceiling Panel for Servicing

3-9. Duct for Fresh Air

7-4. Setting the Model Code

■

Wall-Mounted Type (KH Type) ................................... 22

3-10. Removing the Wall Fixture from the Unit

3-11. Selecting and Making a Hole

3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

<RCS-SH80UA. WL>

■

4-Way Air Discharge Semi-concealed Type

(XH Type)................................................................... 54

7-5. Indicator section Installation

7-6. Operating Controller Installation

3-13. Removing the Casing to Install the Indoor Unit

3-14. Preparing the Indoor Side Tubing

3-15. Wiring Instructions

■

Ceiling Mounted Type (TH Type)......................... 55

7-7. Indicator Section Installation

7-8. Operating Controller Installation

7-9. Electrical Wiring

3-16. Wiring Instructions for Inter-Unit Connections

3-17. Shaping the Tubing

7-10. Test Run Switch

3-18. Installing the Drain Hose

7-11. Misoperation Alarm Indicators

<RCS-BH80UA.WA>

■

Ceiling-Mounted Type (TH Type). .............................. 31

3-19. Suspending the Indoor Unit

3-20. Duct for Fresh Air

7-12. Separate type Signal Receiving Unit Installation

7-13. Electrical Wiring

3-21. Installing the Drain Piping

7-14. Test Run Switch

7-15. Misoperation Alarm Indicators

7-16. Basic Wiring Diagram

Concealed-Duct Type (UH Type) ............................... 35

3-22. Required Minimum Space for Installation and Service

3-23. Suspending the Indoor Unit

7-17. Wiring System Diagram for Group Control

7-18. Wiring System Diagram for Multiple

3-24. Installing the Drain Piping

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Page

8. HOW TO INSTALL THE WEEKLY TIMER

(OPTIONAL PART) ................................................... 65

8-1. Mounting Dimensions for Continuous Installation

8-2. When Using a Wall Box for Flush Mounting

8-3. Wiring Diagram

8-4. Test Run Setting

8-5. Memory Back Up Function for Power Failure

Compensation

9. HOW TO INSTALL THE SYSTEM CONTROLLER

(OPTIONAL PART) ................................................... 67

9-1. System Controller Installation

9-2. Electrical Wiring

9-3. Address Switch Setting

9-4. Mode Setting

9-5. How to Perform Zone Registration

9-6. Connection with Other Equipments

9-7. Memory Back Up Switch

9-8. Test Run

10. HOW TO PROCESS TUBING .................................. 79

10-1. Use of the Flaring Method

10-2. Flaring Procedure with a Flare Tool

10-3. Precaution before Connecting Tubes Tightly

10-4. Precautions during Brazing

10-5. Connecting Tubing between Indoor and Outdoor

Units

10-6. Insulating the Refrigerant Tubing

10-7. Taping the Tubes

10-8. Finishing the Installation

11. AIR PURGING .......................................................... 82

12. TEST RUN ................................................................ 85

12-1. Preparing for Test Run

12-2. PCB Setting

12-3. R.C. Address Setting Method

12-4. Automatic Address Setting Method

12-5. Displaying Indoor / Outdoor Unit Combination

Numbers

12-6. Test Run Procedure

12-7. Items to Check Prior to Test Run

12-8. The Main Alarms of Mis-wiring & Mis-setting

12-9. The Main Alarms of Unit Troubles

12-10. The Main Alarms of Power Supply Troubles

13. PUMP DOWN............................................................ 93

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1. GENERAL

Check local electrical codes

and regulations before

obtaining wire. Also, check

any specified instructions or

limitations.

CAUTION

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.

1-4. Additional Materials Required for Installation

1-1. Tools Required for Installation (Not Supplied)

1. Standard screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire

(See your local codes.)

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

5. 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

See Table 1-1 to 1-9.

Table

1-1

1-2

1-3

1-4

1-5

1-6

1-7

1-8

1-9

Type

4-Way Air Discharge Semi-Concealed

Wall-Mounted

Ceiling-Mounted

Concealed-Duct

Outdoor Unit

Wired Remote Controller

Wireless Remote Controller

Weekly Timer

System Controller

1-3. Type of Copper Tube and Insulation Material

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.

If you wish to purchase these materials separately

from a local source, you will need:

1. Deoxidized annealed copper tube for refrigerant

tubing.

2. Foamed polyethylene insulation for copper tubes as

required to precise length of tubing. Wall thick-

ness of the insulation should be not less than 5/16 in..

3. Use insulated copper wire for field wiring. Wire

size varies with the total length of wiring. Refer to

Section 5. “Electrical Wiring” for details.

S4359146

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Table 1-1 XH (4-Way Air Discharge Semi-Concealed)

Part Name

Full-scale installation diagram

Flare insulator

Washer

Figure

Q’ty

Remarks

For determining suspension bolt pitch

For wide and narrow tubes

For suspending indoor unit from ceiling

(White)

For wide tube flare nuts

For securing drain hose

For drain joint

Insulating tape

Hose band

Packing

Drain insulator

Drain hose

For drain joint

For drain outlet

Drain hose adaptor

Sealing putty

For sealing recessed portion of power supply

For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Tube connector

Table 1-2 KH (Wall-Mounted)

Part Name

Figure

Q’ty

Remarks

For supporting the indoor unit

Wall fixture *1

Insulator *1

For insulation of the tubing of the indoor unit

For securing the indoor unit

(WD)

Mounting plate *1

Tapping screw *1

Full-scale diagram

Wall fixture *2

Rawl plug *2

(WL)

Truss-head

Phillips

4 × 1 in.

For fixing the wall fixture

For determining the place where the indoor unit is

installed

For supporting the indoor unit

10 For fixing the wall fixture

Cover *2

For improved tubing appearance

Truss-head

Phillips

4 × 5/8 in.

Tapping screw *2

10 For fixing the wall fixture

Insulator

For insulation of the tubing of the indoor unit

For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Tube connector

* 1 KH3642 only

* 2 KH2442 only

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Table 1-3 TH (Ceiling-Mounted)

Part Name

Special washer

Figure

Q’ty

Remarks

For temporarily suspending

indoor unit from ceiling

Drain insulator

For drain hose joint

Flare insulator

1 Set For wide tube joints

Drain hose adaptor

Drain hose clamp

Black

White

For wide tube and drain hose joint

For wide flare joints

Insulating tape

(heat-resisting)

Vinyl clamp

For ends of flare insulator

Full-scale installation

diagram

For determining suspension

bolt pitch

Sealing putty

Drain hose

For sealing recessed portion of power supply

For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Tube connector

Table1-4 UH (Concealed-Duct)

Part Name

Figure

Q’ty

Remarks

Flare insulator

For wide and narrow tubes

For wide and narrow tube flare nuts

(Black)

(White)

Insulating tape

Tapping screw TOTA4-10

Jumper cable*

Hose band

14 or 20 or 24 For air intake duct connection

For increasing the fan speed

For securing drain hose

For drain joint

Packing

Sealing putty

Drain insulator

Drain hose

For sealing recessed portion of power supply

For drain joint

Drain hose adaptor

Clamp

For securing drain hose & refrigerant tubing

For sizing up of narrow tube from 1/4 in. to 3/8 in.

(only for 24 type)

Tube connector

Jumper cable is housed inside the electrical component box.

Table 1-5 (Outdoor Unit)

Part Name

Figure

Q’ty

Remarks

Hexagonal Wrench

Grommet

To open and shut the Narrow Tube Service Valve

For protecting refrigerant pipe by attaching to the

edge of Tubing Outlet

For protecting inter-unit control line by attaching to

the edge of wiring outlet

Bushing

Installation Instruction

Owner’s manual

S4359146

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Table 1-6 (Accessories for the Wired Remote Controller)

Part Name

Figure

Q’ty

Part Name

Figure

Q’ty

Wired remote controller

(comes with 7-7/8 in. wire)

Spacers

Machine screws

M4 × 1 in.

Wire joints

Wood screws

Table 1-7 (Accessories for the Wireless Remote Controller)

<RCS-SH80UA.WL>

Part Name

Figure

Q’ty

Part Name

Figure

Q’ty

Operation controller

Spacers

Run

Timer Heating preparations

Pan-head tapping screws

4 × 13/32 in.

Indicator section

Truss-head tapping screws

4 × 5/8 in.

Wireless remote controller

(WD)

Wireless remote controller

mounting cradle

Vinyl clampers

L 5-29/32

(WL)

Batteries

Wire joints

<RCS-BH80UA.WL>

Part Name

Figure

Q’ty

Part Name

Figure

Q’ty

Small screws

Separate type signal receiving unit

(comes with 7-7/8 in. wire)

M4 × 1-9/16 in.

Carrier for ceiling installation

Wireless remote controller

Wood screws

Spacers

Wireless remote controller

mounting cradle

Wire joints

Batteries

Clamper

Ceiling installation paper pattern

Machine screws

M4 × 1 in.

(

3-3/4 × 2-1/32 in.)

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Table 1-8 (Accessories for the Weekly Timer)

Part Name Figure

Weekly timer

Q’ty

Part Name

Wood screws

Figure

Q’ty

Connecting wiring

length 4 ft.

Spacers

Machine screws

M4 × 1 in.

Clampers

Table 1-9 (Accessories for the System Controller)

Part Name

System controller

Figure

Q’ty

Part Name

Figure

Q’ty

SYSTEM CONTROLLER IDENTIFICATION LABEL

ALL Central Control

ZONE1 Central Control

ZONE2 Central Control

ZONE3 Central Control

ZONE4 Central Control

ALL RCU.

ZONE1 RCU.

ZONE2 RCU.

ZONE3 RCU.

ZONE4 RCU.

Label

(Identification label)

*Please attach this label on surface of the lid after cleaning.

*If need to write down some detail, use magic marker.

ALL ON

INPUT

Inter-

unit

control

wiring

ALL OFF

INPUT

Label

(Terminal base label)

Rubber bushing

(7/8 in.)

COMMON

INPUT

U2 Aux.

UNUSED

OPERATION

STATE

OUTPUT

ALARM

OUTPUT

DC12V

FROM

INDOOR

UNIT PCB.

COMMON

OUTPUT

Screws for fixture

(1-3/16 in.)

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1-5. Tubing Length

● Refrigerant tubing between the indoor and

outdoor units should be kept as short as

possible.

Tubing length (L)

INDOOR

UNIT

● Select and decide the installation location so

that the length of the refrigerant tubing will be

within the limits given in Table 1-10.

Elevation difference (H)

OUTDOOR

UNIT

0711_M_I

Fig. 1-1

Table 1-10

Models

Narrow tube in. (mm)

CH2442

CH3642, CH4242

Tubing Data

1/4 (6.35)

3/4 (19.05)

165

3/8 (9.52)

3/4 (19.05)

165

Tubing size

outer dia.

Wide tube

in. (mm)

(ft.)

Limit of tubing length

Outdoor unit is higher

Limit of elevation

difference between

the 2 units

165

100

165

100

than indoor unit

(ft.)

Outdoor unit is lower

than indoor unit

(ft.)

Max. allowable tubing length at shipment (ft.)

Required additional refrigerant (oz./ft.)

100

0.48^*1

100

0.53^*2

(WD)

No additional charge of compressor oil is necessary.

If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.48 oz./ft..

If total tubing length becomes 100 to 165 ft., charge additional refrigerant (R22) by 0.53 oz./ft..

(WL)

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2. SELECTING THE INSTALLATION SITE

Indoor Unit

AVOID:

Ceiling-Mounted Type

Ceiling

● areas where leakage of flammable gas may be

expected.

● places where large amounts of oil mist exist.

Wall

● direct sunlight.

Min.10 inch

● locations near inverter lamps which may affect

Front view

performance of the unit.

NOTE

The rear of the indoor unit can be installed flush

against the wall.

● locations near heat sources which may affect

Ceiling

Air

performance of the unit.

discharge

● locations where external air may enter the room

directly. This may cause “sweating” on the air

discharge ports, causing them to spray or drip.

Air intake

Min.2 ft.

● locations where the remote control unit will be

splashed with water or affected by dampness or

humidity.

Side view

1091_T_I

● installing the remote control unit behind curtains or

furniture.

4-Way Air Discharge Type

Concealed-Duct Type

● locations where the receiver in the indoor unit is

exposed to the inverter lamp light. Faulty operation

of the unit occurs.

DO:

● select an appropriate position from which every

corner of the room can be uniformly cooled.

● select a location where the ceiling is strong enough

to support the weight of the unit.

● select a location where tubing and drain pipe have

the shortest run to the outdoor unit.

Wall-Mounted Type

● allow room for operation and maintenance as well

as unrestricted air flow around the unit.

● install the unit within the maximum elevation

difference above or below the outdoor unit and

within a total tubing length from the outdoor unit as

detailed in Table 1-10.

Min.

6 inch

Min.

6 inch

Min.

12 inch

● allow room for mounting the remote control unit

about 3 ft. off the floor, in an area that is not in

direct sunlight nor in the flow of cool air from the

indoor unit.

0930_K_I

NOTE

● Air delivery will be degraded if the distance from the

floor to the ceiling is greater than 10 ft..

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Exhaust fan

Outdoor Unit

AVOID:

Hot air

Heat source

Out-

door

unit

● heat sources, exhaust fans, etc. (Fig. 2-1)

● damp, humid or uneven locations.

0591_C_I

DO:

Fig. 2-1

● choose a place as cool as possible.

● choose a place that is well ventilated and outside

air temperature does not exceed maximum 115°F

constantly.

Obstacle above

Min.

1 inch

Min.

1 inch

Min.

7 ft.

● allow enough room around the unit for air intake/

4 in.

exhaust and possible maintenance. (Fig. 2-2)

Air

dis-

charge

● provide a solid base; about 6 inch above ground

level to reduce humidity and possible water damage

in the unit and decreased service life. (Fig. 2-3)

● use lug bolts or equivalent to bolt down unit,

reducing vibration and noise.

Min. 2 ft.

0931_C_I

Ground

0932_C_I

Fig. 2-2

(WD)

In case of multiple installations

Unit spacing if air discharge chamber is not used.

Unit spacing when air discharge chamber is used.

Min. 8 inch

Min. 4 ft.

Min. 5 ft.

Min. 1 ft.

Min. 4 ft.

Min. 1 ft. 2 inch

Air

discharge

chamber

(WL)

Min. 12 ft.

Min. 1 ft.

Min. 8 inch

Min. 1 ft.

If you would like to make the separation smaller on the air

discharge side, use an air discharge chamber.

You can install any number of units side-by -side.

Only up to 3 units can be installed side-by-side under the above

conditions. The next group must be spaced at least 1 ft. away

from the first group.

0933_C_S

Air in

Air

discharge

Concrete block

4 inch × 1 ft. 4 inch

beams or equal

Min. 6 inch

Anchor bolts

(4 pieces)

0934_C_I

Fig. 2-3

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2-1. Air Discharge Chamber for Top Discharge

Air discharge

Install the air-discharge chamber in the field when:

● it is difficult to keep a space of minimum 2 ft.

between the air-discharge outlet and the obstacle.

● the air-discharge outlet is facing the sidewalk and

discharge hot air can annoy the passers-by.

Refer to Fig. 2-4.

0426_C_I

22-5/16"

Recommended outer dimensions of wind shield

(field supply)

11-13/16"

3 - ø1-9/16" hole

21-13/16"

6 - ø15/64" hole

1-7/32"

9-27/32"

5-5/32"

23-5/16"

21-13/16"

0936_C_I

1352_C_I

CH3642

CH2442

Fig. 2-4

2-2. Installing the Outdoor Unit in Heavy Snow

Areas

In locations subject to strong winds, snow-proof

ducting should be fitted and direct exposure to the

wind should be avoided as much as possible.

The following problems may occur when the outdoor

unit is not provided with a platform and snow-proof

ducting.

a) The outdoor fan may not run and there may be

damage to the unit

b) There may be no air flow.

c) The tubing may freeze and burst.

d) The condenser pressure may drop because of

strong wind, and the indoor unit may freeze.

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2-3. Precautions When Installing in Heavy Snow

Areas

(1) The platform should be higher than the maximum.

snow depth. (Fig. 2-5)

In regions with snow fall, the outdoor unit should be

provided with a platform and snow-proof duct.

(2) The two anchoring feet of the outdoor unit should

be attached to the platform, and the platform

should be installed beneath the air-intake side of

the outdoor unit.

(3) The platform foundation must be solid and the

unit must be secured with anchor bolts.

(4) When installing on a roof subject to strong wind,

countermeasures must be taken to prevent the

unit from being overturned.

Without snow-

proof ducting

(Low platform)

Snow-proof

ducting

(High platform)

2-4. Dimensions of Snow / Wind-proof Ducting

and Refrigerant Tubing Space for Installation

0937_C_I

Fig. 2-5

Fig. 2-6

Min. 4"

Outdoor

Unit

12"

Duct

12"

Outdoor Unit

Duct

(WD)

Duct

Min. 4"

Unit: inch

1117_C_I

Higher than the

maximum

snow depth

(WL)

Air

Intake

Air

Intake

Platform (foundation)

About 1/2 of the

unit height

0488_C_I

Fig. 2-7

Example of Installation

0490_C_I

Fig. 2-8

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3. HOW TO INSTALL THE INDOOR UNIT

■

4-Way Air Discharge Semi-Concealed Type

(XH Type)

Hole-in-anchor

Hole-in-plug

3-1. Suspending the Indoor Unit

Concrete

Insert

This unit uses a drain pump. Use a carpenter’s level to

check that the unit is level.

3-2. Preparation for Suspending

(1) Fix the suspension bolts securely in the ceiling

using the method shown in the diagrams (Figs.

3-1 and 3-2), by attaching them to the ceiling

support structure, or by any other method that

ensures that the unit will be securely and safely

suspended.

Suspension bolt (M10 or 3/8")

(field supply)

0038_T_I

Fig. 3-1

(2) Follow Fig. 3-2 and Table 3-1 to make the holes

in the ceiling.

A (Ceiling opening)

(Suspention bolt pitch)

Drain hose

side

Table 3-1

Unit: inch (mm)

Length

Type

Grille center

XH1242, XH1842 , XH2442

(PNR-XH2442)

32-9/32 (820) 22-9/32 (566)

43-11/16 (1,110) 33-11/16 (856)

XH3642, XH4242

(PNR-XH3642)

Refrigerant

tubing side

1969_X_S

(3) Determine the pitch of the suspension bolts using

the supplied full-scale installation diagram. The

diagram and table (Fig. 3-3 and Table 3-2) show

the relationship between the positions of the

suspension fitting, the unit, and the panel.

Fig. 3-2

Drain connection (another side)

(VP25)

Refrigerant tubing joint (wide tube side)

Refrigerant tubing joint

(narrow tube side)

Suspension lug

1970_X_S

Fig. 3-3

Table 3-2

Unit : inch (mm)

Length

Type

XH1242, XH1842, XH2442 6-3/16

7-5/32 10-9/32 12-1/8

(182) (261) (308)

7-5/32 11-15/32 13-1/16

4-7/8

(124)

4-7/8

(124)

(PNR-XH2442)

XH3642, XH4242

(PNR-XH3632)

(157)

6-3/16

(157)

(182)

(291)

(338)

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3-3. Placing the Unit Inside the Ceiling

(1) When placing the unit inside the ceiling, deter-

mine the pitch of the suspension bolts using the

supplied full-scale installation diagram. (Fig. 3-4)

The size of the opening for the indoor unit can be

confirmed by attaching the full-scale installation

diagram beneath the unit. (Fig. 3-4)

Full-scale installation diagram

(printed on a cardboard packing)

Tubing and wiring must be laid inside the ceiling

when suspending the unit. If the ceiling is already

constructed, lay the tubing and wiring into posi-

tion for connection to the unit before placing the

unit inside the ceiling.

Full-scale installation

diagram

2040_X_I

Fig. 3-4

(2) The length of suspension bolt must be appropri-

ate for a distance between the bottom of the bolt

and the bottom of the ceiling of 19/32 in. or more

as shown in Fig. 3-4.

Suspension bolt

Suspension lug

Nuts and washers

(3) Thread the 2 hexagonal nuts (field supply) and

washers onto the 4 suspension bolts as shown in

Fig. 3-5.

(Use above and below)

Upper

Lower

Use 2 sets of nuts and washers (upper and

lower), so that the unit will not fall off the suspen-

sion lugs.

Notch

Double nuts

1-7/8 inch

(4) Remove the protective cardboard used to protect

the fan parts during transport.

1971_X_I

Fig. 3-5

(5) Adjust the distance between the unit and surface

of the ceiling. (1-7/8 in.) (Fig. 3-4)

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3-4. Installing the Drain Piping

Transparent part for

checking drainage

Hard PVC pipe

(not supplied)

Hose band

(supplied)

(1) Prepare standard hard PVC pipe for the drain and

use the supplied drain hose and hose band to

prevent water leaks.

The PVC pipe must be purchased separately.

The transparent part allows you to check drain-

age. (Fig. 3-6)

Drain hose

Packing

(supplied)

Drain hose

(supplied)

adapter

(supplied)

0964_X_I

Tighten the hose clamps

Fig. 3-6

CAUTION

so their locking nuts face

upward. (Fig. 3-6)

Drain insulator (supplied)

(2) After checking the drainage, wrap the supplied

packing and drain pipe insulator around the pipe.

(Fig. 3-7)

NOTE

Ensure the drain pipe has a downward gradient

(1/100 or more) and that there are no water traps.

0197_X_I

Fig. 3-7

● Do not install an air

Air bleeder

CAUTION

bleeder tubes, as this

may cause water to spray

from the drain tube outlet.

(Fig. 3-8)

0047_X_I

● If it is necessary to increase the height

of the drain pipe, the section directly

after the connection port can be raised

a maximum of 19-11/16 in. Do not raise

it any higher than 19-11/16 in., as this

could result in water leaks.

Fig. 3-8

11-3/4 in. or less (as short as possible)

19-11/16 in. or less

(Fig. 3-9)

● Do not install the pipe with an upward

gradient from the connection port. It

will cause the drain water to flow

backwards and leak when the unit is

stopped. (Fig. 3-10)

1972_X_I

Fig. 3-9

Upward gradient

● Do not apply force to the piping on the

unit side when connecting the drain

pipe. The pipe should not be allowed

to hang unsupported from its connec-

tion to the unit. Fasten the pipe to a

wall, frame, or other support as close

to the unit as possible. (Fig. 3-11)

0049_X_I

Fig. 3-10

● Provide insulation for any drain pipes

that are installed indoors.

Support

pieces

0050_X_I

Fig. 3-11

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3-5. Checking the Drainage

After wiring and piping are completed, use the follow-

ing procedure to check that the water will drain

smoothly. For this, prepare a bucket and wiping cloth

ready to catch and wipe up spilled water.

Do not supply power to the

unit until the tubing and

wiring to the outdoor unit

are completed.

(1) Take off the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain

pan to check drainage.

(2) Do Test Run to check the drainage after complet-

ing installation. When performing Test Run, be

sure to observe the Test Run procedure.

Refer to page 89.

Be careful since the fan will

CAUTION

start turning when checking

the drainage.

5/16"(4 × 8 mm)

tapping screw

(3) After drain checking is finished, return the

Operation Selector switch to the RUN position

(ON position) and remount the tube cover.

To mount the tube cover,

CAUTION

use 5/16" (4 × 8 mm) tapping

Tube cover

screws. Do not use long

screws as they may punc-

ture the drain pan and cause

water leakage.

Siphon

0966_X_I

Fig. 3-12

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■

Ceiling Panel

Never touch or attempt to

move the air direction louver

by hand or you may damage

the unit. Instead, use the

remote control unit if you

want to change the direction

or air flow.

CAUTION

3-6. Before Installing the Ceiling Panel

(1) Remove the air-intake grille and air filter from the

ceiling panel. (Figs. 3-13 and 3-14)

(a) Remove the 2 screws on the latch of the air-

intake grille. (Fig. 3-13)

Screw

(b) Press on the 2 latches of the air-intake grille

with your thumb in the direction of the arrow

to open the grille. (Fig. 3-13)

Latch

remove the safety string (hook on the grille

side). (Fig. 3-14)

Air intake grille

(d) Pull the air-intake grille towards you to

remove it from the ceiling panel.

(2) Pull down the two panel catches on the body of

the indoor unit body. (Fig. 3-15)

Ceiling panel

0149_X_I

Fig. 3-13

Air filter

45°

Safety string

0150_X_I

Fig. 3-14

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3-7. Installing the Ceiling Panel

(1) Lift the ceiling panel and position it to align the

panel hook with the panel catch of the indoor unit.

(5) Install the air filter and air-intake grille by perform-

ing the steps in section 3-6 in reverse.

NOTE

The ceiling panel must be mounted in the correct

direction. Note that the 2 catches of the panel differ in

size.

Rehook the safety string before closing the air-intake

grille.

Confirm that the catches are correctly matched be-

tween the ceiling panel and the indoor unit body.

3-8. When Removing the Ceiling Panel for

Servicing

(2) Next, check to see that the ceiling panel is prop-

erly aligned with the seamline of the ceiling. If it is

not, remove the ceiling panel and slightly readjust

the indoor unit body to the proper suspension

point.

When removing the ceiling panel for servicing, remove

the air-intake grille and air filter, disconnect the wiring

connector inside the electrical component box, and

then remove the 4 mounting screws.

(3) When the ceiling panel has been properly

aligned, use the supplied 4 mounting screws (M5)

with washers to permanently fasten the ceiling

panel.

(4) Install the wiring connector from the ceiling panel

to the connector in the electrical component box

of the indoor unit. After installing the connector,

use the clamp on the body of the indoor unit to

secure the wiring.

Unit body

Ceiling panel

Panel catch

Electrical

component box

(arrange facing downwards)

(2 locations)

Electrical

component box

Clamp

Ceiling panel wiring

connector

Screws M5 with washer

(supplied)

Air filter

Air-intake grille

1973_X_I

Fig. 3-15

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3-9. Duct for Fresh Air

For fresh air intake

● There is a duct connection part on sideface of the

indoor unit. (Fig. 3-16)

● Optional air-intake plenum (including duct connection

box and flange) can be attached to the indoor unit.

Air-intake plenum

CMB-GSJ80U

Type

PNR-XH2442

(XH1242, XH1842, XH2442)

PNR-XH3642

(XH3642, XH4242)

CMB-GSJ140U

2-5/32

Detail of fresh air intake

(1) Accessories

1974_X_S

● Check that the following parts are in the box when unpacking.

Fig. 3-16

NAME

Cord with socket

(9P)

QT’Y

REMARKS

Connecting line. Not necessary for

intaking fresh air.

Screw

(M5 × L5 in.)

Air-intake filter

(for fastening)

Screw

(M4 × L1/2 in.)

Duct connection flange/ box

(for fastening)

Duct connection box

(for fresh air)

)

(for connecting fresh air duct

Duct connection flange

(2) Installation

●

Installation steps (a) to (e) are the same for both the

CMB-GSJ80U and the GSJ140U. The drawing

illustrates installation of air-intake plenum to the

CMB-GSJ80U.

Installation

screws

Socket cover

Panel lead wire (8P)

(a) Installing the air-intake plenum

● Set the air-intake plenum to the indoor unit taking

care not to set the incorrect direction. (Fig. 3-17)

● Fasten the air-intake plenum with the accessory

screws. (M5 × L5 in., 4pcs) (Fig. 3-17)

Clamper

(b) Installing the duct connection box

● Fasten the duct connection flange to the duct

connection box with the accessory screws.

(M4 × L1/2 in., 4pcs) (Fig. 3-18)

Air-intake

plenum

8P socket (red)

(electrical

component box)

● Put the duct connection box into the rectangular

hole of the air-intake plenum and fasten it to the

both sides of the indoor unit and plenum with the

accessory screws. (M4 × L1/2 in., 3pcs) (Fig. 3-18)

8P socket (red)

(ceiling panel side)

● Install the indoor unit to the ceiling.

(Install the indoor unit according to items 3-1 to 3-6.)

Indoor unit

When installing in a pre-

existing location, install the

indoor unit before installing

the duct connection box.

CAUTION

1975_X_S

Fig. 3-17

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(e) Installing the ceiling panel

Duct

connection

flange

● Attach the ceiling panel to the chamber.

Drawing the panel downwards sets the panel in

position temporarily with the panel catch (at 2

locations).

Duct connection box

Installation screws

(M4 × 1/2 in.)

● Remove the socket cover of the air-intake plenum

and pass the 8P sockets through it. (Fix the panel

lead wire to chamber side clamper.) (Fig. 3-17)

● Connect the 8P socket (electrical component box

side) to the 8P socket (ceiling panel side) of the

indoor unit electrical component box.

Panel catch

● Reattach the socket cover.

Ceiling panel

1976_X_S

Fig. 3-18

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■ Wall-Mounted Type (KH Type)

3-10. Removing the Wall Fixture from the Unit

Wall fixture

KH2442

Remove and discard the set screws and take off the

wall fixture. (Fig. 3-19)

Set screws only for transportation

1390_T_I

3-11. Selecting and Making a Hole

Fig. 3-19

KH2442

Tape

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is

horizontal, using a level or tape measure to

measure down from the ceiling. (Fig. 3-20)

Full-scale installation diagram

(2) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

0940_T_I

CAUTION

wiring or conduit is located.

Also take this precaution if

the tubing goes through a

wall at any other location.

Fig. 3-20

NOTE

(3) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the

wall. The required minimum hole diameter for

these models is 3-3/16 in. (Fig. 3-21)

Hole should be made at a slight downward slant to the

outdoor side.

Indoor

side

Outdoor

side

(4) Measure the thickness of the wall from the inside

edge to the outside edge and cut PVC pipe at a

slight angle 1/4 in. shorter than the thickness of

the wall. (Fig. 3-22)

0066_T_I

(5) Place the plastic cover over the end of the pipe,

(for indoor side only) and insert in the wall.

(Fig. 3-23)

Fig. 3-21

PVC pipe (locally purchased)

Cut at slight angle

0941_T_I

Fig. 3-22

INSIDE

OUTSIDE

PVC pipe

Wall

Plastic

cover

Slight

angle

0942_K_I

Fig. 3-23

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KH3642

One hole is required for the air conditioner tubing, and

may be either on the left or right side. (Also see sec-

tion 3-14. Preparing the Indoor Side Tubing.)

Tape

Full scale

installation diagram

(1) Tape the full-scale installation diagram on the

wall at the location selected. Make sure the unit is

horizontal, using a level or tape measure to

measure down from the ceiling. (Fig. 3-24)

1354_T_I

Fig. 3-24

(2) Determine if the hole is to be drilled at the left or

right hole location.

(3) Before drilling a hole, check that there are no

studs or pipes behind the determined location.

Avoid area where electrical

wiring or conduit is located.

Also take this precaution if

the tubing goes through a

wall at any other location.

CAUTION

(4) Using a sabre saw, key hole saw or 3-5/32 in.

hole-cutting drill attachment, make a hole in the

wall. The required minimum hole diameter for

these models is 3-3/16 in. (Fig. 3-25)

NOTE

Hole should be made at a slight downward slant to the

outdoor side.

(5) Measure the thickness of the wall from the inside

edge to the outside edge and cut PVC pipe at a

slight angle 1/4 in. shorter than the thickness of

the wall. (Fig. 3-26)

Indoor

side

Outdoor

side

(6) Place the plastic cover over the end of the pipe,

(for indoor side only) and insert in the wall.

(Fig. 3-27)

0066_T_I

Fig. 3-25

PVC pipe (locally purchased)

Cut at slight angle

0941_T_I

Fig. 3-26

INSIDE

OUTSIDE

PVC pipe

Wall

Plastic

cover

Slight

angle

0942_K_I

Fig. 3-27

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3-12. Installing the Wall Fixture onto Wooden or

Gypsum Wall

wall fixture

KH2442

Confirm that the wall is strong enough to support the unit.

a) If the Wall is Wooden

(1) Attach the wall fixture to the wall with the 9

screws provided. (Fig. 3-28)

0943_T_I

Fig. 3-28

If you are not able to line up the holes in the wall

fixture with the beam locations marked on the

wall, use rawl plugs or toggle bolts to go through

the holes on the panel or drill 13/64 in. dia. holes

in the panel over the stud locations and then

mount the wall fixture.

3/16 in.

dia. hole

Rawl plug

(2) Check with a tape measure or carpenter’s level.

This is important so that the unit is correctly

installed.

0944_T_I

(3) Make sure the wall fixture is flush against the

wall. Any space between the wall and unit will

cause noise and vibration.

Fig. 3-29

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for

appropriate mounting screws. (Fig. 3-29)

KH3642

Confirm that the wall is strong enough to support the unit.

Wall fixture

a) If the Wall is Wooden

(1) Attach the wall fixture to the wall with the 12

screws provided. (Fig. 3-30) If you are not able to

line up the holes in the wall fixture with the beam

locations marked on the wall, use rawl plugs or

toggle bolts to go through the holes on the panel

or drill 3/16 in. dia. holes in the wall fixture over

the stud locations.

1355_M_I

Fig. 3-30

(2) Check with a tape measure or carpenter’s level

that the wall fixture is level. This is important so

that the unit is correctly installed.

(3) Make sure the wall fixture is flush against the

wall. Any space between the wall and unit will

cause noise and vibration.

b) If the Wall is Brick, Concrete or Similar

Drill 3/16 in. dia. holes in the wall. Insert rawl plugs for

appropriate mounting screws. (Fig. 3-29)

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3-13. Removing the Casing to Install the Indoor Unit

KH2442

How to Remove the Casing

(1) Remove the plastic cover. (Fig. 3-31)

(2) Remove the clamp for the wiring connector.

(Fig. 3-32)

Plastic cover

(3) Disconnect the wiring connector. (Fig. 3-33)

(4) Set the flap in the horizontal position. (Fig. 3-34)

(5) Remove the 3 screws. (Fig. 3-34)

Screw

0945_T_I

(6) Remove the casing. (Fig. 3-34)

Fig. 3-31

NOTE

When replacing the casing, be careful not to crush

the lead wires between the casing and the frame.

(Fig. 3-34)

Clamp

Fig. 3-32

Screw

2023_T_I

Casing

Frame

Flap

Wiring

connector

Screws

0947_T_I

Fig. 3-34

Fig. 3-33

2024_T_I

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Left

tubing

3-14. Preparing the Indoor Side Tubing

Right-rear

tubing

(Recommended)

Left-rear

tubing

KH2442

Tubing can be extended in 4 directions as shown in

Fig. 3-35.

Right tubing

Arrangement for Left Tubing

Fig. 3-35

0949_T_I

(a) Cut out the left tubing outlet. (Fig. 3-36)

Arrangement for Right Tubing

(a) Cut out the right tubing outlet using a hacksaw.

(Fig. 3-37)

Right tubing

outlet

Left tubing

Arrangement for Left-rear and Right-rear Tubing. _outlet

(a) It is not necessary to cut a hole.

0951_T_I

Fig. 3-37

Fig. 3-36

0950_T_I

KH3642

Tubing can be extended in 4 directions as shown in

Fig. 3-35.

Arrangement for Right-rear Tubing

(a) Remove the 2 screws and slide out the side

cover. (Fig. 3-38)

1356_T_I

(b) Extend the wide tube from the outdoor side and

connect it directly to the mating tube inside the

indoor unit. Use a flare nut. (Fig. 3-39)

Fig. 3-38

Arrangement for Right Tubing

Tubing

(a) Remove the 2 screws and take off the side cover.

(Fig. 3-38)

from the

outdoor

unit

(b) Cut out the L-shaped tubing outlet using a hacksaw.

(Fig. 3-40)

tubing between the indoor and outdoor units.

(Fig. 3-42)

1357_T_I

Fig. 3-39

Arrangement for Left and Left-rear Tubing.

(a) Remove the 4 screws (2 on each side) and take

off both left and right side cover. (Fig. 3-41)

(b) Remove 4 screws to remove the bottom cover.

tubing as in Fig. 3-43.

Hack

saw

1358_T_I

Fig. 3-40

Indoor unit

L-shaped

tube

Left

side

cover

Right

side

cover

Bottom

cover

1359_T_I

L-shaped tube

1361_T_I

1360_T_I

Fig. 3-41

Fig. 3-42

Fig. 3-43

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3-15. Wiring Instructions

General Precautions on Wiring

(1) Before wiring, confirm the rated voltage of the

unit as shown on its name plate, then carry out

the wiring closely following the wiring diagram.

(2) Provide a power outlet to be used exclusively for

each unit a power supply disconnect and circuit

breaker for overcurrent protection should be

provided in the exclusive line.

(3) To prevent possible hazards from insulation

failure, the unit must be grounded.

(4) All wiring must be connected tightly.

(5) Do not allow wiring to touch refrigerant tubing,

compressor, or any moving parts of the fan.

Unauthorized changes in the

internal wiring can be very

dangerous. The manufac-

turer will accept no respon-

sibility for any damage or

misoperation that occurs as

a result of such unautho-

rized changes.

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3-16. Wiring Instructions for Inter-Unit Connections

KH2442

(a) Insert the inter-unit wiring (according to local

codes) into the through-the-wall PVC pipe. Run

the wiring toward the indoor side allowing approx.

5". to extend from the wall face. (Fig. 3-44)

Never fix the wiring by any

Rear

panel

Wall

Plastic

cover

means before the indoor

unit is fully seated on the

rear panel.

CAUTION

Wiring

(b) Remove the side cover and the metallic cover.

(Fig. 3-45 or 3-46, depending on model.)

a lock nut. (Fig. 3-45 or 3-46)

1362_T_I

(d) Give some play to the inter-unit wiring from the

outdoor unit to the corresponding terminals on the

terminal plate.

KH3642

● Be sure to refer to the

Wall fixture

wiring system diagram

label inside the metallic

cover and carry out the

correct field wiring.

CAUTION

Wall

Wrong wiring can cause

the unit to malfunction.

● Check local electrical

codes and any specified

wiring instructions or

limitations.

Connector

Wiring

(e) Secure the metallic cover with its screw. Then

replace the side cover.

1363_T_I

Fig. 3-44

KH2442

KH3642

Lock

nut

Metallic cover

Plastic cover

Screw

Lock

nut

Power line

Connector

Grounding

line

Side cover

1395_T_I

Look nut

Elbow

Fig. 3-46

conduit

0968_T_I

Fig. 3-45

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Cover

3-17. Shaping the Tubing

Refrigerant

tubing

KH2442

(1) Shape the refrigerant tubing so that it can easily

go into the hole. (Fig. 3-47)

Inter-unit

wiring

(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 wall fixture.

Drain hose

0954_T_I

Fig. 3-47

(3) Carefully bend the tubing (if necessary) to run

along the wall in the direction of the outdoor unit

and then insulate to the end of the fittings. The

drain hose should come straight down the wall to

a point where water runoff will not stain the wall.

Insulating

tape

(4) Connect the refrigerant tubing to the outdoor unit.

(After performing a leak test on the connection,

insulate it with insulating tape. (Fig. 3-48)) Also,

refer to Section 10-5. “Connecting Tubing be-

tween Indoor and Outdoor Units”.

0955_T_I

Fig. 3-48

Refrigerant tubing

Inter-unit wiring

(5) Assemble the refrigerant tubing, drain hose and

inter-unit wiring as shown in Fig. 3-49.

Drain hose

1098_T_I

KH3642

Fig. 3-49

(1) Shape the narrow refrigerant tube and the drain

hose in the desired direction so that they can

easily go into the wall hole. (Fig. 3-50)

Narrow

tube

(2) Push the wiring, narrow tube, and drain hose

through the hole in the wall.

(3) Bend the tubing (if necessary) to run along the

wall in the direction of the outdoor unit, then tape

as far as the fittings. The drain hose should come

straight down the wall to a point where runoff

won't stain the wall.

Drain hose

(4) Hang the indoor unit on the wall fixture. (Fig. 3-51)

1365_T_I

Fig. 3-50

(5) Install the mounting plate to secure the indoor unit

solidly to the wall. The plate can be positioned in

either of the 2 ways shown. (Fig. 3-52)

Wall

Indoor

unit

Mounting plate

Wall fixture

1366_T_I

Fig. 3-51

Screws

1367_T_I

Fig. 3-52

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3-18. Installing the Drain Hose

Slant

(a) The drain hose should be slanted downward on

the outdoor side. (Fig. 3-53)

Indoor

unit

(b) Never form a trap in the course of the hose.

Drain

hose

hose so that chilled condensation will not damage

furniture or floors. (Fig. 3-54)

0957_T_I

Fig. 3-53

* Foamed polyethylene or its equivalent is recom-

mended.

Condensation

Do not supply power to the

unit or operate it until all

tubing and wiring to the

outdoor unit are completed.

Insulation material

(field supply)

must be used.

0958_T_I

Fig. 3-54

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■ Ceiling-Mounted Type (TH Type)

Front face

3-19. Suspending the Indoor Unit

(1) Place the full-scale diagram (supplied) on the

ceiling at the spot where you want to install the

indoor unit. Use a pencil to mark the drill holes.

(Fig. 3-55).

Rear

Full-scale diagram

0035_T_I

NOTE

Fig. 3-55

Since the diagram is made of paper, it may shrink or

stretch slightly because of high temperature or humid-

ity. For this reason, before drilling the holes maintain

the correct dimensions between the markings.

Hole-in-anchor

Hole-in-plug

Concrete

Insert

(2) Drill holes at the 4 points indicated on the full-

scale diagram.

(3) Depending on the ceiling type:

a) Insert suspension bolts as shown in Fig. 3-56.

Suspension bolt (M10 or 3/8")

(field supply)

0038_T_I

b) Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-57.

Fig. 3-56

It is important that you use

extreme care in supporting

the indoor unit from the

ceiling. Ensure that the

ceiling is sufficiently strong

enough to support the

Ceiling tiles

Ceiling support

weight of the unit. Before

hanging the ceiling unit, test

the strength of each at-

tached suspension bolt.

(4) Screw in the suspension bolts, allowing them to

protrude from the ceiling as shown in Fig. 3-57.

The distance of each exposed bolt must be of

equal length within 2 inches. (Fig. 3-58)

0084_T_I

Fig. 3-57

unit

Ceiling

surface

Fixture

0971_T_I

Fig. 3-58

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Pull out the

Air-Intake grille

pushing claws

of the hinges

Hinge

(5) Before suspending the indoor unit, remove the 2

screws on the latch of the air-intake grilles, open

the grilles, and remove them by pushing the

claws of the hinges as shown in Fig. 3-59.

Then remove both side panels sliding them along

the unit toward the front after removing the two

screws which fix them. (Fig. 3-60)

Screw

Latch

(6) Preparation for suspending the indoor unit. The

suspension method varies depending on whether

the unit is next to the ceiling or not.

Air-intake grille

(Fig. 3-61 and 3-62)

0973_T_I

Fig. 3-59

(7) Suspend the indoor unit as follows.

(a) Mount a washer and two hexagonal nuts on

each suspension bolt as shown in Fig. 3-63.

Slide toward

front side

Side panel

0972_T_I

Fig. 3-60

Suspension bolt

(field supply)

unit

Ceiling surface

Washer (supplied)

Double nut

(field supply)

Fixture

0974_T_I

Fig. 3-61

Suspension bolt

(field supply)

Washer (field supply)

unit

Washer (supplied)

Double nut

(field supply)

0976_T_I

Fig. 3-62

Ceiling

surface

Washer

(supplied)

Nut

(field supply)

Suspension bolt

1096_T_I

Fig. 3-63

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(b) Lift the indoor unit, and place it on the

washers through the notches, so as to fix it

in place. (Fig. 3-64)

suspension bolt to suspend the indoor unit

as shown in Fig. 3-65.

NOTE

A ceiling surface is not always level. Please confirm

that the indoor unit is evenly suspended. For the

installation to be correct, leave a clearance of about

3/8 in. between the ceiling panel and the ceiling

surface and fill the gap with an appropriate insulation

or filler material.

0978_T_I

Fig. 3-64

(8) If the tubing and wiring are to go towards the rear

of the unit, make holes in the wall.

(Fig. 3-66)

0979_T_I

(9) Measure the thickness of the wall from the inside

to the outside and cut PVC pipe at a slight angle

to fit. Insert the PVC pipe in the wall. (Fig. 3-67)

Fig. 3-65

NOTE

The hole should be made at a slight downward slant to

the outside.

Indoor

side

Outdoor

side

0066_T_I

Fig. 3-66

PVC pipe (locally purchased)

INSIDE

OUTSIDE

PVC pipe

Wall

Slight

angle

0068_T_I

Cut at slight angle

0069_T_I

Fig. 3-67

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3-20. Duct for Fresh Air

Duct connection port

(Knock-out hole)

There is a duct connection port (knock-out hole) at the

right-rear on the Panel Top of the indoor unit for

drawing in fresh air. If it is necessary to draw in fresh

air, remove the cover by knocking out and connect the

duct to the indoor unit through the connection port.

(Fig. 3-68)

Panel Top

If connection at the right-rear on the Panel Top is not

appropriate, another duct connection port can be made

by cutting an opening on the left side of the Rear Panel

of the indoor unit as shown in Fig. 3-69.

1017_M_I

Fig. 3-68

2442

3-15/16"

1-3/8"

3642, 4242

7-3/32"

3-21. Installing the Drain Piping

Right side

1-31/32"

Rear side

Cut this portion

● Prepare a standard PVC pipe for the drain and

connect it to the indoor unit drain pipe with the

supplied hose clamps to prevent water leaks.

4-11/32"

● Connect the drain piping so that it slopes downward

from the unit to the outside. (Fig. 3-70)

3-15/16"

● Never allow traps to occur in the course of the

1353_M_I

piping.

Fig. 3-69

● Insulate any piping inside the room to prevent

dripping.

● Use the supplied drain pipe to connect the drain

Min. 1/100

pipe with the drain outlet of the indoor unit.

● After connecting the drain pipe securely, wrap the

supplied drain pipe insulator around the pipe, seal

the gap at the drain socket with the supplied black

insulation tape, then secure it with clamps.

(Fig. 3-71)

Good

● After the drain piping, pour water into the drain pan

to check that the water drains smoothly.

Not good

0961_T_I

Check local electrical codes

and regulations before

Fig. 3-70

CAUTION

obtaining wire. Also, check

any specified instruction or

limitations.

Drain pipe

clamp

(supplied)

Hard PVC pipe

(not supplied)

Drain hose

adapter

(supplied)

Packing

(supplied)

Drain hose

(supplied)

1119_X_I

Fig. 3-71

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■ Concealed-Duct Type ( UH Type)

3-22. Required Minimum Space for

Installation and Service

● This air conditioner is usually installed above the

ceiling so that the indoor unit and ducts are not

visible. Only the air intake and air outlet ports are

visible from below.

Electrical

component box

A (Suspension bolt pitch)

Inspection

access

● The minimum space for installation and service is

min.

9-27/32

17-23/32

Indoor Unit

shown in Fig. 3-72 and Table 3-3.

● It is recommended that space is provided (17-23/32

× 17-23/32 in.) for checking and servicing the

electrical system.

Refrigerant

tubing

min. 25-19/32

● Fig. 3-73 and Table 3-4 show the detailed dimen-

Air outlet duct flange

sions of the indoor unit.

Unit: inch

1977_U_I

Unit: inch (mm)

Table 3-3

Type

Fig. 3-72

12, 18

A (Length)

42-17/32 (1,080)

30-23/32 (780)

61-13/32 (1,560)

Number of

duct flanges

Table 3-4

Unit: inch

No. of holes

Dimension

Type

23-5/8

(7-7/8×3)

26-1/16

37-7/8

27-9/16 30-23/32 11-13/32 10-5/16 26-25/32 28-5/32 7-3/32

39-3/8 42-17/32 11-13/32 10-23/32 38-19/32 39-31/32 5-1/8

–

13-3/8

UH1242, UH1842

35-7/16

9-21/32

9-27/32 12

9-7/16 16

UH2442

UH3642

(7-3/32×5)

(9-21/32×1)

54-11/32

(9-1/16×6)

19-9/32

(9-21/32×2)

56-25/32

58-9/32 61-13/32 13-3/16 12-7/32 57-15/32 58-27/32 5-1/8

Refrigerant tubing joint (narrow tube)

Refrigerant tubing joint (wide tube)

Upper drain port (O.D. 1-1/4 in.)

Bottom drain port (O.D. 1-1/32 in.)

Suspension lug

Power supply outlet (2-ø1-3/16 hole)

Fresh air intake port (ø5-29/32 hole)

Flange for the flexible air outlet duct (ø7-7/8 hole)

Tube cover

13/32

3/4

L-ø1/4

(Hole)

3/4

A (O.D.)

H (Duct suspension bolt pitch)

G (Ceiling opening dimension)

4-ø15/32

(Hole)

Electrical component box

Flange for the air intake duct

(Option or field supply)

12-7/32

31/32 8-9/32

31/32

6-7/8

1-7/32

3-17/32

M-ø1/8

(Hole)

Inspection access

(17-23/32

17-23/32)

(Field supply)

1-3/8

1-9/16

(5-29/32)

2-3/4

5-1/8

11-7/32

(Suspension bolt pitch)

2-15/16

2-9/16

Inspection access panel

Ceiling

1978_U_I

Fig. 3-73

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3-23. Suspending the Indoor Unit

Hole-in-anchor

Hole-in-plug

Concrete

Insert

Depending on the ceiling type:

• Insert suspension bolts as shown in Fig. 3-74

• Use existing ceiling supports or construct a

suitable support as shown in Fig. 3-75.

Suspension bolt (M10 or 3/8")

(field supply)

It is important that you use

extreme care in supporting

the indoor unit inside the

ceiling. Ensure that the

0038_T_I

Fig. 3-74

Ceiling tiles

ceiling is strong enough to

support the weight of the

unit. Before hanging the unit,

test the strength of each

attached suspension bolt.

Ceiling support

(1) When placing the unit inside the ceiling, deter-

mine the pitch of the suspension bolts referring to

the dimensional data on the previous page.

(Fig. 3-73)

0039_S_I

Fig. 3-75

Tubing must be laid and connected inside the

ceiling when suspending the unit. If the ceiling is

already constructed, lay the tubing into position

for connection to the unit before placing the unit

inside the ceiling.

Suspension bolt

Suspension lug

Nuts and washers

(2 sets)

(2) Screw in the suspension bolts allowing them to

protrude from the ceiling as shown in Fig. 3-74.

(Cut the ceiling material, if necessary.)

Upper

Lower

(3) Thread the 2 hexagonal nuts and washers (field

supply) onto the 4 suspension bolts as shown in

Figs. 3-76 and 3-77. Use 2 sets of nuts and

washers (upper and lower), so that the unit will

not fall off the suspension lugs.

0041_X_I

Fig. 3-76

Suspension bolt

Hexagonal nut

0784_U_I

Fig. 3-77

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● Fig. 3-78 shows an example of installation.

Bolt anchor

Suspension bolt

Air outlet duct

Air-intake duct

Air-outlet grille

Ceiling material

Indoor unit

Air-intake grille

0785_U_I

Fig. 3-78

3-24. Installing the Drain Piping

Transparent part for

checking drainage

Hard PVC pipe

(not supplied)

Hose band

(supplied)

(1) Prepare a standard hard PVC pipe for the drain

and use the supplied hose band to prevent water

leaks.

The PVC pipe must be purchased separately.

When doing this, leave a gap between the drain

socket of the unit and the PVC pipe to allow the

drainage to be checked. The transparent drain

pipe allows you to check drainage. (Fig. 3-79)

Drain hose

Packing

(supplied)

Drain hose

(supplied)

adapter

(supplied)

0964_X_I

Fig. 3-79

Tighten the hose clamps so

their locking nuts face

upward. (Fig. 3-79)

CAUTION

Clamps (supplied)

(2) After connecting the drain piping securely, wrap

the supplied packing and drain pipe insulator

around the pipe, then secure it with the supplied

clamps. (Fig. 3-80)

Drain insulator (supplied)

0046_X_I

NOTE

Fig. 3-80

Make sure the drain pipe has a downward gradient

(1/100 or more) and that there are no water traps.

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● Do not install an air

bleeder as this may

cause water to spray

from the drain pipe

outlet. (Fig. 3-81)

Air bleeder

CAUTION

Not good

●

If it is necessary to increase the height of the

drain pipe, the section directly after the connec-

tion port can be raised a maximum of 19-11/16 in.

Do not raise it any higher than 19-11/16 in., as

this could result in water leaks.

1593_U_I

Fig. 3-81

11-13/16 in. or less

19-11/16 in. or less

Good

(Fig. 3-82)

● Do not install the pipe with an upward gradient

from the connection port. This will cause the

drain water to flow backward and leak when the

unit is not operating. (Fig. 3-83)

1979_U_I

Fig. 3-82

Upward gradient

● Do not apply force to the piping on the unit side

when connecting the drain pipe. The pipe

should not be allowed to hang unsupported

from its connection to the unit. Fasten the pipe

to a wall, frame, or other support as close to the

unit as possible. (Fig. 3-84)

No good

1595_U_I

Fig. 3-83

Support pieces

3-25. Checking the Drainage

After wiring and drain piping are completed, use the

following procedure to check that the water will drain

smoothly. For this, prepare a bucket and wiping cloth

to catch and wipe up spilled water.

Good

1596_U_I

(1) Connect power to the power terminal board (L1,

L2 terminal) inside the electrical component box.

Fig. 3-84

(2) Remove the tube cover and through the opening,

slowly pour about 43 oz. of water into the drain

pan to check drainage.

(3) Short the check pin (CN5 white) on the indoor

control board and operate the drain pump. Check

the water flow and see if there is any leakage.

Be careful since the fan will

start when you short the pin

on the indoor control board.

CAUTION

(4) When the check of drainage is complete, open

the check pin (CN5 white) and remount the

insulator and drain cap onto the drain inspection

port.

To mount the tube cover,

use 5/16" (4 × 8 mm) tapping

screws.

CAUTION

Do not use long screws as

they may puncture the drain

pan and cause water leak-

age.

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3-26. Increasing the Fan Speed

If external static pressure is too great (due to long

extension of ducts, for example), the air flow volume

may drop too low at each air outlet. This problem may

be solved by increasing the fan speed using the

following procedure:

Electrical component box

Booster cable

Fan

motor

Booster cable

Fan motor socket

(At shipment)

(1) Remove 4 screws on the electrical component

box and remove the cover plate.

(Booster cable installed)

0491_M_I

Fig. 3-85

(2) Disconnect the fan motor sockets in the box.

12 Type

18 Type

(3) Take out the booster cable (sockets at both

ends) clamped in the box.

150

0.5

0.4

0.5

0.4

(4) Securely connect the booster cable sockets

between the disconnected fan motor sockets in

step 2 as shown in the Fig. 3-85.

100

0.3

0.2

0.1

0.3

0.2

(5) Place the cable neatly in the box and reinstall

the cover plate.

0.1

200

300

400

500

200

300

400

Indoor Fan Performance

Air Flow (CFM)

1981_U_I

1980_U_I

24 Type

36 Type

200

150

100

0.8

0.6

0.5

0.4

0.3

0.2

0.1

150

100

0.5

0.4

0.3

0.2

0.1

300

500

700

900

500

1000

Air Flow (CFM)

1982_U_I

1983_U_I

NOTE

HT : Using the booster cable

H : At shipment

Fig. 3-86

■ How to read the diagram

The vertical axis is the external static pressure (Pa) while the horizontal axis represents the AIR FLOW (CFM).

The characteristic curves for “HT”, “H”, “M” and “L” fan speed control are shown.

The nameplate values are shown based on the “H” air flow. For the 24 type, the air flow is 636 CFM, while the

external static pressure is 49 Pa at “H” position. If external static pressure is too great (due to long extension of

duct, for example), the air flow volume may drop too low at each air outlet.

This problem may be solved by increasing the fan speed as explained above.

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4. HOW TO INSTALL THE OUTDOOR UNIT

4-1. Removing the Protective Spacer for

Transportation

Compressor

Remove the packing skid from the bottom of unit and

then remove the plastic spacer used to secure the

compressor during transportation. (Fig. 4-1)

Place the unit on a level concrete pad, block or equal

and anchor.

Refer to Section 2. “Selecting the Installation Site”.

Packing

skid

Plastic spacer

0496_C_I

4-2. Installing the Outdoor Unit

Fig. 4-1

(1) Install blocks or a solid platform under the out-

door unit which provides a minimum height of

6 in. from ground level. (Fig. 4-2)

(2) The outdoor unit must be bolted down tightly to

the blocks or platform with 4 anchor bolts.

4-3. Tubing Direction

● Tubing can be extended in 4 different directions as

6-11/16

4-21/64

shown in Fig. 4-3.

● Service valves are housed inside the unit. To access

them, remove the access panel by removing the 3

attaching screws, then slide the panel downward

and pull it toward you.

Anchor

bolts

(not supplied)

If either rear, right or front tubing is needed, punch

out the knockout holes with a hammer or similar tool.

● After punching out the knockout holes, mount

plastic protectors on the tubing outlets. These

accessories are packed inside the unit and can be

accessed through the access panel.

Height :

Min: 6 in.

Unit: inch

1168_C_I

Fig. 4-2

● Use tube benders to extend refrigerant tubing to the

outside.

Connector Size

Power Supply

1/2"

Inter-unit Power Line

1/2"

Inter-unit

Rear

wiring outlets

Power supply

wiring outlets

Access panel

Right

Power

supply line

Inter-unit

power line

Control

wiring

Front

Tubing

outlets

Down

outlets

Inter-unit

control line

1102_C_I

Fig. 4-3

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5. ELECTRICAL WIRING

5-1. 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.

(7) Regulations on wire diameters differ from locality to

locality. For field wiring rules, must follow your

LOCAL ELECTRICAL CODES before beginning.

(2) Provide a power outlet to be used exclusively for

each unit, and a power supply disconnect and

circuit breaker for overcurrent protection should

be provided in the exclusive line.

You must ensure that installation complies with all

relevant rules and regulations.

(8) To prevent malfunction of the air conditioner

caused by electrical noise, care must be taken

when wiring as follows:

(3) To prevent possible hazards from insulation

failure, the unit must be grounded.

● The remote control wiring and the inter-unit

control wiring should be wired apart from the

inter-unit power wiring.

(4) Each wiring connection must be done in accor-

dance with the wiring system diagram. Wrong

wiring may cause the unit to misoperate or

become damaged.

● Use shielded wires for inter-unit control wiring

between units and ground the shield on both

sides.

(5) Do not allow wiring to touch the refrigerant tubing,

compressor, or any moving parts of the fan.

(9) If the power supply cord of this appliance is

damaged, it must be replaced by a repair shop

appointed by the manufacture, because special

purpose tools are required.

(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.

(10) All wiring must be used class 1.

5-2. Recommended Wire Length and Wire Diameter for Power Supply System

Must follow LOCAL ELECTRICAL CODES for wiring.

Outdoor Unit

* AWG = American Wire Gauge

MOP

(Fuse or HACR

type circuit braker)

Trade size

of Conduit

Trade size

of Conduit

(A) Power Supply

Power Supply Terminal Base

Capacity Max. Wire Diameter

Model Name

AWG #12

CH2442

CH3642

CH4242

3/4 in.

25 A

50 A

AWG #6

1-1/4 in.

Max. length 69 ft.

AWG #12

Max. length 69 ft.

AWG #10

Max. length 67 ft.

35 A/40 A (230/208 V) 50 A

45 A

50 A

Indoor Unit

MOP

Trade size

of Conduit

Trade size

of Conduit

(B) Power Supply

Max. length 330 ft.

Power Supply Terminal Base

Capacity Max. Wire Diameter

Type

(Fuse or HACR

type circuit braker)

X, K, T, U

3/4 in.

15 A

25 A

AWG #10

3/4 in.

Control Wiring

AWG #18 (0.75 mm²)

(D) Remote Control Wiring

(E) Control Wiring For Group Control

AWG #18* (0.75 mm²)

AWG #18*²(0.75 mm²)

Use high voltage wire (300 V)^*1

Max. 3,300 ft.

Max. 1,650 ft.

Max. 1,650 ft. (Total)

NOTE

With ring type wire terminal.

Wire joint connection.

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5-3. Wiring System Diagrams

(1) Basic wiring diagram for standard control

Indoor Unit

Outdoor Unit

R.C. Address on the PCB: 0 (S2, BLK)

(0: Factory shipped state)

Inter-unit

power wiring

Single phase

230/208V

Ground

Inter-unit

control wiring

(Low voltage)

Power supply

Single phase

230/208V

Ground

Remote controller

(Option)

*Remote controller wirings are wire joint connection.

2085_M_I

NOTE

CH Type

(1) Refer to Section 5-2. “Recommended Wire

Length and Wide Diameter for Power Supply

System” for the explanation of “A”, “B”, “C”, “D”,

and “E”, in the above diagrams.

5P terminal board + 2P terminal board

2 G L1 L2

U1 U2

Inter-unit

control wiring

(2) Inter-Unit Control Wiring (C) and remote control-

ler wiring (D), (E) has no polarity.

Power

supply

Inter-unit

power wiring

2086_M_I

But for other wiring, respect polarity.

Be sure to connect as shown in the Wiring

System Diagram.

KH Type

XH, TH, UH Type

4P terminal board

5P terminal board

(3) R.C. Address should be set before turning the

power on.

(4) Regarding the R.C. Address setting, refer to

page 87. Auto. address setting can be executed

by a remote controller automatically.

U1 U2

Inter-unit

control wiring power wiring

U1 U2

Inter-unit

control wiring

Remote

controller wiring

Remote

controller wiring

Inter-unit

power wiring

3003_M_I

2088_M_I

2087_M_I

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(2) Basic wiring diagram for group control

This diagram shows when several units (max. 8) are

controlled by a remote controller. In this case, a

remote controller can be connected at any indoor unit.

Indoor Unit

Outdoor Unit

R.C. Address on the PCB: 1 (S2, BLK)

Inter-unit

power wiring

single phase

230/208V

Ground

Inter-unit

control wiring

(Low voltage)

Power supply

single phase

230/208V

RED

BLK

Ground

Remote controller

(Option)

Indoor Unit

Outdoor Unit

R.C. Address on the PCB: 2 (S2, BLK)

Inter-unit

power wiring

single phase

230/208V

Inter-unit

control wiring

(Low voltage)

Power supply

single phase

230/208V

Ground

Indoor Unit

Outdoor Unit

R.C. Address on the PCB: 8 (S2, BLK)

Inter-unit

power wiring

single phase

230/208V

Inter-unit

control wiring

(Low voltage)

Power supply

single phase

230/208V

Ground

*Remote controller wirings are wire joint connection.

2089_M_I

NOTE

● R.C. Address should be set before turning the power on.

● Auto. address setting can be executed by a remote controller automatically.

Please refer to 12-4 “Automatic Address Setting Method”.

● Each successive unit will respond at one-second intervals following the order of the R.C. address when the

remote controller is operated.

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Loose wiring may cause the

terminal to overheat or result

in unit malfunction. A fire

hazard may also exist.

Stranded wire

Therefore, ensure that all

wiring is tightly connected.

Ring

pressure

terminal

When connecting each power wire to the correspond-

ing terminal, follow the instructions on “How to connect

wiring to the terminal” and fasten the wire securely with

the fixing screw of the terminal plate.

1106_M_I

Fig. 5-1

5-4. How to Connect Wiring to the Terminal

Special

washer

Screw

■ For stranded wiring

Ring pressure

terminal

(1) Cut the wire end with a wire cutter or wire-cutting

pliers, then strip the insulation to expose the

stranded wiring about 3/8 in.. (Fig. 5-1)

Screw and

Special washer

Terminal plate

Wire

Ring

pressure

terminal

(2) Using a Pillips head screwdriver, remove the

terminal screw(s) on the terminal plate.

Wire

(3) Using a ring connector fastener or pliers, securely

clamp each stripped wire end with a ring pressure

terminal. (Fig. 5-1)

1107_M_I

Fig. 5-2

(4) Place the ring pressure terminal, and replace and

tighten the removed terminal screw using a

screwdriver. (Fig. 5-2)

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6. HOW TO INSTALL THE WIRED REMOTE CONTROLLER

OPTIONAL PART

(

)

3-21/32 in. or more

4-29/32 in. or more

(from wall)

Spacer

(during continuous

installation)

6-1. Installation site selection

● Install the remote controller at a height of between

3–5 ft. above the floor.

● Do not install the remote controller in a place where

it will be exposed to direct sunlight or near a

window or other place where it will be exposed to

the outside air.

3-17/32 in. or more

(from wall)

4-29/32 in. or more

(during continuous

installation)

Wall

3/32 in.

(amount offset from JIS box)

● Be sure to install the remote controller vertically,

such as on a wall.

Hole for routing

remote control

cable

● The mounting position for the remote controller

should be located in an accessible place for control.

● Never cover the remote controller or recess it into

the wall.

JIS CB8340

One switchbox

(no cover)

Mounting dimensions for continuous installation

● When mounting the remote controller on a wall,

please see Fig. 6-1 and Fig.6-2.

1987_C_I

Fig. 6-1

Spacer

(WD)

3-17/32 in. or more

(from wall)

4-29/32 in. or more

(during continuous

installation)

Wall

Hole for routing

remote control

cable

JIS CB8340

Two switchbox

(no cover)

1988_C_I

Fig. 6-2

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6-2. Wired Remote Controller Installation

● Do not supply power to

the unit or try to operate it

until the tubing and

wiring to the outdoor unit

is completed.

● Do not twist the control

CAUTION

wiring with the power

wiring or run it in the

same metal conduit,

because this may cause

malfunction.

Concealed box for 1

Spacer

M4 × 25

Screws (2)

● Install the remote control-

ler away from sources of

electrical noise.

● Install a noise filter or

take other appropriate

action if electrical noise

affects the power supply

circuit of the unit.

Under case

(Back case)

Wired remote

controller

Decorative

cover

1989_C_I

Fig. 6-3

● If local codes allow, this remote controller can be

mounted using a conventional wall box for flush

mounting.

Control panel

(WD)

(1) When you open the decorative cover, you will see

two gaps under the remote controller. Insert a

coin into these gaps and pry off the back case.

(Fig. 6-4)

Gap

Coin

(2) Attach the back case with the 2 small screws

provided. Using a screwdriver, push open the cut-

outs on the back case. These holes are for

screws. Use the spacers and take care not to

tighten the screws excessively. If the back case

will not seat well, cut the spacers to a suitable

thickness. (Fig. 6-3)

1990_M_I

Fig. 6-4

(3) Connect the remote controller wiring (2 wires)

correctly to the corresponding terminals in the

electrical component box of the indoor unit.

When wiring, do not connect

CAUTION

the remote controller wires

to the adjacent terminal

block for the power wiring.

Otherwise, the unit will break

down.

(4) To finish, fit the back tabs of the case into the

remote controller and mount it.

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6-3. Basic Wiring Diagram

Install wiring correctly

● Use shielded wires for inter-unit control wiring and

ground the shield on both sides. (Fig. 6-5)

Otherwise misoperation because of noise may

occur.

CAUTION

(incorrect wiring will damage

the equipment).

Shielded wire

ground

0797_M_I

Fig. 6-5

Group

control

Standard

remote control

Multiple

remote control

Connection wiring

for group control

1 2

Wire joint

1 2

Indoor unit

No. 1

Indoor unit

No. 2

Indoor unit

No. 3

Indoor unit

No. 8

1 2

Inter-unit control wiring

1 2

Outdoor unit

: Ground (earth)

2030_M_I

(WD)

Inter-unit wiring

Indoor

unit 1

Indoor

unit 2

Indoor

unit 7

Indoor

unit 8

Group-control wiring

(Main) (Sub)

2031_M_I

● Diagram of outer dimensions

● Wiring procedure

Install the wiring according to the above wiring

diagram.

5/32

● The address setting is automatically

executed after turning on the system.

An indoor unit address is assigned to each

indoor unit.

● Operation takes place successively at

intervals of 1 second, by using combinations

of the address setting of each unit.

4-23/32

5/8

1991_M_I

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6-4. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of

8) are controlled by a remote controller (master unit).

In this case, a remote controller can be connected at

any indoor unit.

Remote

controller

Wiring procedure

Connection wiring for

1 2

group control

Wire according to the left diagram:

Wire joint

● Address setting is executed automatically when the

outdoor unit is turned on.

1 2

Indoor unit

No. 1

Indoor unit

No. 2

Indoor unit

No. 3

Indoor unit

No. 8

● Each successive unit will respond at one-second

intervals following the order of the group address

when the remote controller is operated.

1 2

Inter-unit

control

wiring

1 2

Outdoor unit

: Ground (earth)

2032_M_I

● Group control using 2 remote controllers.

It does not matter which of the 2 remote controllers

you set as the main controller.

(WD)

When using multiple remote controllers (up to 2 of

them can be used), one is the main remote controller

and the other is the sub-remote controller.

Remote

controller

(main)

(sub)

1 2

● To set up a sub-remote controller, change its

remote control address connector (RCU. ADR)

located on its PCB from main to sub position (main:

when shipped from factory).

Connection wiring

for group control

1 2

Wire joint

Indoor unit

No. 2

Indoor unit

No. 8

Indoor unit

No. 1

Indoor unit

No. 3

: Ground (earth)

2033_M_I

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6-5. Wiring System Diagram for Multiple Remote

Control

■ When Installing Multiple Remote Controllers

This multiple remote controller system is used for

operating the unit(s) at different positions. (A maximum

of 2 remote controllers can be installed.)

● Setting method

Remote controller

address connector

To execute this control, make the setting according

to the following procedure.

Main

RCU check

Sub

(1) Of the two installed remote controllers, make one

the main remote controller (factory-shipped

state).

RCU. ADR

(2) On the other remote controller, change the

address connector on the PCB from main to sub

position.

1992_M_I

In this state, it functions as a sub-remote controller.

● Basic wiring diagram

(main)

1 2

(sub)

(Option)

1 2

Install wiring correctly

(incorrect wiring will damage

the equipment).

CAUTION

● To operate 1 indoor unit with 2 remote controllers

set at different places.

Remote control cable

(wire it at local

Remote control

cable terminal

board

1 2

6-6. How to Switch the Indoor Temperature Sensor

installation site)

Indoor unit

(WD)

The indoor unit and the remote controller both contain

an indoor temperature sensor. The sensors on either

unit can be used but normally only the sensor set on

the indoor unit is used. However, use the following

procedure if you must use the sensor on the remote

controller.

Earth

1993_M_I

(1) Hold down the

4 seconds.

buttons for at least

Note: The Unit No. first displayed is the main indoor

unit address for group control.

Note: Do not press the

(2) Select CODE NO. 32 with the Temp.setting ( )

buttons.

(3) Change the set data from 0000 to 0001 with the

button.

Timer (

)

button.

(4) Press the

button. (Setting is OK if the blinking

display changes to a lit up display.)

(5) Press the

button.

This is the usual off condition. At this time,

(remote controller) appears on the LCD display.

NOTE

If using 2 remote controllers, either one (main or

sub-remote controller) can be used to make setting

but only the main unit functions as the remote

controller sensor.

The remote controller sensor will not function

during group control unless the group address is

set in the main remote controller indoor unit.

Do not use remote controller switch for the remote

control sensor if the remote sensor is being used

jointly with the remote controller switch.

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6-7. Explanation of Alarm Messages

Possible Cause of Malfunction

Alarm

message

Error in receiving serial communications signal.

Error in transmitting serial communications signal.

Remote controller is detecting

error signal from indoor unit.

• Serial

commu-

nication

errors

• Indoor unit is detecting error signal from the remote controller.

(No serial communications signal)

• Mis-setting

Indoor unit is detecting error

signal from outdoor unit.

Error in receiving serial communications signal.

Error in transmitting serial communications signal.

Outdoor unit is detecting error

signal from indoor unit.

Error in receiving serial communications signal.

• Indoor unit is damaged.

• Power is not supplied.

Indoor unit is not working

correctly.

Outdoor unit is transmitting error

signal.

Error in transmitting serial communications signal.

Indoor unit address setting is duplicated.

Improper setting of indoor unit or

remote controller.

Remote controller address (RCU.ADR) switch is duplicated.

Do not press Auto. address button S001: (A. ADD) of another

R.C. line during Auto. address operation.

E12

E14

E15

When using group control, main indoor unit address setting is duplicated.

(For single heat pump type.)

Error in Auto. address setting.

(No. or capacity of judged indoor unit is small.)

Error in Auto. address setting.

E16

E18

(No. or capacity of judged indoor unit is large.)

Indoor unit is detecting error signal from another indoor unit.

(WD)

Activation of

protective

device

Protective device in indoor unit • Thermal protector in indoor fan motor is activated.

is activated.

Protective device in outdoor

unit is activated.

• Thermal protector in outdoor fan motor is activated.

• Comp. thermal protector is activated.

Incorrect discharge gas temp. of comp.

High-pressure switch is activated.

Incorrect power supply voltage . Negative phase, defective

phase or voltage drop.

Incorrect discharge gas temp. of comp.

P17

Protective device in indoor unit Improper wiring connections of ceiling panel.

is activated.

Float switch is activated.

P10

NOTE

● RCU : Remote Control Unit (remote controller)

● R.C. : Refrigerant Circuit

● comp. : Compressor

● temp. : Temperature

● PCB : Printed Circuit Board

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Alarm

message

Possible Cause of Malfunction

Thermistor

failure

Indoor thermistor is either open Indoor coil temp. (E1 = TH1) cannot be detected.

or damaged.

Indoor coil temp. (E2 = TH2) cannot be detected.

Indoor coil temp. (E3 = TH3) cannot be detected.

Indoor room (air-intake) temp. can not be detected.

Discharge gas temp. (comp. = TH0A) cannot be detected.

Outdoor coil gas temp. (C2 = TH0C) cannot be detected.

Outdoor coil liquid temp. (C1 = TH0D) cannot be detected.

F10

Outdoor thermistor is either

open or damaged.

F25

EEPROM (ICB of PCB) failure

F29

Fault with

comp. and its

circuit

Comp. motor is overloaded.

Protective device for comp. is

activated.

Comp. motor is locked.

Current of comp. cannot be detected when it is turned on.

Current of comp. is detected when it is not operated.

Comp. contactor (Mg SW) is chattering.

F27

H18

Alarm

message

Possible cause of Malfunction

Model setting of indoor unit is not matching the outdoor unit.

When using group control, main indoor unit address setting is duplicated.

(Judging by indoor unit.)

Outdoor unit address (R.C. No.) is duplicated.

Priority setting of indoor unit is duplicated.

—

(WD)

Improper wiring between indoor units.

(There is group connection wiring in case of individual control.)

Capacity code of indoor unit is not set.

Improper wiring of group control wiring.

L11

Alarm

message

Possible Cause of Malfunction (The following messages are displayed only for the system controller.)

• Indoor or outdoor unit is not working correctly.

• Control lines between indoor unit, outdoor unit, and system

controller are not wired correctly.

• Serial

commu-

nication

errors

System controller is transmitting

incorrect signal.

C05

C06

P30

System controller is detecting

incorrect signal.

• Same as for C05, above.

• Connector CN1 is not connected correctly.

• Mis-setting

Protective device of the sub-

When using wireless remote controller or system controller,

indoor unit is activated in group connect wired remote controller with the indoor unit temporarily

Activation of

protective

device

contorl.

to check the alarm message in detail.

NOTE

● R.C. : Refrigerant Circuit

● comp. : Compressor

● temp. : Temperature

● PCB : Printed Circuit Board

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7. HOW TO INSTALL THE WIRELESS REMOTE CONTROLLER

(OPTIONAL PART)

Important

When using this air conditioner (ECO multi system air

conditioner) with the wireless remote controller it may

sometimes be impossible to change the operation

modes while other indoor unit is running.

●

When this happens, a double beep tone sounds,

the (operation lamp) lights up, and the (Timer

lamp) and (Standby lamp) blink alternately.

Operation is the same even during (AUTO mode)

automatic cooling or heating.

● A beep tone sounds 5 times and no changes can

be made when any of the ON/OFF, MODE, Tem-

perature setting buttons were pressed while set

under central control by the system controller.

7-1. Wireless Remote Controller Installation

The remote controller can be operated from either a

non-fixed position or a wall-mounted position.

To ensure that the air conditioner operates correctly,

do not install the remote controller in the following

places:

● In direct sunlight.

(WL)

● Behind a curtain or other place where it is covered.

● More than 26 ft. away from the air conditioner.

● In the path of the air conditioner’s airstream.

● Where it may become extremely hot or cold.

● Where it may be subject to electrical or magnetic

interference.

Put on

Screws for fixture

Truss-head

tapping screws

(4 × L5/8")

Mounting cradle

(1) If Wall-mounted Fixed Position

Install the remote controller at a convenient

location on a nearby wall. However, before

attaching the remote controller mounting cradle,

check that the remote controller can operate from

the desired wall position. (Fig. 7-1)

Push

1994_M_I

Fig. 7-1

■ How to Install Batteries

See Fig. 7-2.

(1) Press and slide the lid on the back of the remote

controller in the direction of the arrow.

(2) Install two AAA alkaline batteries. Make sure the

batteries point in the direction marked in the

battery compartment.

ACL button

Cover

(3) Press the ACL button, then replace the lid. If you

press it, the current time, ON time, and OFF time

are all reset to 0:00.

1995_M_I

Fig. 7-2

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7-2. Room Temperature Sensor Setting

The room temperature sensors are built into the indoor

unit and the wireless remote controller. Either of these

room temperature sensors can operate.

The system is shipped from the factory set to the

indoor unit sensor. To switch to the remote controller

sensor, press the sensor switching button located

inside the remote controller cover and check that A/C

SENSOR on the LCD display panel goes out.

ADR

SET

ACL

SENSOR

NOTE

Sensor button

1996_M_I

If the sensor switch is set to the remote controller side,

but no room temperature data is sent to the main unit

for 10 minutes, the sensor is automatically switched to

the indoor unit side. As much as possible, install the

remote controller facing the unit.

Fig. 7-3

7-3. Address Switches

If you are installing more than 1 indoor unit (up to 6) in

the same room, it is necessary for you to assign each

unit its own address so they each can be operated by

their remote controller.

Up to 6 indoor units can be controlled separately

through the address switches. The operating control

has the reception address switch and the remote

controller has transmission address switch. This

function is utilized by matching the transmission and

reception address switches.

(WL)

Remote controller

address display

ADR

Address switch

positions

* Any address

switch position

available

1 2 3

4 5 6

1 2 3

4 5 6

1 2 3

4 5 6

7-4. Setting the Model Code

1 Flap display selector switch

Make the slide switch settings in the battery compartment box of the remote controller depending on the type

of indoor unit in which the wireless receiving unit is used.

2 Operation mode switch

In this Split System Air Conditioner set the switch to “A”.

* The switch is factory set to “S” / “A”.

* Always press the reset button after switching the setting.

2 Operation

mode switch

XH, TH type

KH type

UH type

1 Flap display

selector switch

1997_M_I

Heat pump with

Auto mode (CH type)

Heat pump without

Auto mode

Cooling only

Fig. 7-4

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<RCS-SH80UA. WL>

■ 4-Way Air Discharge Semi-concealed Type

(XH Type)

Air intake grille

Mark section

(indicator section)

7-5. Indicator section Installation

● Remove the ceiling panel and indicator cover

and install the indicator section.

(1) Remove the ceiling panel.

Ceiling panel

(2) Remove the corner cover behind the mark sec-

tion. (3 screws)

0574_X_I

(3) Remove the mark section inside the ceiling panel.

(2 screws)

(4) Install the indicator section in the location where

the mark section was attached. (2 screws)

(5) Form the wire to match the panel ribs as in the

Fig. 7-6.

Corner cover

3 screws

0517_X_I

(6) Install the corner cover. (Restrain the wire with

the corner cover.)

Fig. 7-5

7-6. Operating Controller Installation

Pass the wiring through under the shaft.

● Do not twist the operating

CAUTION

controller wires together

with the power supply

wires. Doing so can result

in malfunction.

(WL)

Wiring

● If noise is induced in the

unit power supply, take

appropriate measures, for

example installing a noise

filter.

2 screws

Indicator section

0518_X_I

Fig. 7-6

Install the operating controller at the indoor unit intake

port section.

(1) Fasten the operating controller to the indoor unit

intake port section (electrical component box

opposite side) with the 2 accessory screws

(4 × L13/32 in.).

(2) Connect the operating controller 2 wires (WHT,

BLK) to the remote control wire (WHT) in the

electrical component box. (For details on the

wiring, see “7-9. Electrical wiring” P56.)

Operating

controller

Electrical

component box

Screws

1998_M_I

Fig. 7-7

(3) Install the ceiling panel.

(4) Connect the indicator section and the operating

controller by 6P connector (white).

(5) Form the wires with vinyl clampers and fasten.

(6) Connect the ceiling panel wiring connector (2P,

3P) to the body connector in the electrical compo-

nent box.

(7) For details on test operation, see “Test Run”.

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■ Ceiling Mounted Type (TH Type)

7-7. Indicator Section Installation

Remove the side panel to install the indicator section.

(Fig. 7-8)

Indicator section Panel

Side panel

Indicator section

(1) Remove the side panel.

Cover B

Open the air intake grille, remove the screw at

one place and then remove the side panel by

sliding it toward the front (arrow direction).

(2) Remove cover A and cover B.

Put the minus-screwdriver into the recess of

cover A to remove cover A and cover B.

(When removing the cover, take care not to

scratch the panel.)

(Not used when

the indicator section

is installed.)

Cover A

Recess

Air intake grille

(3) Remove cover B from cover A.

(4) Install the indicator section at cover A.

(5) After passing through the lead wires, install cover

A and the indicator section at the panel hole.

(The protrusion part of cover A is fixed with the

panel hole.)

Cover A

1536_T_I

Fig. 7-8

(6) Bundle the lead wires along with the wiring of the

louver motor.

(7) Install the side panel.

7-8. Operating Controller Installation

(WL)

● Do not twist the operating

controller wires together

with the power supply

Install the operating controller on the top face of the air

intake section (space between the fan motor and the

electrical component box). (Fig. 7-9)

wires. Doing so can result

(1) Fasten the operating controller to the ceiling

panel of the air intake section with the 2 acces-

sory screws (4 × L13/32 in.).

(2) Draw the lead wires into the electrical component

box and connect the operating controller 2 wires

(WHT, BLK) to the remote control wires in the

electrical component box.

CAUTION

in malfunction.

● If noise is induced in the

unit power supply, take

appropriate measures, for

example installing a noise

filter.

(3) Connect the indicator section and the operating

controller by 6P connector in the electrical

component box.

Operating controller

Electrical component box

1537_T_I

Fig. 7-9

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7-9. Electrical Wiring

Signal receving unit

Indoor PCB

Operating controller

Indicator section

CN1

(0.7 ft.)

(4.3 ft.)

CN2

CN1

BLU

YEL

PNK

RED

GRY

BLK

BLU

YEL

PNK

RED

GRY

BLK

W1 (4.3 ft.)

WHT

BLK

Relay connector

2035_M_I

Fig. 7-10

Connection method

(1) Connect W1 to the indoor PCB WL connector.

(2) Connect W3 from the indicator section with W2

from the operating controller using the relay

connector.

7-10. Test Run Switch

Test run switch is located at operating control unit.

Regarding the test run, please refer to section 12. Test

Run.

NOTE

● In case of 4-way air discharge type, test run opera-

tion is not possible without the ceiling panel installa-

tion.

All OFF( ) for

initial settings.

● During the test run, all of the 3 indicator lamps on

the indoor unit will flash.

1 2 3 4

1.TEST RUN

2.PCB CHK.

3.RCU: MAIN

RCU: SUB

4.NORMAL

ALL •

ADR

1 2 3

● During the test run, the air conditioner runs continu-

ously and the thermostat does not control the

system.

4 5 6

(WL)

● To protect the air conditioner from overloading, the

outdoor unit will not start running for 3 minutes after

power is applied or the air conditioner is turned off

and then back on.

Servicing

switches

Address

switch

Flap

button

ON/OFF

operation

button

1999_M_I

Fig. 7-11

● When the air conditioner fails to start the test run, 1

or more of the 3 alarm indicator lamps on the indoor

unit will flash (See next section).

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7-11. Misoperation Alarm Indicators

Alarm indicator lamps on the indoor unit indicate the

error cause when the air conditioner fails to operate

upon being switched on. The possible alarm indica-

tions are given in Table 7-1. Fig.7-12 shows the

location of the alarm lamps on the indoor unit. (See

Table 7-1, Fig. 7-12)

Table 7-1

Alarm

Cause of Trouble

(OPERATION

(TIMER

lamp)

(STANDBY

lamp)

S.C. errors* between the indoor unit’s controller (PCB) and the remote

controller.

●

Compressor protector is working.

S.C. errors between indoor and outdoor units.

Indoor or outdoor thermistor is malfunctioning.

Outdoor unit protector is working.

Indoor unit protector is working.

TEST RUN switch on the operation controller is in ON state.

S.C. : Serial communications

(WL)

OPERATION TIMER

lamp lamp

STANDBY

lamp

Remote control

receiver

2000_M_I

Fig. 7-12

NOTE

Stick the alarm message label accompanying with the

wireless remote controller on the electrical component

box to find the cause of trouble in case of need.

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<RCS-BH80UA.WA>

● If the signal receiving unit

is installed near rapid-

start type or inverter type

fluorescent lamp (neither

one having glow lamps),

it may be impossible to

receive signals from the

wireless remote control-

ler. To avoid signal inter-

ference from fluorescent

lamps, install the receiv-

ing unit at least 6.6 ft.

CAUTION

away from the lamps and

install at a location where

wireless remote controller

signals can be received

when the fluorescent

lamps are on.

7-12. Separate type Signal Receiving Unit Installation

Signal receiving unit

Spacer

M4 × L1 in

Screws (2)

● Do not twist the operating

CAUTION

controller wires together

with the power supply

wires. Doing so can result

in malfunction.

ALL•

RCU SUB

PCB CHK.

TEST RUN

RCU MAIN

NORMAL

ADR

5 6

● If noise is induced in the

unit power supply, take

appropriate measures, for

example installing a noise

filter.

(WL)

Switch box (no cover)

Notch

Cover plate

2001_M_I

Fig. 7-13

● If local codes allow, this signal receving unit can be

mounted using a conventional wall box for flush

mounting.

(1) Insert a minus driver into the gap under the signal

receving unit and pry off the cover (Fig. 7-14)

(2) Attach the signal receving unit with the 2 small

screws provided.

Use the spacers and take care not to tighten the

screws excessively.

2002_M_I

Fig. 7-14

If the signal receving unit will not seat well, cut

the spacers to a suitable thickness. (Fig. 7-13)

(3) Connect the signal receving unit wiring (2 wires)

correctly to the corresponding terminals in the

electrical component box of the indoor unit.

When wiring, do not connect

the signal receving unit

wires to the adjacent termi-

nal block for the power

wiring. Otherwise, the unit

will break down.

CAUTION

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● When using the signal receiving unit on a wall with

the front exposed, choose a wall surface that the

signal receiving unit can be mounted on.

Clamper (supplied)

About 3/32-1/8 in.

Run the remote control

cable through a notch

on the upper case.

(1) Insert a flat tip (minus) screwdriver into the slot on

the lower side of the signal receiving unit and pry

off the back case as shown in Fig. 7-14.

(2) The wire rooting at the signal receiving unit

comes out of the upper case (thin portion at

upper center) so use nippers or a similar tool to

cut out a notch beforehand large enough for the

remote control cable (option) to pass through as

shown in Fig. 7-15.

Connector

Remote control cord

(Option)

2003_M_I

2004_M_I

Fig. 7-15

Fig. 7-16

Remote control cord (Option)

Clamper

(3) Remove the wire which is connected prior ship-

ping from the connector.

(4) Connect the remote control cable (option) to the

signal receiving unit connector shown in Fig. 7-16

after the clamper (supplied) with the unit is installed.

(5) After arranging the wiring on the printed circuit

board as shown in Fig. 7-17 so that it is contained

within the signal receiving unit, attach the back

case. At this time, arrange so that the head of the

clamper faces the side.

2005_M_I

Fig. 7-17

(6) Remove the cover plate and install the signal

receiving unit using the 2 wood screws.

(7) Fasten to the wall using the cord clip (supplied).

(8) Reinstall the cover plate.

Signal receiving unit

Wood screws (2)

● To use the signal receiving unit while mounted on a

ceiling, install by using the carrier for ceiling instal-

lation supplied with the unit.

ALL•

RCU

PCB CHK.

TEST RUN

SUB

RCU MAIN

NORMAL

ADR

(1) Remove the cover plate by inserting a flat tip

(minus) screwdriver or similar tool into the notch

in the lower section and prying it off.

5 6

(WL)

(2) Cut out a section (3-3/4 × 2-1/32 in.) on the

ceiling using the paper pattern (supplied) as a

guide.

(3) Run the wire through the mounting carrier and insert

into the installation hole as shown in Fig. 7-19.

(4) Fit securely into the ceiling material at sections

(A) and (B) as shown in Fig. 7-20.

2006_M_I

Fig. 7-18

(5) Connect the wire (2-wire core) from the signal

receiving unit with the wire from the indoor unit.

(See section on how to wire the receiving unit.) as

shown in Fig. 7-20.

(6) Use the supplied spacers to adjust for a thickness

several inches more than the ceiling material and

lightly fasten the receiving unit in place with the

small screws (M4 × 1-9/16 in., 2 pcs.) supplied

with the unit.

2007_M_I

(7) Tighten the machine screws after fitting sections

(A) and (B) into the openings, in the gap between

the signal receiving unit and ceiling surface as in

Fig. 7-21. Do not apply strong force when tighten-

ing the screws. Excessive force might warp or

damage the cover. When finished the signal

receiving unit should still be able to move slightly

when pressed as shown in Fig. 7-21.

Fig. 7-19

2009_M_I

Fig. 7-20

(8) Reinstall the cover plate.

2008_M_I

Fig. 7-21

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7-13. Electrical Wiring

Make correct wiring without

any mistakes (incorrect

wiring will damage the

equipment).

CAUTION

● Recommended wire diameter and allowable length

for signal receiving unit wiring and its branch wiring:

AWG #18, MAX 1,300 ft.

Terminal board

WHT

BLK

Signal receiving

unit

for indoor unit

remote controller

wiring

Wire from signal receiving unit

Connection

Signal receiving unit wiring (field supply)

2010_M_I

Signal receiving

unit wiring

Wire joint (2 pcs.

white, supplied)

1. Peel away 9/16 in. of shield from the wire

for the connection.

2. Join the 2 wires as shown and crimp-connect

them with the wire joint (supplied).

3. When no crimp tool is available or if a

solder connection was made then cover

with insulating tape.

Signal receiving

unit wiring

Wire joint CE-1

(supplied)

3004_M_I

7-14. Test Run Switch

(WL)

(1) Remove the cover plate of the signal receiving unit.

Set the "TEST RUN" switch of the dipswitches to

the ON position.

ALL•

RCU

PCB CHK.

TEST RUN

SUB

RCU MAIN

NORMAL

(2) Press the ON/OFF operation button on the

wireless remote controller.

1 2 3

ADR

ALL•

4 5 6

RCU : SUB

PCB CHK.

TEST RUN

● During the test run, all of the 3 indicator lamps on

the indoor unit will flash.

The TEST RUN switch is

CAUTION

used only for servicing the

air conditioner. DO NOT use

this switch for normal opera-

tion. Otherwise, it may put

stress on the system.

2012_M_I

Fig. 7-22

(3) Make a test run using the air conditioner in

COOL, HEAT or FAN modes.

● To protect the air conditioner from overloading, the

outdoor unit will not start running for 3 minutes after

power is applied or the air conditioner is turned off

and then back on.

(4) After the test run, press the ON/OFF operation

button on the wireless remote controller. Then,

set the TEST RUN switch back to the OFF

position to cancel the test run mode.

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7-15. Misoperation Alarm Indicators

A blinking lamp for other than the signal receiving unit

filter shows that a problem has occurred in the unit so

make an inspection. (Refer to servicing information in

the service manual, etc.) Also, if wired remote control-

ler and dedicated service check lines (854-9-9536-

044-97: service use) are available, then detailed error

information can be obtained by connecting to the

service connector as shown in the drawing. For

information on how to connect to the signal receiving

unit, refer to instruction manual that comes with the

dedicated service check lines.

Service

connector

ALL•

RCU : SUB

PCB CHK.

TEST RUN

RCU : MAIN

NORMAL

2013_M_I

Fig. 7-23

Table 7-2

Lamp

Bright

Cause of Trouble

OPERATION

lamp

TIMER

lamp

STANDBY

lamp

●

No power supply or mis-wiring of signal receiving unit.

S.C.* errors between the indoor unit’s controller (PCB) and

signal receiving unit.

●

⅜

●

S.C. errors between indoor and outdoor units.

Alternately Indoor unit protector is activated.

Alternately Outdoor unit protector is activated.

Compressor protector is activated.

Concurrent Mis-setting of indoor unit.

Concurrent Mis-setting of outdoor unit.

(WL)

S.C. : Serial communications

OPERATION lamp

TIMER lamp

STANDBY lamp

FILTER lamp

2014_M_I

Fig. 7-24

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7-16. Basic Wiring Diagram

Install wiring correctly

● Use shielded wires for inter-unit control wiring and

ground the shield on both sides. (Fig. 7-25)

Otherwise misoperation because of noise may

occur.

CAUTION

(incorrect wiring will damage

the equipment).

Shielded wire

ground

0797_M_I

Fig. 7-25

Group

control

Standard

remote control

Multiple

remote control

Connection wiring

for group control

1 2

Terminal

1 2

Indoor unit

No. 1

Indoor unit

No. 2

Indoor unit

No. 3

Indoor unit

No. 8

1 2

Inter-unit control wiring

1 2

Outdoor unit

: Ground (earth)

2036_M_I

Inter-unit wiring

Indoor

unit 1

Indoor

unit 2

Indoor

unit 7

Indoor

unit 8

(WL)

Group-control wiring

(Main) (Sub)

2031_M_I

● Wiring procedure

Install the wiring according to the above wiring

diagram.

● The address setting is automatically ex-

ecuted after turning on the system.

An indoor unit address is assigned to each

indoor unit.

● Operation takes place successively at

intervals of 1 second, by using combinations

of the address setting of each unit.

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7-17. Wiring System Diagram for Group Control

This diagram shows when several units (maximum of

8) are controlled by a signal receiving unit (master

unit). In this case, a signal receiving unit can be

connected at any indoor unit.

Signal receiving unit

Connection wiring for

Wiring procedure

1 2

group control

Wire according to the left diagram:

Wire joint

● Address setting is executed automatically when the

outdoor unit is turned on.

(2 wires)

1 2

Indoor unit

No. 1

Indoor unit

No. 2

Indoor unit

No. 3

Indoor unit

No. 8

● Each successive unit will respond at one-second

intervals following the order of the group address

when the remote controller is operated.

1 2

Inter-unit

control

wiring

1 2

Outdoor unit

: Ground (earth)

2037_M_I

● Group control using 2 signal receiving unit.

It does not matter which of the 2 signal receiving unit

you set as the main controller.

When using multiple signal receiving unit (up to 2 of

them can be used), one is the main signal receiving

unit and the other is the sub-signal receiving unit.

Signal

receiving unit

(main)

(sub)

1 2

● To set up a sub-signal receiving unit, change its

remote control address connector (RCU. ADR)

located on its PCB from main to sub position (main:

when shipped from factory).

Connection wiring

for group control

(WL)

1 2

Wire joint

(2 wires)

Indoor unit

No. 2

Indoor unit

No. 8

Indoor unit

No. 1

Indoor unit

No. 3

: Ground (earth)

2038_M_I

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7-18. Wiring System Diagram for Multiple

■ When Installing Multiple

This multiple system is used for operating the unit(s) at

different positions. (A maximum of 2 signal receiving

unit can be installed.)

● Setting method

To execute this control, make the setting according

to the following procedure.

(1) Of the two installed signal receiving unit, make

one the main signal receiving unit (factory-

shipped state).

(2) On the other signal receiving unit, change the

address connector on the PCB from main to sub

position.

In this state, it functions as a sub-signal receiving

unit.

● Basic wiring diagram

Install wiring correctly

CAUTION

(incorrect wiring will damage

the equipment).

Signal receiving unit

(main)

(sub)

(Option)

1 2

(WL)

1 2

● To operate 1 indoor unit with 2 signal receiving unit

set at different places.

Connection wiring

Remote control

cable terminal

board

1 2

Indoor unit

Earth

2015_M_I

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8. HOW TO INSTALL THE WEEKLY TIMER

OPTIONAL PART

(

)

Spacer

Do not supply power to the

unit or try to operate it until

the tubing and wiring to the

outdoor unit is completed.

Wall

3-17/32 in. or more 4-29/32 in. or more

8-1. Mounting Dimensions for Continuous Installation

● For vertical continuous installation, the space

between the weekly timer and the remote controller

must be 1 in. or more.

Wiring outlet

Switch box

● Do not twist the control

wiring with the power

wiring or run it in the

same metal conduit,

because this may cause

malfunction.

CAUTION

2016_C_I

Fig. 8-1

● Install the weekly timer

away from sources of

electrical noise.

● Install a noise filter or

take other appropriate

action if electrical noise

affects the power supply

circuit of the unit.

The mounting position for the weekly timer should be

located in an accessible place for control. Never

cover the weekly timer or recess it into the wall.

Concealed box

Spacer

(WL)

8-2. When Using a Wall Box for Flush Mounting

M4 × 31/32 in.

Screws (2)

● If local codes allow, this weekly timer can be

mounted using a conventional wall box for flush

mounting.

(1) Remove the flat-top screw on the bottom of the

back case. When you open up the decorative

cover, you will see two gaps under the weekly

timer. Insert a coin into these gaps and remove

the back case. (Figs. 8-2, 8-3)

Weekly

timer

Decorative

cover

2017_C_I

(2) Attach the back case with the 2 small screws

provided. Using a screwdriver, push open the

cut-outs on the back case. These holes are for

screws. Use the spacers and take care not to

tighten the screws excessively. If the back case

does not sit well, cut the spacers to a suitable

thickness. (Fig. 8-2)

Fig. 8-2

Control panel

(3) Connect the 4 wires to the weekly timer 4P

terminal base (see next page).

Gap

Coin

(4) To finish, fit the back tabs of the back case into

the weekly timer and mount it using the flat-top

screw.

2018_M_I

Fig. 8-3

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8-4. Test Run Setting

8-3. Wiring Diagram

(For wiring, always use the supplied wires)

● After installation, check the output state of the

weekly timer with the “FORCED OPR.” switch

(OFF to ON) located on the rear side of its PCB.

After confirming normal operation, turn the

Timer terminal

Remote

controller

Weekly

timer

“FORCED OPR.” switch back to OFF without fail.

System

controller

Connection wiring (supplied)

FORCED OPR.

switch

0806_M_I

● Layout

The weekly timer and remote controller may be

located, either one on the left or right sides.

● Wiring procedure

2021_M_I

Do the wiring according to the following procedure.

Fig. 8-5

Loosen the retaining screw of the lead wire of the

weekly timer, remove the collar, and connect the

suppplied connection wiring to the timer terminal

(4P connector) of the weekly timer. Place the

supplied connection wiring into the groove neatly,

and then refasten the collar.

8-5. Memory Back Up Function for Power Failure

Compensation

● This weekly timer keeps the settings of operating

buttons memorized; so that after a power failure

the operation can be restarted in the same set

state by pressing the PROGRAM button.

To indoor unit

Remote control To weekly

cable terminal timer

board

To remote

controller

● Using the “Back Up”

After installation, confirm that the BAT.BKUP

switch on the rear side of the weekly timer’s PCB is

ON.

Connection wiring

(supplied)

Connector

(WL)

2019_M_I

Back-up switch

Pass the supplied connection wiring through the

lead-wire drawing-out port on the bottom case of

the weekly timer, then run it behind the wall and

connect it to the timer terminal (4P terminal) of the

remote controller. (Fig. 8-4)

2022_M_I

Fig. 8-6

(Use the supplied collar for fastening the wire of

the remote controller.)

Connection wiring (supplied)

Lead wire

drawing

out port

2020_C_I

Fig. 8-4

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9. HOW TO INSTALL THE SYSTEM CONTROLLER

(OPTIONAL PART)

Do not supply power to the

unit or try to operate it until

the tubing and wiring to the

outdoor unit is completed.

9-1. System Controller Installation

Switch box

(no cover)

● Do not twist the control

M4 × 1-3/16 in.

Screws (2)

wiring with the power

wiring or run it in the

same metal conduit,

because this may cause

malfunction.

CAUTION

Back case

● Install the system con-

troller away from sources

of electrical noise.

Flat-top

Screw

System

controller

2041_C_I

● Install a noise filter or

take other appropriate

action if electrical noise

affects the power supply

circuit of the unit.

Fig. 9-1

● If local codes allow, this system controller can be

mounted using a conventional wall box for flush

mounting.

Gap

Coin

(1) Remove the flat-top screw on the bottom of the

back case. When you open up the decorative

cover, you will see two gaps under the system

controller. Insert a coin into these gaps and

remove the back case. (Figs. 9-1, 9-2)

2042_M_I

(2) Connect the wires to terminal base of the system

controller (see next page).

Fig. 9-2

(3) Attach the back case with the 2 M4 screws

provided.

(4) To finish, fit the back tabs of the back case into

the system controller and mount it using the flat-

top screw.

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9-2. Electrical Wiring

How to connect electrical wiring

Indoor unit PCB

(1) Connect B1, B2 to indoor PCB CRV connector

using accessary 2P connector. (*No polarity)

Total wire legth is less than 985 ft. and size is

AWG#18.

CRV

(CN91: WHT)

(2) Connect B5, B6 to indoor unit 2P terminal base.

(*No polarity). Wire size is AWG#18.

Accessary connector

Wire joint connection

● Basic wiring

B1:

Power supply: DC12V *No polarity

2P terminal base

System controller

To CRV connector (CN91) on indoor PCB

B2:

Indoor unit

2044_M_I

B3:

B4:

B5:

B6:

Not be used

Fig. 9-3

Auxiliary of inter-unit control wiring

Inter-unit control wiring. (Low voltage)

To indoor unit 2P terminal base (U1, U2)

*No polarity

● Terminals for remote monitoring

A1:

A2:

A3:

A4:

A5:

A6:

Input for turning on air conditioners concurrently.

Input for turning off air conditioners concurrently.

Common input for turning air conditioners on or off.

On operation state indicator output.

Alarm indicator output.

Connector for

weekly timer

(Under the terminal)

3005_M_I

Fig. 9-4

Common indicator output.

Basic wiring diagram of control wiring

RC1

RC2

RC3

● Max. 64 indoor units and 30 outdoor units can be

connected in 1 system.

Inter-unit

control wiring

● Up to 10 system controller can be connected in 1

1-1

1-2

1-3

2-1

2-2

2-3

3-1

system.

System controller

2045_M_I

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9-3. Address Switch Setting

SW1

Main/sub selection switch

OFF: System controller operates as main controller.

ON: System controller operates as sub-controller.

OFF

ALL/ZONE mode selection switch

ALL mode:

All indoor units can be controlled by system controller

ZONE 1, 2, 3, 4 mode:

Indoor units in one of zone 1, 2, 3, or 4 can be controlled

by system controller. All indoor units cannot be set.

ALL mode

ZONE 1 mode OFF OFF

OFF OFF

OFF

ZONE 2 mode ON OFF OFF ON

ZONE 3 mode OFF ON

ZONE 4 mode ON ON

Central control/Remote control mode selection switch.

OFF: Central control mode.

Individual setting by remote controller can be inhibited by

system controller.

ON: Remote control mode.

Setting by system controller is inhibited by other central

control equipments.

Central control Main/Sub selection switch

(OFF: Main, ON: Sub)

1 When AMY adaptor etc. is used with system controller,

set the switch to ON position.

2 When only one system controller is used, set the switch to

OFF position.

3 Except 1, when multiple system controllers are used,

set only one system controller to OFF position others to

ON position.

ALL mode system controller to be OFF position.

(recommended)

(Central control) button operation switch

OFF:

ON :

(Central control) button operation is permitted.

button operation is inhibitted.

*All switches are OFF position at shipment.

2046_M_I

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SW2

Weekly timer input switches.

System controller operation can be set when weekly timer

activates (ON/OFF).

OFF

Switch No.

System controller operation

Timer OFF→ON

All ON

Timer ON→OFF

All OFF

OFF OFF OFF

ON OFF OFF

No change

Individual control All indoor units to

3 of all indoor units be

1*¹

OFF ON OFF

to be permitted

All OFF and all

Ditto

indoor units to be ON ON OFF

1*¹

All indoor units to

2*²

OFF OFF ON

All OFF and all

indoor units to be ON OFF ON

2*²

Incase of Remote control mode, use 1 or 2.

In case of ZONE 1, 2, 3, 4 mode, ALL, all indoor units means

one of ZONE 1, 2, 3, 4.

*¹:

1 (Central control 1) means ON/OFF operation cannot

excecute by remote controller.

2 (Central control 2) means ON/OFF, MODE change.

Temp. setting cannot be excecuted by remote controller.

*²:

Auxiliary switch

Must be set to OFF position.

Beep tone switch

OFF: Beep tone when each button is pushed.

ON: No tone when each button is pushed.

Indication switch

Normally set to OFF position.

When set to ON position, indication is not displayed on LCD

of system controller.

2047_M_I

*All switches are OFF position at shipment.

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9-4. Mode Setting

Central control

mode

Remote control

mode

According to function of each system controller, set

SW1 as Fig. 9-5.

(1) Central control/Remote control mode

OFF

ALL

central control

ALL

remote control

● Central control mode

Inter-unit control wiring

System controller is used as central control equip-

ment.

ZONE1

OFF

central control

address 1-16

Individual setting by remote controller can be

inhibitted by system controller

ZONE1

central control

ZONE1

remote control

● Remote control mode

ZONE2

central control

address 17-32

System controller is used as remote controller.

Setting by system controller is inhibitted by other

central control equipments.

OFF

ZONE2

central control

ZONE2

remote control

(2) ALL/ZONE mode

ZONE3

central control

address 33-48

OFF

ZONE3

central control

ZONE3

remote control

● ALL mode

All indoor units can be controlled by system control-

ler.

ZONE4

central control

address 49-64

OFF

● ZONE mode

ZONE4

central control

ZONE4

remote control

Indoor units in one of ZONE 1, 2, 3 or 4 can be

controlled by system controller

2048_M_I

(3) Function of system controller is 10 types accord-

ing to combination of central control/remote

control mode and ALL/ZONE mode setting as the

table 9-1.

Fig. 9-5

(4) Stick the system controller unit label in a con-

spicuous position.

Table 9-1

Central control

1. ALL/Central

Remote control

6. ALL/Remote

ALL

ZONE1 2. ZONE1/Central 7. ZONE1/Remote

ZONE2 3. ZONE2/Central 8. ZONE2/Remote

ZONE3 4. ZONE3/Central 9. ZONE3/Remote

ZONE4 5. ZONE4/Central 10. ZONE4/Remote

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9-5. How to Perform Zone Registration

To operate the system controller properly, zone registration is required after finishing the test run (and after

setting all indoor unit addresses) using one of the following methods.

(a) Zone registration using the remote controller (RCS-SH80UG)

Refer to page 73

(b) Zone registration using the system controller (SHA-KC64UG)

Refer to page 74

Refer to page 75

For methods (a) and (b), you should make a zone registration table manually before performing the

registration as shown on the next page.

For method (c), zone registration is executed automatically, proceeding from small indoor unit address and

small central addresses to larger numbers in numerical order. For example:

Central address

ZONE–group

1-1

1-2

1-3

2-1

1-4

2-2

1-5

2-3

1-6

3-1

Indoor unit address 1-1

NOTE

1. An indoor unit address is assigned to each indoor unit during automatic address

operation. Each indoor unit address combines an R.C. address and indoor unit number

as follows:

1 – 1 : Indoor unit address (UNIT No.)

Indoor unit No.

Refrigerant circuit No. (R.C. address)

2084_M_I

This address is displayed on remote controller for UNIT No. when the UNIT button is

pressed.

2. The central address represents the zone and group number. These addressed are

assigned in ascending numerical order.

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(a) Zone registration using the remote controller

(RCS-SH80UG)

(Determination of central address)

● In this case, after confirming which indoor unit is

connected to the remote controller and that the air

conditioner in the OFF state, you set the central

addresses one at a time.

● If the system has no remote controller, connect a

remote controller to the system temporarily. Then

follow this procedure.

NOTE

The indoor unit address must already have been set

before performing zone registration. If necessary, refer

to the Installation Manual supplied with the outdoor

unit.

(1) Press the

and

buttons at the same time

of the remote controller for more than 4 seconds.

(2) Do not press

buttton.

(3) Once in this mode, the UNIT No., CODE No., No.

of SET DATA and

indications will flash on

the display as shown Fig. 9-6.

NOTE

In case of group control “ALL” instead of “UNIT No.”

will flash on the display. Select the main indoor unit

address by pressing the

button once.

2049_M_I

Fig. 9-6

(4) Set CODE No. to 03 using the

) buttons.

and

(

NOTE

The CODE No. 03 must be selected to perform zone

registration using the remote controller.

(5) Set the Central address which you want to assign

to the indoor unit address using the

and

(

) buttons according to the zone

registration table.

(6) Press the

button. The CODE No. and Central

address changes from flashing to ON state. If you

make mistake, then press the

reset the central address.

button and

(7) Press the

button to finish zone registration.

2050_M_I

For example, in this case

Indoor unit address: 1–8

Central address

: 17 (ZONE 2, GROUP 1)

Fig. 9-7

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(b) Zone registration using the system controller

(SHA-KC640G)

● In this case, you set all central addresses by

If no data is

registered

no number is

displayed.

system controller at once manually.

ZONE

(1) Press the

and

ZONE

buttons at the same

Selected group

No. if no data is

registered.

time for more than 4 seconds.

and CODE No. C1 will flash.

If data is

(2) After confirming that CODE No. C1 is displayed,

registered

the unit No.

is displayed.

press the

button. Once in this mode, a

GROUP

SELECT

ZONE

change takes place as Fig. 9-8.

(3) Select the zone and group No. which you want to

set with

buttons.

ZONE

and

(GROUP)

2051_M_I

If already set, press the

buttons.

Fig. 9-8

(4) Set the unit No. (Indoor unit address) with

and buttons, according to the zone registra-

tion table.

R.C. No. ...................

Indoor unit No...........

ZONE

button

(5) Press the button.

GROUP No. turns ON and UNIT No. (Indoor unit

address) changes from flashing to ON state.

UNIT No. is registered to selected ZONE No. and

GROUP No..

GROUP

SELECT

ZONE

If you make mistake, then press the

button

and reselect the ZONE, GROUP and UNIT No.

2052_M_I

For example, in this case

Zone 3, group No. 7

(6) Register the other UNIT No. in the same way by

following the steps (3) to (5).

Unit No. (indoor unit address) 2-8

(7) Finally, complete the registration by pressing the

button.

Unit No. 2-8 is registered to zone 3-group 7.

Fig. 9-9

flashes for a few minutes, then OFF.

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controller (SHA-KC64UG)

(1) Press the

and

ZONE

buttons at the same

time for more than 4 seconds.

and CODE No. C1 will flash.

ZONE

(2) Select CODE. No. C2 by pressing

( ) button and press the

and

button.

C2 changes from flashing to ON state and

automatic zone registration will start.

GROUP

SELECT

ZONE

(3) Registered GROUP No. will be disappeared all.

(4) Central address will be assigned from small

indoor unit address to large one in numerical

order automatically.

2053_M_I

Finishing automatic zone registration,

changes from flashing to OFF.

Fig. 9-10

(5) If the error is happened, the “CHECK” starts

flashing and zone registration finishes at this

time. Press the

button.

(6) Finally, complete automatic zone registration

mode by pressing the button.

flashes for a few minutes, then OFF.

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■

How to check overlapping of central address No.

(1) Press the and buttons at the same

ZONE

time for more than 4 seconds.

and CODE No. C1 will flash.

ZONE

(2) Select CODE. No. C3 by pressing

( ) button and press the

button.

C3 changes from flashing to ON state and

will flash. Then auto. overlap checking will start .

GROUP

SELECT

ZONE

(3) If C3 changes from ON to flashing and

stops flashing and disappears, there is no over-

lapping.

Then finally, complete the auto overlap checking

2054_M_I

mode by pressing the

button.

Fig. 9-11

(4) If some of GROUP No., ZONE No. and UNIT No.

flash, you should try again the zone registration.

1 Select CODE No. C1 by pressing

( ) button and press the

button.

2 Select the flashing GROUP No. with ZONE

and GROUP button.

Then press the

button and reselect the

ZONE, GROUP and UNIT No.

3 Then finally, complete the auto. overlap

checking mode by pressing the

button.

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■ ZONE registration table

Indoor unit

address

(UNIT No.)

Indoor unit

address

(UNIT No.)

Central

address

ZONE GROUP

address

Unit location

ZONE GROUP

Unit location

NOTE 1. Assign indoor unit addresses to the desired positions (central addresses)

manually.

2. For group control, only the main indoor unit should be assigned.

Sub indoor units cannot be assigned.

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9-6. Connection with Other Equipments

System controller

Equipment

Example

Input/output

Terminal

Input/output

Wire length:

less than 330 ft.

CPEV

AWG#16

ON/OFF output

Alarm output

ON/OFF

Potential tree

A contact, static

(relay output)

Alarm

Contact capacity

DC 30V, 0.5A

Output common

ALL ON (+)

Pulse width:

more than

All ON input

All OFF input

Pulse (photo

compler input)

+24

CPEV

AWG#16

984 ft./sec.

Wire length:

less than 330 ft.

ALL OFF (+)

Contact capacity

DC 24V, 10mA

Input common

COM

2055_M_I

9-7. Memory Back Up Switch

Check the back up switch is ON for back side of PCB

by system controller.

9-8. Test Run

Back up switch

(1) Power on for all indoor units. Next, power on for

system controller.

will flash, checking the indoor unit address

automatically.

Back up battery

(2) If group No. displayed on system controller is not

same as indoor unit No.* which is connected, see

Fig. 9-5 and setting again.

2056_M_I

*In case of group control, main unit No. only.

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10. HOW TO PROCESS TUBING

Deburring

The narrow tubing side is connected by flare nut, and

the wide tubing side is connected by brazing.

Before

After

10-1. 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.

10-2. Flaring Procedure with a Flare Tool

(1) Cut the copper tube to the required length with a

tube cutter. It is recommended to cut about

0126_M_I

Fig. 10-1

12 – 20 in. longer than the estimated tubing length.

(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. 10-1)

Copper

tubing

NOTE

Reamer

When reaming, hold the tube end downward and be

sure that no copper scraps fall into the tube. (Fig. 10-2)

(3) Remove the flare nut from the unit and mount it

on the copper tube.

0127_M_I

Fig. 10-2

(4) Make a flare at the end of copper tube with a flare

tool.* (Fig. 10-3)

*Use “RIGID ” or equivalent.

NOTE

Flare nut

A good flare should have the following characteristics:

Copper

tubing

● inside surface is glossy and smooth.

● edge is smooth.

Flare tool

● tapered sides are of uniform length.

0128_M_I

Fig. 10-3

10-3. Precaution before Connecting Tubes Tightly

(1) Apply a sealing cap or water-proof tape to pre-

vent dust or water from entering the tubes before

they are used.

(2) Apply refrigerant lubricant to the matching sur-

faces of the flare and union before connecting

them together. This helps to reduce gas leaks.

(Fig. 10-4)

Apply refrigerant

lubricant here and here

0129_M_I

Fig. 10-4

(3) For proper connection, align the union tube and

flare tube with each other, then screw in the flare

nut lightly at first to obtain a smooth match.

(Fig. 10-5)

● Adjust the shape of the narrow and wide tubes

using a tube bender at the installation site and

connect them to the each tubing side valve using

a flare nut.

Union

Flare nut

0130_M_I

Fig. 10-5

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10-4. Precautions during Brazing

Torque wrench

● Replace air inside the tube with nitrogen gas to

prevent copper oxide film from forming during the

brazing process.

Spanner

Indoor unit

● Do not allow the tubing to get too hot during the

brazing process.

Outdoor unit

The nitrogen gas inside the tubing may overheat,

causing refrigerant system valves to become

damaged. Therefore allow the tubing to cool be-

tween brazings.

0131_C_I

Fig. 10-6

Insulation

Thickness:

Min. 5/16 in.

Thickness:

Min. 5/16 in.

10-5. Connecting Tubing between Indoor and

Outdoor Units

(1) Tightly connect the indoor side refrigerant tubing

with the outdoor side tubing. (Fig. 10-6)

Narrow tube

Wide tube

0999_C_I

Fig. 10-7

(2) To fasten the flare nuts, apply specified torque as:

Table 10-1

Refrigerant tubing

Tube Dia.

Tightening Torque

Approx. 120 — 160 Ibs-in.

(140 — 180 kg-cm)

Approx. 300 — 360 lbs-in.

(340 — 420 kg-cm)

Approx. 870 — 1040 lbs-in.

(1000 — 1200 kg-cm)

1/4" (6.35 mm)

Seal (supplied)

Insulation tape (white)

(supplied)

3/8" (9.52 mm)

3/4" (19.05 mm)

Flare insulator (supplied)

Tube insulator

(not supplied)

Unit side

insulator

10-6. Insulating the Refrigerant Tubing

Always insulate tubes after

Flare nut

Vinyl clamps (supplied)

1015_X_I

CAUTION

Fig. 10-8

draining water and complet-

ing leak tests on all connec-

tion points.

Refrigerant tubing and insulator

(not supplied)

Important

Drain insulator

and clamp.

Large

Drain pipe and insulator

(not supplied)

To avoid condensation and water leaks, the wide tube

(gas line) must be insulated with the supplied insula-

tion materials.

(supplied)

Taping the flare nuts

Packing

clamp.

Small

hose band

(supplied)

Insulation

tape

Vinyl

Wind white insulation tape around the flare nuts at the

wide tube connections. Place the seal (supplied) on

the unit. Then cover up the tubing connections with the

flare nut insulator, and cover the gap at the union with

the supplied black insulation tape. Finally, fix the

insulator at both ends with vinyl clamps. (Fig. 10-8)

Flare clamp

insulator

Seal

Insulation material

The material used for insulation must have good

insuIation characteristics, be easy to use, be age

resistant, and must not easily absorb moisture.

1373_X_I

Never grasp the drain or refrigerant connecting

outlets when moving the unit.

After a tube has been insu-

Fig. 10-9

CAUTION

lated, never try to bend it

into a narrow curve because

it can cause the tube to

break or crack.

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10-7. Taping the Tubes

(1) At this time, the refrigerant tubes (and electrical

wiring if local codes permit) should be taped with

armoring tape in 1 bundle. To prevent the con-

densation from overflowing the drain pan, keep

the drain hose separate from the refrigerant

tubing.

Clamp

Drain hose

Insulated tubes

(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. 10-10)

(3) Clamp the tubing bundle to the wall, using 1

clamp about every 3 feet.

1124_M_I

NOTE

Fig. 10-10

Do not wind the armoring tape too tightly since this will

decrease the heat insulation effect. Also ensure that

the condensation drain hose splits away from the

bundle and drips clear of the unit and the tubing.

Apply putty here

10-8. Finishing the Installation

After finishing insulating and taping over the tubing,

use sealing putty to seal off the hole in the wall to

prevent rain and draft from entering. (Fig. 10-11)

Tubing

0137_C_I

Fig. 10-11

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11. AIR PURGING

Manifold valve

Air and moisture in the refrigerant system may have

undesirable effects as indicated below.

Pressure

gauge

● pressure in the system rises

● operating current rises

Charge hose

● cooling (or heating) efficiency drops

● moisture in the refrigerant circuit may freeze and

block capillary tubing

Nitrogen gas cylinder

(In vertical standing

position)

● water may lead to corrosion of parts in the refriger-

ant system

Therefore, the indoor unit and the tubing between the

indoor and outdoor units must be checked for leaks and

evacuated to remove air and moisture.

■ Air Purging with a Vacuum Pump (for Test Run)

Outdoor unit

Preparation

Check that each tube (both narrow and wide) between

the indoor and outdoor units has been properly con-

nected and all wiring for the test run has been com-

pleted. Remove the valve caps from both the wide and

narrow service valves on the outdoor unit. Note that

both narrow and wide tube service valves on the

outdoor unit are kept closed at this stage.

Service

valve

Narrow

tube

Wide tube

Leak test

Indoor unit

(1) With the service valves on the outdoor unit

closed, remove the 1/4 in. flare nut and its bonnet

on the wide tube service valve. (Save the flare

nut and its bonnet for reuse.)

3-way valve is used for 3642 type.

2090_C_I

(2) Attach the nitrogen gas cylinder to the service

port of the wide tube via a manifold valve with

pressure gauges. (See Fig. 11-2)

Fig. 11-1

Manifold valve

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 closed.

CAUTION

Pressure

gauge

Cap

(3) Pressurize the system to about 150 P.S.I.G. with

dry nitrogen gas and close the cylinder valve when

the gauge reading reaches about 150 P.S.I.G.

Then, test for leaks with liquid soap.

Nitrogen gas

cylinder

Narrow tube

Wide tube

1370_C_I

Fig. 11-2

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To avoid nitrogen entering

the refrigerant system in a

liquid state, do not use the

nitrogen cylinder up side

down. Use the cylinder in a

vertical standing position.

(Refer to the previous page.)

Manifold valve

CAUTION

Pressure

gauge

(4) Do a leak test of all joints of the tubing (both

indoor and outdoor) and both wide and narrow

service valves. Bubbles indicate a leak. Wipe off

the soap with a clean cloth after the leak tests.

(5) 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.

Vacuum pump

Outdoor unit

Evacuation

(1) Attach the charge hose end (described in the

preceding steps) to the vacuum pump to evacu-

ate the tubing and indoor unit.

Service

valve

Confirm that the “Lo” knob of the manifold valve

is open. Then, run the vacuum pump. The

operation time for evacuation varies with the

tubing length and capacity of the pump. The

following table shows the required time for

evacuation:

Narrow

tube

Wide tube

Required time for evacuation

when 30 gal/h vacuum pump is used

Indoor unit

If tubing length is

less than 50 ft.

If tubing length is

longer than 50 ft.

45 minutes or more

90 minutes or more

3-way valve is used for 3642 type.

2091_C_I

Fig. 11-3

NOTE

Manifold valve

The required time in the above table is calculated on

the assumption that the ideal (or target) vacuum

condition is around 10 mmHg abs.

Vacuum

gauge

(2) When the desired vacuum is reached, close the

“Lo” knob of the manifold valve and turn off the

vacuum pump.

Cap

Vacuum pump

Narrow tube

Wide tube

0540_C_I

Fig. 11-4

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Charging additional refrigerant

● Charge additional refrigerant (calculated from the

narrow tube length as shown in Sec. 1-5) using the

wide tube service valve with the system in cooling

operating mode. (Fig. 11-5)

Wide tube

Outdoor

unit

Indoor

unit

Narrow tube

Max. allowable Required

tubing length additional

at shipment

charge

● Use a balance to measure the refrigerant accu-

165 ft.

rately.

1396_M_I

Fig. 11-5

Finishing the job

(1) With a hex wrench, turn the narrow tube service

valve stem counterclockwise to fully open the

valve. (Fig. 11-6)

OPEN

(2) With a screwdriver, turn the wide tube service

valve stem counterclockwise to fully open the

valve. (Fig. 11-6)

Hex wrench

To avoid gas from leaking

CAUTION

when removing the charge

hose, make sure the stem

of the wide tube is turned

all the way out (“BACK

SEAT” position).

Narrow tube

Wide tube

1002_C_I

Fig. 11-6

(3) Loosen the charge hose connected to the wide

tube service port (1/4 in.) slightly to release the

pressure, then remove the hose.

(4) Replace the 1/4 in. flare nut and its bonnet on the

wide tube service port and fasten the flare nut

securely with an adjustable wrench or box

wrench. This process is very important to prevent

gas from leaking from the system.

(5) Replace the valve caps on both the wide and

narrow service valves and fasten them securely.

This completes air purging with the vacuum pump. The

air conditioner is now ready for a test run.

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12. TEST RUN

12-1. Preparing for Test Run

● Before attempting to start the air conditioner,

(Power must be turned ON

at least 5 hours before

attempting test run)

check the following:

(1) All loose matter is removed from the cabinet

especially steel filings, bits of wire, and clips.

(2) The control wiring is correctly connected and all

electrical connections are tight.

Power mains switch

0765_C_I

(3) The protective spacers for the compressor used

for transportation have been removed. If not,

remove them now.

Fig. 12-1

(4) The transportation pads for the indoor fan have

been removed. If not, remove them now.

Narrow tube service

valve (3-way valve)

(5) The power has been connected to the unit for at

least 5 hours before starting the compressor. The

bottom of the compressor should be warm to the

touch and the crankcase heater around the feet

of the compressor should be hot to the touch.

(Fig. 12-1)

Wide tube service

valve (ball valve)

Fully OPEN

(6) Both the wide and narrow tube service valves are

open. If not, open them now. (Fig. 12-2)

1371_C_I

Fig. 12-2

● Test run procedure

❏ The purpose of the test run function is to let you control the operation of the unit directly without the

thermostat turning the unit on or off. As indicated in the following procedure, switch out of TEST

RUN when you are finished, or the air conditioner can be damaged because it will not cycle on and

off normally.

❏ To protect the air conditioner from overloading, the outdoor unit will not start running for 3 minutes

after power is applied or the unit is turned OFF.

Press the

(TEST RUN) button on the remote

Alarm message

controller. (Fig. 12-3)

Press the

(ON / OFF operation) button

to start the test run.

Press the

(MODE) button to select either

COOL or HEAT mode.

When the test run has started, “TEST” shows on

display of the remote controller.

During the test run, the air conditioner runs

continuously and the thermostat does not control

the system.

After the test run, press the

button once

again to cancel this mode and check that “TEST”

is not shown on the display.

The TEST RUN button is

TEST RUN/CHECK

button

ON/OFF operation MODE button

button

used only for servicing the

air conditioner. Do not press

this button for normal

operation, or the system

may be damaged.

CAUTION

2057_C_I

Fig. 12-3

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12-2. PCB Setting

● Setting of outdoor control PCB

(A) Standard control (single outdoor unit)

In case of single outdoor unit installation, even if

in case of twin, triple or quartet type (2, 3 or 4

indoor units), no setting necessary.

Keep factory shipment state (R.C. address is set

in “0”).

In this case, auto. address operation takes place

automatically for the first time when the power is

switched on. This takes about a few minutes.

(B) Group control (Multiple outdoor units)

In case of group control (up to 8 indoor units can

be connected with one remote controller), before

turning the power supply on set the R.C. address

with S2, S3 on the outdoor control PCB.

R.C. address: Refrigerant circuit address 1 ~ 30.

Regarding the example of R.C. address for group

control, please refer to page 43 and sec. 12-3

(page 87).

controller)

In case of central control (when using the system

controller,that is, when linking outdoor units in a

network),

(a) Before turning the power supply on, set the

R.C. address with S2, S3 on the outdoor

control PCB.

(b) Remove the short plug (CN006, 2P Black)

from all outdoor units except any one of

outdoor unit.

Regarding the example of R.C. address for

central control and the position of CN006, please

refer to sec. 12-3.

(page 87).

● Setting of indoor control PCB

No setting necessary.

Each indoor unit address (UNIT No.: R.C. – No.) is decided after auto. address operation.

Indoor unit No.

Refrigerant Circuit No. (R.C. address)

Manual setting for indoor unit address can be performed also by remote controller.

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12-3. R.C. Address Setting Method

Outdoor unit R.C. address setting method

In case of group control or central control, set the R.C. address to 1, 2, 3, ... according to the No. of outdoor

units.

Outdoor control PCB

CN006 (2P Black)

Refrigerant circuit address

(factory setting = 0)

Refrigerant circuit address (black)

: S2

Refrigerant circuit address

(2P DIP switch, green or Blue)

position position

ON side

: S3

OFF side

A. ADD (S1):

Automatic address setting start button

Used for central control (link system)

and group control (Normally, not used)

2093_C_I

R.C. address

(S3 2P dip switch, green or blue)

R.C. address

(S2 Rotary switch, Black)

ON side

00 auto address

(“0” when shipped from factory)

Both OFF

Set to 0

OFF side

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12-4. Automatic Address Setting Method

12-5. Displaying Indoor / Outdoor Unit Combina-

tion Numbers

— For group control and central control with multiple

outdoor units —

Display the indoor / outdoor unit address after auto-

matic address setting.

Carry out automatic address setting with the

remote controller.

(1) When installing multiple units, match the indoor

unit address numbers and the outdoor R.C.

address numbers and display them at an easy-to-

check location (near the nameplate) with an oil-

based magic marker or other indelible marker so

that the individual indoor and outdoor unit combi-

nations can be checked.

(1) All auto. address operation

Press the

the same time for more than 4 seconds.

Press the button after confirming the

and

(

) buttons at

CODE No. AA (CODE No. AA: All Auto.

address operation).

Example:

After addresses are automatically set in

order for the outdoor units from No. 1 to No.

30, the system returns to the normal

stopped state.

Outdoor Unit 1 – Indoor Units 1-1, 1-2, 1-3, ....

Outdoor Unit 2 – Indoor Units 2-1, 2-2, 2-3, ....

(2) This is necessary for maintenance. Always label

these.

(2) Individual auto. address operation for each

refrigerant circuit

*Check indoor unit address with the remote

controller. Press the

button for at least 4

To select each refrigerant circuit individually

and set addresses automatically, press the

seconds and check the indoor unit address with

the

button. (Each time you press the

and

time for more than 4 seconds, then press

the ) button once to set

CODE No. A1.

(

) buttons at the same

button, the address changes 1-1, 1-2, ...

2-1, 2-2, ...) The fan for only the selected indoor

unit turns on at high speed, so check which

indoor unit runs and label the indoor unit address.

(If there is 1 outdoor unit, the addresses are 1-1,

1-2, ...)

(

(CODE No. A1: Auto. address operation)

Select R.C. No. which you want to execute

the auto. address operation with

button.

When you press the

button again, the system

returns to normal remote control mode.

Press the

button. The auto. address

operation will start. CODE No. changes from

flashing to ON state.

If the error is happened during the operation,

the alarm message will display. Check and

remove the cause. If you want to interrupt

the operation, press the

button then the

unit stands in waiting mode (Press the

button).

If the auto. address operation finishes, the

display will disappear.

Execute the operation of the other R.C. line

in the same way by following the above

steps 2 to 3.

Complete the auto. address operation by

pressing the

button.

NOTE

Required time for auto. address operation:

In case of group control : a few minutes for each R.C.

In case of central control : max. about 20 min. for

each R.C.

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12-6. Test Run Procedure

Start

Yes

Turn on RCU address SW

of sub remote control unit

Multiple remote

control?

Recheck the test items before test operation.

(Sec. 12-7)

Check the indoor and outdoor unit combination (wiring). (Sec. 5-3)

Single type?

Multiple indoor

units for one outdoor

units?

Yes

(One indoor unit and one

remote controller for one

outdoor unit)

Turn on power supply for indoor units side

first Then turn on power supply for outdoor

unit side.

Group control

for multiple outdoor

units?

Yes

Set the outdoor unit R.C. address.

Turn on power supply switch.

(Sec. 12-2 (B))

Go next

R.C. line

Press A. ADD (S1) button (See P87).

Execute auto. address operation with the

remote controller.

(Sec. 12-4)

Yes

Finish all

R.C. line?

Central control

for multiple outdoor

units?

Yes

CN4: Open (*)

Set the outdoor unit R.C. address.

Turn on power supply switch.

Go next

R.C. line

(Sec. 12-2 (C))

Press A. ADD (S1) button (See P87).

Execute auto. address operation with the

remote controller.

(Sec. 12-4)

Yes

Finish all

R.C. line?

Display the combination number.

(Sec. 12-5)

(Sec. 12-1)

Set the remote controller to test operation.

(Sec. 12-8, 9, 10)

Check according the self-diagnostics function table,

see Sec. 12-8, 9, 10, and if there is a location to correct,

correct it.

Is operation possible?

Note: Check the indoor side drain water.

Yes

Return the remote controller to normal.

End

NOTE

0509_M_I

1) One of CN006 of all linked outdoor units shold be short.

2) In case of using system controller, zone registration is required after finishing Test run.

Regarding the zone registration, please refer to page 74 and 75.

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12-7. Items to Check Prior to Test Run

(1) Turn on the power supply switch more than 5 hours before in order to charge the crank case heater.

(2) Fully open the outdoor service valve after making the leak inspection of field connected tubing, vacuuming,

and gas charging if necessary.

(3) Check the capacity code setting.

The factory setting is as shown in the table. Double check it.

The capacity code is set by S4 (green or blue, 4P DIP switch) on outdoor control PCB.

Outdoor control PCB

S4 (green or Blue) capacity code

(4P DIP switch)

ON side

OFF side

2094_C_I

S4. Capacity code

No.

Outdoor PCB

Model No.

24 type

ON ON ON OFF

OFF ON OFF ON

ON ON OFF ON

36 type

48 type

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12-8. The Main Alarms of Mis-wiring & Mis-setting

Remote

controller

Cause

• In case of individual remote control In case of group control In case of multiple remote control

display

Nothing

displayed

• Remote controller not properly connected.

• Power supply not ON.

• Remote controller not properly connected.

• Wiring connection fault of

indoor/outdoor units

• Wiring connection fault of some indoor/outdoor units

inside the group

• Power supply of outdoor unit not ON.

• Combination of indoor/outdoor units is wrong.

* Power supply of some indoor unit is not ON.

—

• 2 main remote controllers set.

(*)

•Improper wiring connections of ceiling panel

* Ref: Alarm “P9” is not generated if the remote controller is set at test run.

12-9. The Main Alarms of Unit Troubles

Trouble detected

Remote controller display

Indoor protection

Fan motor protection thermostat

Outdoor protection Fan motor protection thermostat

Compressor protection thermostat

Abnormal discharge temp.

High pressure switch

Indoor protection

Float switch

P10

Indoor sensor

Open/or damaged

F1-F3

F4-F9

Outdoor sensor

Open/or damaged

Compressor

protection

Compressor motor is overloaded.

Compressor motor is locked.

Compressor current detection circuit is abnormal.

Low pressure protector is activated.

12-10. The Main Alarms of Power Supply Troubles

Cause

Remote controller display

Outdoor protection Power supply voltage is abnormal.

(More than 260 V or less than 160 V between L and N phase)

Negative phase or defective phase

Compressor contactor (Mg SW) is chattering.

H18

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■ Basic Functions of the Service Valves

Narrow Tube Service

Wide Tube Service

Valve (Ball Valve)

Action

Valve (3-Way)

CLOSED

O-ring

Stem

Shipping and

air purging

0549_C_I

0550_C_I

0546_C_I

Fully

OPEN

Fully

OPEN

Operating and

test running

the air conditioner

0547_C_I

Half

OPEN

Fully

OPEN

Measuring pressure

and gas charging

0548_C_I

Narrow tube service valve

Wide tube service valve

Service port (B)

Valve cap

Stem

O-ring

Valve cap

Stem

0554_C_I

0989_C_I

1372_C_I

3-Way Valve

2-Way Valve

CH2442

CH3642, CH4242

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13. PUMP DOWN

Pump down means collecting all refrigerant gas in the

system back into the outdoor unit without losing ant of

the gas. Pump down is used when the unit is to be

moved or before servicing the refrigerant circuit.

Pump down procedure

Be sure to carry out pump

CAUTION

down with the unit in cooling

mode.

(1) Connect the low pressure side (wide tube valve

service port) charging hose of the manifold valve

to the service port (B) on the wide tube service

valve.

(2) Using a hex wrench, turn the narrow tube service

valve clockwise all the way to close the service

valve.

(3) Press the operation button and start cooling

operation.

(4) When the low pressure gauge reading falls to

14.2 to 7.1 psi (1 to 0.5 kg/cm²), fully close the

wide tube valve stem with a standard screwdriver.

Then quickly stop the unit.

(5) Disconnect all gauges and hoses, and replace

the bonnets and the valve caps as they were

previously.

(6) Purge all air remaining inside the tubing before

operating the air conditioner.

S4359146

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