Panasonic CS-KE12NB41 and CZ-18BT1U + CU-KE12NK1 Manual v2
en
INSTALLATION INSTRUCTIONS
CS-KE12NB41 & CZ-18BT1U + CU-KE12NK1 CS-KE18NB4UW & CZ-18BT1U + CU-KE18NKU
(852-6-4190-577-00-2)
APPENDIX B
A-2
This air conditioner uses the refrigerant R410A.
External diameter of service port R410A: 5/16"
Split System Air Conditioner
85264190577002 2011
INSTALLATION INSTRUCTIONS
NOTE
CV6233187839
Contents Page
IMPORTANT! Please Read Before Starting .................................. 2
1. GENERAL .......................................................... 4 1-1. Tools Required for Installation (not supplied) 1-2. Accessories Supplied with Unit 1-3. Optional Copper Tubing Kit 1-4. Type of Copper Tube and Insulation Material 1-5. Additional Materials Required for Installation
2. INSTALLATION SITE SELECTION ................... 5 2-1. Indoor Unit 2-2. Outdoor Unit
3. HOW TO INSTALL THE INDOOR UNIT ............. 7 3-1. Preparation for Suspending 3-2. Suspending the Indoor Unit 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. How to Install the Ceiling Panel 3-7. Wiring Instructions 3-8. Recommended Wire Length and Diameter 3-9. Wiring Instructions for Inter-unit Connections
4. HOW TO INSTALL THE OUTDOOR UNIT ....... 15 4-1. Wiring Instructions for the Outdoor Unit
5. REFRIGERANT TUBING .................................. 16 5-1. Use of the Flaring Method 5-2. Flaring Procedure with a Flare Tool 5-3. Caution before Connecting Tubes Tightly 5-4. Connecting Tubing between Indoor and
Outdoor Units 5-5. Insulation of Refrigerant Tubing 5-6. Taping the Tubes 5-7. Finishing the Installation
6. AIR PURGING................................................... 18 Air Purging with a Vacuum Pump (for Test Run) Basic Functions of the Service Valves Pump Down Service Valve Connections
7. REMOTE CONTROLLER INSTALLATION POSITION ......................................................... 22 7-1. Mounting on a Wall
8. ADDRESS SWITCH .......................................... 23 8-1. Address Setting of the Remote Controller
Model Combinations
Combine indoor and outdoor units only as listed below.
Model No.
Indoor Unit Outdoor Unit
CS-KE12NB41 CU-KE12NK1
Power Source: 60 Hz, single-phase, 115 V
CS-KE18NB4UW CU-KE18NKU
Power Source: 60 Hz, single-phase, 230/208 V
Ceiling Panel
CZ-18BT1U
2
IMPORTANT! Please Read Before Starting
This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently.
For safe installation and trouble-free operation, you must:
Carefully read this instruction booklet before beginning.
Follow each installation or repair step exactly as shown.
Observe all local, state, and national electrical codes.
Pay close attention to all warning and caution notices given in this manual.
This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.
This symbol refers to a hazard or unsafe practice which can result in personal injury or prod- uct or property damage.
If Necessary, Get Help These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions.
In Case of Improper Installation The manufacturer shall in no way be responsible for improp- er installation or maintenance service, including failure to follow the instructions in this document.
SPECIAL PRECAUTIONS
When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.
are completed or reconnected and checked.
system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.
following local electrical codes.
heating at connection points and a possible fire hazard.
the unit must be grounded.
When Transporting
Be careful when picking up and moving the indoor and out- door units. Get a partner to help, and bend your knees when lifting to reduce strain on your back. Sharp edges or thin alu- minum fins on the air conditioner can cut your fingers.
When Installing
Select an installation location which is rigid and strong enough to support or hold the unit, and select a location for easy maintenance.
In a Ceiling or Wall
Make sure the ceiling/wall is strong enough to hold the units weight. It may be necessary to construct a strong wood or metal frame to provide added support.
In a Room
Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors.
Keep the fire alarm and the air outlet at least 1.5 m away from the unit.
In Moist or Uneven Locations
Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration.
In an Area with High Winds
Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle.
In a Snowy Area (for Heat Pump-type Systems)
Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.
When Connecting Refrigerant Tubing
gas leaks during the installation. Be careful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas.
WARNING
WARNING
WARNING
CAUTION CAUTION
piping work do not mix air except for speci- fied refrigerant (R410A) in refrigeration cycle. It causes capacity down, and risk of explosion and injury due to high tension inside the refrige- rant cycle.
cause fire.
other than specified type. It may cause product damage, burst and injury etc.
3
the flare and union tubes before connecting them, then tighten the nut with a torque wrench for a leak- free connection.
or re-installation, and while repairing refrigeration parts. Handle liquid refrigerant carefully as it may cause frost- bite.
When Servicing
before opening the unit to check or repair electrical parts and wiring.
parts.
that no metal scraps or bits of wiring have been left inside the unit being serviced.
Others
the refrigeration system. Escaped refrigerant gas, on contact with fire or heat, can produce dangerously toxic gas.
gas is leaking. If escaped gas comes in contact with a stove, gas water heater, electric room heater or other heat source, it can produce dangerously toxic gas.
fins of the outdoor unit. You may get injured.
accidentally.
You may be injured and the unit may be damaged.
CAUTION
The illustrations are based on the typical appearance of a standard model. Consequently, the shape may differ from that of the air conditioner that you are installing.
NOTE
4
Printed on container box
For unit & PVC tube connection
For drain hose connection
RemarksQty For full-scale installation diagram
1
2
4
4
4
4
2
1
For temporarily suspending indoor unit from ceiling
Flare insulation
For wide / narrow tube connection
For wide / narrow tube / flare nut connection
For flare / drain insulating connection
For drain tube connection
Insulation tape
Vinyl tie
Drain hose insulation
Washer
AAA alkaline battery
Remote controller
Remote control holder
Parts PartsFigure RemarksQty Figure
Drain hose
Full-scale installation diagram
5-1/2"(L140)
Hose band
Truss head screw
Truss head screw
Special screw
Cushion rubber
Tapping screw
8
2 set
2
8
1
1
1
2
1/8"(T3) 3/16"(T5)
13/32"(T10)
3/32"(T2)
Truss-head Phillips 5/32 5/8" (4 16mm)
3/16 13/32" (5 10mm)
5/32 15/32" (4 12mm)
3/16 1-9/16" (5 40mm)
Packed in the outdoor unit
Packed in the ceiling panel
Use M10 or 3/8" for suspension bolts. Suspension bolts and nuts (locally purchased)
Model Narrow Tube Wide Tube
Outer Dia. Thickness Outer Dia. Thickness
CS-KE12NB41 1/4" (6.35 mm) 0.0314" (0.8 mm) 3/8" (9.52 mm) 0.0314" (0.8 mm)
CS-KE18NB4UW 1/4" (6.35 mm) 0.0314" (0.8 mm) 1/2" (12.70 mm) 0.0314" (0.8 mm)
1. General
This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instruc- tions for the indoor and outdoor units and make sure all accessory parts listed are with the system before beginning.
1-1. Tools Required for Installation (not supplied) 1. Standard screwdriver 2. Phillips head screwdriver 3. Knife or wire stripper 4. Tape measure 5. Carpenters 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
Table 1
1-3. Optional Copper Tubing Kit
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 air conditioning workshop.
1-4. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from a local source, you will need:
1. Deoxidized annealed copper tube for refrigerant tubing as detailed in Table 2. Cut each tube to the appropriate lengths 1' to 1'4" (30 cm to 40 cm) to dampen vibration between units.
2. Foamed polyethylene insulation for the specified copper tubes as required to precise length of tubing. Wall thickness of the insulation should be not less than 5/16" (8 mm).
3. Use insulated copper wire for field wiring. Wire size varies with the total length of wiring. Refer to 3-7. Wiring Instructions for details.
Table 2 CAUTION
Check local electrical codes and regulations before obtaining wire. Also, check any specified instructions or limitations.
5
1-5. Additional Materials Required for Installation
1. Refrigeration (armored) tape 2. Insulated staples or clamps for connecting wire
(See local codes) 3. Putty 4. Refrigeration lubricant 5. Clamps or saddles to secure refrigerant tubing
2. Installation Site Selection
2-1. Indoor Unit
AVOID:
direct sunlight.
nearby heat sources that may affect performance of the unit.
areas where leakage of flammable gas may be expected.
places where large amounts of oil mist exist.
DO:
select an appropriate position from which every corner of the room can be uniformly cooled.
select a location that will hold the weight of the unit.
select a location where tubing and drain hose have the shortest run to the outside.
allow room for operation and maintenance as well as unre- stricted air flow around the unit. (Fig. 1)
install the unit within the maximum elevation difference (H) above or below the outdoor unit and within a total tubing length (L) from the outdoor unit as detailed in Table 3 and Fig. 2.
install the indoor unit more than 3.3' (1 m) away from any antenna or power lines or connecting wires used for television, radio, telephone, security system, or intercom. Electrical noise from any of these sources may affect operation.
Fig. 1
3.3 ft.
(1m) (1m)
(1m)
3.3 ft. (1m)
3.3 ft. 3.3 ft.
3.3 ft.
(1m)
Fig. 2
T ub
in g
le ng
th (
L)
E le
va tio
n di
ffe re
nc e
(H )
Outdoor unit
Indoor unit
WARNING To prevent abnormal heat genera- tion and the possibility of fire, do not place obstacles, enclosures and grilles in front of or surround- ing the air conditioner in a way that may block air flow.
CAUTION
Air delivery will be degraded if the distance from the floor to the ceiling is greater than 10 ft. (3 m).
* If total tubing length becomes 25 to 65 ft. (Max.) or 25 to 100 ft. (Max.), charge additional refrigerant (R410A) by 0.16 or 0.27 oz./ft. No additional charge of compressor oil is necessary. For more detailed charging information, refer to the Technical & Service Manual.
Max. Allowable Tubing Limit of Tubing Limit of Elevation Required Amount of Model Length at Shipment Length (L) Difference (H) Additional Refrigerant
(ft.) (ft.) (ft.) (oz./ft.)*
CS-KE12NB41 25 65 23 0.16
CS-KE18NB4UW 25 100 50 0.27
Table 3
6
2-2. Outdoor Unit
AVOID:
heat sources, exhaust fans, etc. (Fig. 3)
damp, humid or uneven locations.
DO:
choose a place as cool as possible.
choose a place that is well ventilated.
install in a location where at least two sides are unob- structed, so that the flow of air at the intake port or exhaust port is not blocked, and so that sufficient space is ensured for maintenance to be carried out without trouble. In general the top also must be unob- structed. (Figs. 4a and 4b)
provide a solid base (level concrete pad, concrete block, 4" 1'4" (10 40 cm) beams or equal), a mini- mum of 4" (10 cm) above ground level to reduce humidity and protect the unit against possible water damage and decreased service life. (Figs. 5a and 5b)
Outdoor unit
Hot air Heat source
Exhaust fanNO
Fig. 3
Air intake Min. 2" (5 cm)
Air dischargeMin. 2" (5 cm)
Min. 8" (20 cm)
Valve side Min. 10" (25 cm)
Min. 7' (2 m)
Min. 7' (2 m)
Ground
O bs
ta cl
e
Obstacle above
A ir
di sc
ha rg
e
Min. 2" (5 cm) Air intake
Air intake
Concrete or equal
About 4" (10 cm)
Min. 4" (10 cm)
Anchor bolts (4 pcs.)
About 1'4" (40 cm)
Cushion rubber
Fig. 5a
Drain holes
CAUTION A solid base must not cover the hole of the bottom plate.
Fig. 4a
Air intake Min. 4" (10 cm)
Air dischargeMin. 2" (5 cm)
Min. 1'4" (40 cm)
Valve side Min. 10" (25 cm)
Min. 7' (2 m)
Min. 7' (2 m)
Ground
O bs
ta cl
e
Obstacle above
A ir
di sc
ha rg
e Min. 4" (10 cm) Air intakeFig. 4b
(CU-KE18NKU)
(CU-KE12NK1)
install cushion rubber under units feet to reduce vibra- tion and noise. (Fig. 5c)
use lug bolts or equal to bolt down unit, reducing vibra- tion and noise.
install in a location where no antenna of a television or radio exists within 10' (3 m).
Fig. 5b Fig. 5c
7
Hole-in-anchor Concrete Insert
Suspension bolt (M10 or 3/8")
Hole-in-plug
(locally purchased)
Fig. 6-1
23-5/8"(600mm)
21-1/32"(534mm)
Ceiling opening dimensions
Suspension bolt pitch
23 -5
/8 "(
60 0m
m)
21 -1
/3 2"
(5 34
mm )
C ei
lin g
op en
in g
di m
en si
on s
S us
pe ns
io n
bo lt
pi tc
h
Drain tube connection port
22-5/8"(575mm)
6-11/16" (170mm)(160mm)(53mm)
6-5/16"2-3/32"
(4 5m
m) 1-
25 /3
2"
(4 5 m
m) 1-
25 /3
2" (1
17 mm
) 4-
19 /3
2"
Refrigerant tubing joint (narrow tube side)
Power supply port
1- 3/
16 "
(3 0 m
m)
(2 15
mm )
8- 15
/3 2"
11 -5
/3 2"
(2 83
mm )
(outer dia 1-1/32"( 26mm))
1/4( 6.35mm) (flared)
1/ 2"
2
3/ 32
" (1
3~ 18
mm )
O ve
r 19
/3 2"
( 15
mm )
Supplied screw Full-scale installation diagram (printed on top of container box)
3. How to Install the Indoor Unit
3-1. Preparation for Suspending This unit uses a drain pump. Use a carpenters level to check that the unit is level.
3-2. Suspending the Indoor Unit
(1) Fix the suspension bolts securely in the ceiling using the method shown in the diagrams, by attaching them to the ceiling support structure, or by any other method that ensures that the unit will be securely and safely suspended. (Fig. 6-1)
(2) Follow the diagram to make the holes in the ceiling.
(3) Determine the pitch of the suspension bolts using the supplied full-scale installation diagram. The dia- gram shows the relationship between the positions of the suspension fitting, unit, and panel. (Fig. 6-2)
3-3. Placing the Unit Inside the Ceiling
(1) Be sure to remove the fan protection (4pcs) for transportation before hanging up the indoor unit.
(2) When placing the unit inside the ceiling, determine the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 6-3) 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 position for connection to the unit before placing the unit inside the ceiling.
(3) The length of suspension bolts must be appropriate for a distance between the bottom of the bolt and the bottom of the unit of more than 19/32" (15 mm) as shown in the diagram. (Fig. 6-3)
(4) Thread the 3 hexagonal nuts (locally purchased) and 2 supplied washers onto each of the 4 suspension bolts as shown in the diagram. Use 1 nut and 1 washer for the upper side, and 2 nuts and 1 washer for the lower side, so that the unit will not fall off the suspension lugs. (Fig. 6-4)
(5) Adjust so that the distance between the unit and the ceiling bottom is 1/2" (13 mm) to 23/32" (18 mm). Tighten the nuts on the upper side and lower side of the suspension lug. (Fig. 6-4)
Nuts and washers (used for upper and lower)
Double nut Notch
Suspension lug
Suspension bolt
1/2" 23/32" (13~18mm)
Fig. 6-4
Fig. 6-2
Fig. 6-3
8
In cases where it is necessary to raise the height of the drain piping, the drain piping can be raised to a maximum height of 2.78 ft. (850 mm) above the bottom surface of the ceiling. Under no conditions attempt to raise it higher than 2.78 ft. (850 mm) above the bottom surface of the ceiling. Doing so will result in water leakage. (Fig. 6-7) Do not use natural drainage. 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. 6-8) 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. 6-9) Provide insulation for any pipes that are run indoors.
Drain port
Twist tie (4 vinyl ties, supplied)
Hard PVC pipe Position to
Drain hose (supplied)
Hose band (2 bands, supplied)
3/16" (5mm)
3/16" (5mm)
15/16" (25mm)
15/16" (25mm)
5-1/2"(140mm)
Drain hose
(locally purchased) bands (supplied) O.D. 1-1/32" (26mm)) fasten hose insulation (equivalent to
Unit
Fig. 6-5
Air bleeder prohibited
Fig. 6-6
Fig. 6-8
Support bracket
Fig. 6-9
Uphill slope
3-4. Installing the Drain Piping
(1) Prepare standard hard PVC pipe (locally purchased O.D. 1-1/32" (26 mm)) for the drain and use the supplied hose band to prevent water leaks. (Fig. 6-5)
(2) To install the drain hose, first place 1 of the 2 hose bands over the unit drain port and the other hose band over the hard PVC pipe (not supplied). Then connect both ends of the supplied drain hose. (Fig. 6-5)
(3) On the unit drain side, grasp the hose band with pliers and insert the drain hose all the way to the base.
If other commercially available hose bands are used, the drain hose may become pinched or wrinkled and there is danger of water leakage. Therefore be sure to use the supplied hose bands. When sliding the hose bands, be careful to avoid scratching the drain hose.
Do not use adhesive when connecting the supplied drain hose to the drain port (either on the main unit or the PVC pipe).
Reasons: a) It may cause water to leak from the connec- tion. Since the connection is slippery just after the adhesive has been applied, the pipe easily slips off.
b) The pipe cannot be removed when mainte- nance is needed.
(4) Wrap the hose with the supplied drain hose insulation and use the 4 twist ties so that the hose is insulated with no gaps.
Do not bend the supplied drain hose 90 or more. The hose may slip off.
Make sure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.
NOTE
Fig. 6-7
1 ft.(300mm) or less
0 - 45 2.78 ft.(850mm) or less
* Length of supplied drain hose = 5-1/2"(140mm)
CAUTION
Attach so that the hose band fastener is on the side of the drain port. Attach the hose bands so that each is approximately 3/16" (5 mm) to 15/16" (25 mm) from the end of the supplied drain hose.
CAUTION
Do not install an air bleeder as this may cause water to spray from the drain pipe outlet. (Fig. 6-6)
CAUTION
9
A must be within the range of 1/2"(13mm) to 23/32"(18mm). (Fig. 6-11) If not within this range, malfunction or other trouble may occur.
Ceiling opening dimension
Ceiling side
A
Indoor unit
3-5. Checking the Drainage After wiring and drain piping are completed, use the following pro- cedure to check that the water will drain smoothly. For this, pre- pare a bucket and wiping cloth to catch and wipe up spilled water.
Be sure to do the wiring between the units before installing the ceiling panel. (Refer to 3-9. Wiring Instructions for Inter-unit Connections)
(1) Turn on the power. (Here, power refers to the power supply from the outdoor unit.)
(2) Slowly pour approx. 16 ounces (500 ml) of water into the drain pan to check drainage. (Fig. 6-10a)
(3) Remove the 2 screws from the control box cover, then open the cover. Be careful not to drop the cover at this time.
(4) Disconnect the FS 3P connector (red) on the control PCB and operate the drain pump. (Fig. 6-10b) Check the water flow through the transparent drain pipe and see if there is any leakage.
(5) When the check of drainage is complete, reconnect the FS 3P connector and remount the control cover.
3-6. How to Install the Ceiling Panel
Checking the unit position
(1) Check that the ceiling hole is 23-5/8" (600 mm) 23-5/8" (600 mm) (Fig. 6-11)
(2) Confirm that the position of the indoor unit and the ceiling as shown in the diagram. If the positions of the ceiling sur- face and unit do not match, air leakage, water leakage, flap operation failure, or other problems may occur. (Fig. 6-11)
The drain pump will continue to operate for a minimum of 6 min- utes after the FS 3P connector is reconnected.
CAUTION
Never place the panel face-down. Neither hang it ver- tically nor place it on top of a projecting object. Plac- ing it face-down will damage the surface. Do not touch the flap or apply force to it. (This may cause flap malfunction.) (Fig. 6-12)
CAUTION
3-6-1. Before Installing the Ceiling Panel
(1) Remove the air-intake grille and air filter from the ceiling panel.
a) Press on and slide the two latches of the air-intake grille with your thumb in the direction shown by the arrow to open the grille. (Figs. 6-13 and 6-14)
b) With the air-intake grille opened, remove the grille hinge from the ceiling panel by sliding it in the direction shown by the arrow . (Fig. 6-15)2
1
Fig. 6-10a
Fig. 6-12 Fig. 6-13
Water drain
Control box
Drain pan outlet Water
Plastic container for water intake
Over 4" (100mm)
(Approx. 16 ounces (500m ) )
FlapNO
Latch
Air-intake grille Ceiling panel
Air-intake grille hinge
1
1
2
Fig. 6-11
Fig. 6-14
Fig. 6-15
FS
FLAP Control box
RCIND
Fig. 6-10b
10
(2) Removing the corner cover and indicator cover
a) While lightly pressing the cen- ter of the corner cover, pull up the tab for the screw hole. Use the same procedure to remove the indicator cover. (Fig. 6-16)
3-6-2. Installing the Ceiling Panel
(1) Hang the temporary latches on the inside of the ceil- ing panel to the receptacle on the unit to temporarily attach the ceiling panel in place. (Fig. 6-17)
The ceiling panel must be installed in the correct direction relative to the unit. Align the REF. PIPE and DRAIN marks on the ceiling panel corner with the correct positions on the unit.
(2) Align the panel installation holes and the unit screw holes. (Fig. 6-18)
(3) Tighten the supplied special screws at the 4 panel installation locations so that the panel is attached tightly to the unit.
Check that the wiring connectors are not caught between the unit and the ceiling panel.
(4) Check that the panel is attached tightly to the ceiling. (Fig. 6-19)
At this time, make sure that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceiling surface.
If there is a gap between the panel and the ceiling, leave the ceiling panel attached and make fine adjustments to the installation height of the unit to eliminate the gap with the ceiling.
CAUTION
Fig. 6-17
Fig. 6-18
Fig. 6-19
Corner cover
Indicator cover
Press
Pull up2
1
latch
Temporary latches
Temporary
DRAIN mark
Ceiling panel
Special screws
Refrigerant tubing joint
Drainage check
REF.PIPE mark
Panel installation hole (4 locations)
Indoor unit
Ceiling panelCeiling surface
Do not allow gaps
Adjust so that there are no gaps.
Air leakage
Air leakage from ceiling surface
Staining
Condensation, water leakage
If the screws are not sufficiently tightened, trouble such as that shown in the figure
the screws securely. below may occur. Be sure to tighten
If a gap remains between the ceiling surface and the ceiling panel even
adjust the height of the unit again. after the screws are tightened,
The height of the unit can be adjusted from the ceiling panel corner hole, with the ceiling panel attached, to
the drain hose, or other elements. an extent that does not affect the unit levelness,
Fig. 6-16
Fig. 6-20
11
Fig. 6-23
Fig. 6-24 Fig. 6-25
fit into the holes in the ceiling panel. Place the corner cover so that the 3 tabs
Then fasten it in place with the supplied screws.
Pin
Hole for ceiling panel hook
the grille from dropping
Hook that prevents
Can be installed rotated 90
* The grille can be installed with these hinges facing in any of 4 directions.
3-6-4. How to Attach the Corner Cover and Air-Intake Grille
3-6-3. Wiring the Ceiling Panel and the Indicator
(1) Remove the 2 screws from the control box cover, then open the cover. Be careful that the cover does not fall.
(2) Connect the 5P FLAP wiring connector from the ceiling panel to the connector on the control PCB in the control box. (Fig. 6-21)
(3) Connect the 7P IND and 4P RC wiring connector from the indicator to the connectors on the control PCB in the control box. (Fig. 6-21)
(4) Be sure to use the clamps to fasten the connector wires in place. (Fig. 6-21)
(5) Tighten the 2 cover screws to close the cover.
Check that the wiring connectors are not caught between the electrical component box and the cover.
If the indicator connector is not securely connected, the remote controller signal will not be received.
If the connectors are not connected, the auto flap will not operate. Be sure to connect them securely.
A. Attaching the corner cover
(1) Check that the safety strap from the corner cover is fas- tened to the ceiling panel pin, as shown in the figure. (Fig. 6-23)
(2) Use the supplied screws to attach the corner cover to the ceiling panel.
B. Attaching the air-intake grille To install the air-intake grille, follow the steps for 3-6-1. Before Installing the Ceiling Panel in the reverse order. By rotating the air-intake grille, it is possible to attach the grille onto the ceiling panel from any of 4 directions. (Fig. 6-25)
When attaching the air-intake grille, be careful that the flap and the indicator wiring do not become caught. Be sure to attach the safety cord that prevents the air-intake grille from dropping off to the ceiling panel unit as shown in Fig. 6-24.
F LA
P
R C
IN D
Indicator
Indicator
7P IND and 4P RC wiring connector
7P IND and 4P RC
Ceiling panel
5P FLAP wiring connector
Clamps
Control box
Indoor unit
* Pass the wiring connectors through the clamps to fasten them in place, as shown in the figure.
wiring connector
7P
4P 5P
5P FLAP wiring connector
Control box
As to how to attach the indicator cover, refer to Fig.6-23.
Drain pipe side
Refrigerant tube side
Indicator cover Power box
Fig. 6-22
Fig. 6-21
3-7. Wiring Instructions
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.
(2) Provide a power outlet to be used exclusively for each unit, with a power supply disconnect and circuit breaker for overcurrent protection provided in the exclu- sive line.
(3) To prevent possible hazards due to insulation failure, the unit must be ground- ed.
(4) Each wiring connection must be done tightly and in accordance with the wiring system diagram. Wrong wiring may cause the unit to misoperate or become damaged.
(5) Do not allow wiring to touch the refrigerant tubing, compressor, or any moving parts of the fan.
(6) Unauthorized changes in the internal wiring can be very dangerous. The manu- facturer will accept no responsibility for any damage or misoperation that occurs as a result of such unauthorized changes.
3-8. Recommended Wire Length and Diameter
Regulations on wiring diameter differ from locality to locality. For field wiring require- ments, please refer to your local electrical codes. Carefully observe these regula- tions when carrying out the installation. Table 4 lists recommended wire lengths and diameters for power supply systems.
Refer to the wiring system diagram (Fig. 7a or Fig. 7b) for the meaning of (A), (B) and (C) in Table 4.
Refer to your local codes or in the absence of local codes see the National Electric Code: ANSI/NFPA70.
NOTE
12
3-6-5. Checking After Installation
Check that there are no gaps between the unit and the ceiling panel, or between the ceiling panel and the ceiling sur- face. Gaps may cause water leakage and condensation.
Check that the wiring is securely connected. If it is not securely connected, the auto flap will not operate. In addition, water leakage and condensation may occur.
3-6-6. When Removing the Ceiling Panel for Servicing When removing the ceiling panel for servicing, remove the air-intake grille and air filter, disconnect the flap and the indi- cator wiring connectors inside the control box, and then remove the 4 mounting screws.
3-6-7. Adjusting the Auto Flap The air-direction flap on the ceiling panel outlet can be adjusted as follows.
Adjust the flap to the desired angle using the remote controller. The flap also has an automatic air-sweeping mecha- nism.
Never attempt to move the flap by hand.
Proper air flow depends on the location of the air conditioner, the layout of the room and furniture, etc. If cooling or heating seems inadequate, try changing the direction of the air flow.
NOTE
13
Cross-Sectional (A)+(B) (A) Power Supply Wiring Length (ft) (C) Control Fuse or Circuit Area (AWG) (B) Power Line Length (ft) Line Length (ft)
Model (#14) (#12) (#14) Breaker Capacity
CU-KE12NK1 131 (Max.) 230 (Max.) 65 (Max.) 20A
CU-KE18NKU 131 (Max.) 230 (Max.) 100 (Max.) 15A
# ... AWG (American Wire Gauge)
Table 4
Be sure to comply with local codes on running the wire from the indoor unit to the outdoor unit (size of wire and wiring method, etc.). Each wire must be firmly connected. No wire should be allowed to touch refrigerant tubing, the compressor, or any moving part.
Be sure to connect the power supply line to the outdoor unit as shown in the wiring diagram. The indoor unit draws its power from the outdoor unit. Do not run wiring for antenna, signal, or power lines of television, radio, stereo, telephone, secu- rity system, or intercom any closer than 3'3" (1 m) from the power cable and wires between the indoor and outdoor units. Electrical noise may affect the operation.
To avoid the risk of electric shock, each air con- ditioner unit must be grounded. For the installation of a grounding device, please observe local electrical codes. Grounding is necessary, especially for units using inverter circuits, in order to release charged electricity and electrical noise caused by high tension. Otherwise, electrical shock may occur. Place a dedicated ground more than 7' (2 m) away from other grounds and do not have it shared with other electric appliances.
* A disconnect switch may be required by national or local codes.
NOTE
WARNING
WARNING
CAUTION
Always comply with national and local code requirements.
CAUTION
Fig. 7a
(CU-KE12NK1)
Disconnect switch
*
1
2
3
1
2
3
4
5
6
Grounding line
115V
115V
115V
INDOOR UNIT
OUTDOOR UNIT
Field supply
Grounding line
L
N
P ow
er s
up pl
y S
in gl
e ph
as e
11 5V
6 0H
ZTerminal Terminal
(A)
(B)
(C)
(B)
Fig. 7b
(CU-KE18NKU)
Disconnect switch
*
1
2
3
1
2
3
4
5
6
Grounding line
230/208V
230/208V
230/208V
INDOOR UNIT
OUTDOOR UNIT
Field supply
Grounding line
L1
L2
P ow
er s
up pl
y S
in gl
e ph
as e
23 0/
20 8V
6 0H
Z
Terminal Terminal
(A)
(B)
(C)
(B)
WIRING SYSTEM DIAGRAM
14
When connecting each power wire to the corresponding terminal, fol- low the instructions How to connect wiring to the terminal and fasten the wire securely tight with the fixing screw of the terminal plate.
How to connect wiring to the terminal
a) For Indoor Unit
(1) Cut the wire end with a cutting pliers, then strip the insulation to expose the wire about 9/32" (7 mm). See the label (Fig. 9) near the terminal plate.
(2) Using a screwdriver, loosen the terminal screw on the terminal plate.
(3) Insert the wire and tighten the terminal screw completely using a screwdriver.
b) For Outdoor Unit
For solid core wiring (or F-cable)
(1) Cut the wire end with a cutting pliers, then strip the insulation to expose the solid wire about 15/16" (25 mm). (Fig. 10)
(2) Using a screwdriver, remove the terminal screw(s) on the terminal plate.
(3) Using the pliers, bend the solid wire to form a loop suitable for the terminal screw.
(4) Shape the loop wire properly, place it on the terminal plate and fix it securely with the removed terminal screw using a screwdriver.
Loose wiring may cause the ter- minal to overheat or result in unit malfunction. A fire hazard may also exist. Therefore, be sure all wiring is tightly connected.
WARNING
Fig. 9
STRIP SIZE
9/32" (7 mm) (ACTUAL
SIZE)
Fig. 8
Fig. 10
Solid wire Loop
Insulation
S tr
ip 1
5/ 16
" (2
5 m
m )
1 3
2
Earth screw
Clamping strap
(Conduit) Inter unit
Power wiring (Locally purchased)
3-9. Wiring Instructions for Inter-unit Connections
(1) Remove the 1 screw from the terminal cover, then open the cover. Be careful that the cover does not fall.
(2) Remove the 3 screws from the power box cover, then open the cover. Be careful that the cover does not fall.
(3) Use the screw to securely fasten the ground wire from the outdoor unit in place.
(4) Remove the transparent plastic cover from the 3P terminal plate.
(5) While viewing the wiring diagram, connect the inter-unit and power supply line to terminals 1, 2 and 3 on the 3P terminal plate.
(6) Remount the transparent plastic cover onto the 3P terminal plate.
(7) Be sure to use the clamping strap to fasten the wires in place.
(8) Tighten the screws to remount the terminal and the power box cover.
15
For stranded wiring
(1) Cut the wire end with a cutting pliers, then strip the insulation to expose the stranded wiring about 3/8" (10 mm) and tightly twist the wire ends. (Figs. 11 and 12)
(2) Using a screwdriver, remove the terminal screw(s) on the terminal plate.
(3) Using a ring connector fastener or pliers, securely clamp each stripped wire end with a ring connector. (Fig. 11)
(4) Place the ring connector wire, and replace and tighten the removed terminal screw using a screwdriver. (Fig. 13)
Fig. 11
Stranded wire
Ring connector
S tr
ip 3
/8 "
(1 0
m m
)
Fig. 12
Twist wire ends
Fig. 13
Screw
Ring connector
Terminal plateWire
Special washer
Screw and special washer
Ring connector
Wire
4. How to Install the Outdoor Unit
First refer to Section 2. Installation Site Selection.
4-1. Wiring Instructions for the Outdoor Unit
Regulations on wire size differ from locality to locality. For field wiring requirements, please refer to your local electrical codes. Make sure that the installation fully complies with all local and national regulations.
(1) Remove access panel C. (Fig. 14)
(2) Connect the inter-unit and power supply line according to the drawing on the panel side.
(3) Be sure to size each wire allowing approx. 4" (10 cm) longer than the required length for wiring. Store excess wiring inside the cabinet.
(4) When connections are completed, check that all connections are correct as shown in the wiring system diagram on panel side.
(5) Be sure to ground the unit according to your local codes. Fig. 14
Lock nut
Conduit plate
Plug Inter unit (Conduit)
Power supply (Conduit)
Cabinet
Terminal block
Access panel C
16
5. Refrigerant Tubing
5-1. Use of the Flaring Method
Many of the conventional split system air conditioners employ the flaring method to connect refrigerant tubes which run between indoor and outdoor units. In this method, the copper tubes are flared at each end and connected with flare nuts.
5-2. Flaring Procedure with a Flare Tool
(1) Cut the copper tube to the required length with a tube cutter. It is recommended to cut approx. 12" to 20" (30 to 50 cm) longer than the tubing length you estimate.
(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. 15)
When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. (Fig. 16)
(3) Remove the flare nut from the unit and be sure to mount it on the copper tube.
(4) Make a flare at the end of copper tube with a flare tool.* (Figs. 17 and 18)
(*Use RIDGID or equivalent.)
A good flare should have the following characteristics:
inside surface is glossy and smooth.
edge is smooth.
tapered sides are of uniform length.
5-3. Caution before Connecting Tubes Tightly
a) Be sure to apply a sealing cap or water-proof tape to prevent dust or water from getting into the tubes before they are used.
b) Be sure to apply refrigerant lubricant to the match- ing surfaces of the flare and union before connect- ing them together. This is effective for reducing gas leaks. (Fig. 19)
c) For proper connection, align the union tube and flare tube straight with each other, then screw in the flare nut lightly at first to obtain a smooth match. (Fig. 20)
NOTE
NOTE
Fig. 15
Deburring
Before After
Fig. 16
Reamer
Copper tubing
Fig. 17
0 to 0.0196" (0 to 0.5 mm)
If the special R410A flare tool is used:
0.0472" (1.2 mm)
If the previous flare tool (clutch-type) is used:
Adjust so that the amount of tube protrusion is as shown in the figure.
Fig. 18
Flare tool
Flare nut
Copper tubing
Fig. 19
Apply refrigerant lubricant here and here
Fig. 20 Flare nutUnion
17
5-4. Connecting Tubing between Indoor and Outdoor Units
a) Tightly connect the indoor side refrigerant tubing exten- ded from the wall with the outdoor side tubing. (Fig. 21)
b) To fasten the flare nuts, apply specified torque as:
Table 5
5-5. Insulation of Refrigerant Tubing
To prevent heat loss and wet floors due to dripping of con- densation, both tubes must be well insulated with a proper insulation material. The thickness of the insulation should be a minimum 5/16" (8 mm). (Fig. 22)
IMPORTANT
Fig. 21
Fig. 22
Insulation
Min. 5/16" (8 mm)
Thickness: min. 5/16" (8 mm)
Taping the flare nuts
Wind the insulation tape around the flare nuts at the tube connections. Secondly cover up the tubing connec- tions with the flare insulation (1/8" (T3, supplied)). Then wind the other flare insu