Air-Conditioners PLH-2, 2.5KKC FOR INSTALLER ON/OFF – CENTRALLY CONTROLLED ON OFF CHECK CLOCK 1Hr. ˚C FILTER CHECK MODE STAND BY DEFROST E ˚C TEST RUN NOT AVAILABLE INSTALLATION MANUAL For safe and correct use, please read this installation manual thoroughly before installing the air-conditioner unit.
E Contents 1. Safety Precautions ................................................................................... 2 2. Indoor unit installation location ................................................................. 7 3. Outdoor unit installation location .............................................................. 8 4. Installing the indoor unit .......................................................................... 11 5. Installing the outdoor unit ............................................
E 1. Safety Precautions 1.1. Before installation and electric work • • • • • Warning: The unit must be securely installed on a structure that can sustain its weight. If the unit is mounted on an unstable structure, it may fall down causing injuries. Use only specified cables for wiring. The connections must be made securely without pulling on the terminals. Improper connections or installation may generate heat or cause a fire.
E 1. Safety Precautions 1.1. Before installation and electric work • • • • Caution: Do not install the equipment where combustible gas may leak and accumulate resulting in fire. Do not keep food, plants, caged pets, artwork or precision instruments in the indoor unit’s direct airflow or too close to the unit, as these items can be damaged by temperature changes or dripping water. When the room humidity exceeds 80% or when the drain pipe is clogged, water may drip from the indoor unit.
E 1. Safety Precautions 1.1. Before installation and electric work Drain piping • • Caution: Install drain piping according to this Installation Manual to ensure proper drainage. Place thermal insulation on the pipes to prevent condensation. Improper drain piping may cause water leakage and damage to furniture or other possessions. Thermal insulation of the drain pipes is necessary to prevent dew condensation.
E 1. Safety Precautions 1.2. Before starting the trial run • • • • Caution: Before starting operation, check that all panels, guards and other protective parts are correctly installed. Rotating, hot or high voltage parts can cause injuries. Do not touch the refrigerant pipes with bare hands during operation. The refrigerant pipes are sometimes hot and sometimes cold depending on the condition of the flowing refrigerant. Your hands may suffer burns or frostbite if you touch the pipes.
E 2. Indoor unit installation location 2.1. Outline dimensions (mm) 30 H Models PLH-2, 2.5 D W W 760 D 760 H 307 • Mount the indoor unit on a wall strong enough to withstand the weight of the unit. • Select a location so that air can be blown into all corners of the room. • Avoid locations exposed to outside air. • Select a location free of obstructions to the airflow in and out of the unit. • Avoid locations exposed to steam or oil vapour.
E 2. Indoor unit installation location E 3. Outdoor unit installation location 2.3. Refrigerant pipes s Check that the difference between the heights of the indoor and outdoor units, the length of refrigerant pipe, and the number of bends in the pipe are within the limits shown below. (A) Pipe length (one way) max. 40 m max. 50 m Models PLH-2 PLH-2.5 A D • (B) Height difference max. 40 m max. 50 m (C) Number of bends (one way) max. of 12 max.
E 1 ;;; ;;; ;; ;; A 2 3. Outdoor unit installation location 3.2. Ventilation and service space When installing a single outdoor unit 1 Service space Maintain an easily accessible service space in front of the unit as shown in the diagram.
E ;;;;;;;;;;; ;;;;;;;;;;; 1 C B E D 3. Outdoor unit installation location 3.2. Ventilation and service space When installing many outdoor units 1 Side-by-side arrangement Remove the side screw on the pipe cover. Keep the top unobstructed. A A Min. 100 mm B Min.10 mm C Min. 200 mm D Up to 10 units (When the air outlet guides (sold separately) are used, no more than five units should be arranged side by side.) 2 F E Min.
E 3. Outdoor unit installation location E 4. Installing the indoor unit 3.2. Ventilation and service space 1 Installation on a rooftop or other windy places When installing the unit on a rooftop or other location unprotected from the wind, situate the unit’s air outlet so that it is not directly exposed to strong winds. Strong wind entering the air outlet may impede the normal airflow and cause malfunctions. The following shows three examples of precautions against strong winds.
E 25~35 760 H 690~710 G F 640 4.2. Ceiling Openings and Suspension Bolt Installation Locations 25~35 • Using the accompanying installation template and gauge, install the main unit in such a way that the opening on ceiling falls at the place shown in following diagram (usage method of template and gauge is shown printed on them, respectively). * Before using, check the dimensions of template and gauge, because they change due to fluctuations of temperature and humidity.
E 4. Installing the indoor unit 4.3. Suspension Structure (Give site of suspension strong structure.) • The ceiling work differs according to the construction of the building. Buidling constructors and interior decorators should be consulted for details. (1) Extent of ceiling removal: The ceiling must be kept completely horizontal and the ceiling foundation (framework: wooden slats and slat holders) must be reinforced in order to protect the ceiling from vibration.
E 4. Installing the indoor unit 4.4. Unit Suspension Procedures ● Suspend the main unit as shown in the diagram. A Parts to be prepared at site. • Suspension bolts (M10 or W3/8) ..................................................... 4 • Nuts (M10 or W3/8) ....................................................................... 12 Parts to be attached to the unit. • Washers (with insulation) ................................................................. 4 • Washers (without insulation) .................
E 4. Installing the indoor unit E 5. Installing the outdoor unit 4.5. Confirming the Position of Main Unit and Tightening the Suspension Bolts • Using the gauge attached to the grilles, ensure that the bottom of the main unit is properly aligned against the opening on ceiling. Be sure to confirm this, otherwise the dripping of condensation due to leakage of wind and etc occur. • Confirm that the main unit is horizontally levelled, using a level or a vinyl tube filled with water.
E Notes: • Cooling pipes are available as an option. Read the manual before beginning their installation. • Place insulation materials over cooling pipes and drain pipes to prevent condensation. • If commercially available copper pipes are used, wrap liquid and gas pipes with commercially available insulation materials (heatresistant to 100°C or more, thickness of 12 mm or more). • The indoor parts of the drain pipe should be wrapped with polyethylene foam insulation materials (specific gravity of 0.
E 6. Cooling pipe and drain pipe 6.4. Refrigerant piping 6.4. Refrigerant piping 1) Indoor unit 1.2. When using commercially available copper pipes: See that stop valve on outdoor unit is fully shut (unit is shipped with valve shut). After all piping connections between indoor and outdoor unit have been completed, vaccuum-purge air from system through the service port for the stop valve on the outdoor unit. After completing procedures 1.1. or 1.2. above, open outdoor unit stop valves stem fully.
E 6. Cooling pipe and drain pipe 6.4. Refrigerant piping 1 2) Outdoor unit 1 Pipe take-in direction The pipe can be passed in any of the four directions: front, rear, right and lower side. A Front piping (knockout) B Lower piping D C Right piping (knockout) D Back piping E C A 2 E Piping cover B 2 Remove the service panel (three screws) and the piping cover (one screw).
E 6. Cooling pipe and drain pipe 6.5. Drainage Piping Work A B F • Use VP25 (O. D. ø32 PVC TUBE) for drain piping and provide 1/100 or more downward slope. • Be sure to connect the piping joints using adhesive of polyvinyl chloride family. • Observe the figure below for piping work. • C Use attached drain hose to change the pipe extraction direction. A Max. 20m D B about 1.
E 6. Cooling pipe and drain pipe E 7. Electrical work 6.5. Drainage Piping Work 1. Connect the flexible tube (supplied with the unit) to the drain port. (Must not be bent more than 45 degrees.) G A (Affix the tube using PVC adhesive then secure it with a band.) B 2. Install a locally purchased drain pipe (PVC pipe, VP-25). C D H (Affix the pipe using PVC adhesive then secure it with a band.) 3. Insulate the tube and pipe. (PVC pipe, VP-25 and socket) 4. Check that drain flows smoothly.
E C 7.2. Indoor unit B 1. Remove two electrical wiring service panels. 2. Wire the power cable and control cable separately through the respective wiring entries given in the diagram. E 1 2 • Do not allow slackening of the terminal screws • Always install earch. (Earth cable dia: Thicker than 1.6 mm) • Considering the case of suspending the electrical box during services, leave the wiring some allowance. (Approx.
E D C A 7. Electrical work 7.3. Remote controller E 1) Installing procedures F I (2) Seal the service entrance for the remote controller cord with putty to prevent possible invasion of dew drops, water, cockroaches or worms. G H A For installation in the switch box: • B When the remote controller is installed in the switch box, seal the junction between the switch box and the conduit tube with putty. B For direct installation on the wall select one of the following : • B-1.
E 7. Electrical work 7.3. Remote controller 1 A 2) Connecting procedures • A. 1 B. 2 The remote controller cord may be extended up to 500 m. Since the remote controller cord supplied with the unit is 10 m-long, use those electric wires or (two-core) cables of 0.3 mm2 to 1.25 mm2 for extension. Do not use multi-conductor cables to prevent possible malfunction of the unit. 1 Connect the remote controller cord to the terminal block for the lower case.
E 7. Electrical work 7.3. Remote controller 1 3) Fitting the upper case 1 Put the upper latches (at two locations) first then fit the upper case into the lower case as illustrated. 2 To remove the upper case, put a slotted screwdriver tip in the latches as shown in the diagram then move the screwdriver in the direction of arrow. • • Caution: Do not move the screwdriver while inserting the tip far into the latches to prevent broken latches.
E 7. Electrical work 7.4. Outdoor unit 1 C A Warning: Tighten terminal screws securely. D 1 Remove the service panel (2 screws). A Earth terminal (Do not forget to install earth.) B Service panel C Indoor/Outdoor unit connecting terminals E D Power supply terminals E Fasten with wiring clamp F Pipe cover F 2 The wiring outlet consists of the rear pipe hole and wiring hole in the pipe cover (knock out).
E 7. Electrical work 7.5. Power supply wiring diagram (example) Electric wiring should be done according to the appropriate wiring diagram for the model being installed. A For electric wire specifications, see page 31. Be sure to comply with those specifications.
7. Electrical work E 7.6. System control s Remove all of the CN 40 connectors from the indoor controller boards of the slave units. s Then, set the unit addresses of each unit. (Those addresses are also serving as a part of the sequential starting timer).
E 8. Test run 8.1. Before test run s After installation of indoor and outdoor units, and piping and electric wiring work, re-check that the unit is free from leaks of refrigerant, loosened connections, and incorrect polarity. s Measure an impedance between the power supply terminal block (L, N) on the outdoor unit and the ground with a 500 V Megger and Ω. check that it is equal to or greater than 1.
E 8. Test run 8.3. Self-diagnosis C For available LED displays (LEDs 1, 2) on the indoor unit board, refer to the table below. LED2 (Microprocessor power supply) A LED1 (Remote controller power supply) Should remain ON always to indicate the control power supply is turned ON. Lights up to indicate the power is connected to the wired remote controller. Lights up only for the indoor unit connected to the outdoor unit address “0”.
E 9. Troubleshooting If any of the above-mentioned functions do not work properly, search for the cause in the following chart and correct accordingly. (This troubleshooting chart applies only to operation in trial run mode.) Cause Symptoms Group control One-to-one system (1) Wrong indoor-outdoor connections, or a re- • verse phase in the power line to the outdoor • unit In cooling mode, indoor coil temperature code • does not change.
E 10. Field electrical wiring (Power wiring specifications) Models Phase Frequency & Voltage Input capacity Indoor unit (A) Main switch/Fuse Outdoor unit (A) Indoor unit Wire No. Power supply Size mm (mm2) Outdoor unit Wire No. Power supply Size mm (mm2) Indoor unit/Outdoor unit connecting Wire No. × size mm (mm2) Remote controller-Indoor unit Wire No. × size mm (mm2) Control circuit rating Indoor unit power supply PLH-2KKC Wiring Power supply 1. 2. 3. 4. PLH-2.
E 11. Installing the grille 11.1. Checking the contents 1 • 1 2 3 4 5 6 A 3 ø2 0 2 This kit contains this manual and the following parts. Accessory name Q’ty Remark Grille 1 760 × 760 (mm) Screw with captive washer 4 M5 × 0.8 × 25 Gauge 1 (Divided into four parts) Stick for the intake grille open/close 1 ø8 × 750 (PLP-2.5KB only) Tapping screw 2 4 × 10 Hook for temporary placement 2 — A Auto vane 4 5 6 11.2.
11. Installing the grille E 1) 1) Removing the intake grille ■ PLP-2.5KC ■ PLP-2.5KC D A 1 D 1 • Slide the levers in the direction indicated by the arrow 1 to open the intake grille. • Move the intake grille’s shaft, and it will come off. A Grille B Shaft C Intake grille levers C D Intake grille ■ PLP-2.5KB • B A Point the intake grille at the floor, push the button on the grille, and the intake grille will open slowly. Move the intake grille’s shaft, and it will come off.
E 2) 11. Installing the grille 2) Fixing the grille A C D • Using 4 screws no. 2, attach the grille to the unit (ø14). • When installing the grille on the unit, tighten the screw with captive washer securely, allowing no gap between the unit and the grille, or between the grille and the surface of the ceiling. B A Unit B Grille C Ceiling D Allow no gap. 3) 3) Wire connection • Be sure to connect the unit to the connector (red, 10-pole).
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