Panasonic Air Conditioner Installation Instruction

Safety Precautions

WARNING: Indicates possibility of death or serious injury.

CAUTION: Indicates possibility of injury or property damage only.

Follow instructions indicated by symbols: [Prohibited Symbol] (white background) and [Mandatory Symbol] (dark background).

General Warnings:

• Do not use means to accelerate defrosting or cleaning other than those recommended by the manufacturer.
• Do not install the outdoor unit near a veranda handrail; children may climb and fall.
• Do not use unspecified, modified, joint, or extension cords for the power supply. Do not share outlets with other appliances.
• Do not bundle the power supply cord.
• Do not insert fingers or objects into the unit; the fan can cause injury.
• Do not sit or step on the unit; risk of falling.
• Keep plastic packaging away from small children to prevent suffocation.
• When installing or relocating, do not allow substances other than the specified refrigerant (e.g., air) to mix into the refrigeration cycle. Mixing air causes abnormal high pressure, potentially leading to explosion or injury.
• Do not pierce or burn the appliance as it is pressurized. Do not expose to heat, flames, sparks, or other ignition sources, as it may explode and cause injury or death.
• Do not add or replace refrigerant with a type other than specified.
• For R32/R410A models, use specified piping, flare nuts, and tools. Using R22 components may cause abnormally high pressure, explosion, and injury.
• Copper pipes for R32/R410A must be thicker than 0.8 mm.
• Residual oil amount should be less than 40 mg/10 m.
• Engage authorized dealers or specialists for installation. Incorrect installation can cause water leakage, electric shock, or fire.
• For refrigeration system work, install strictly according to these instructions. Defective installation can cause water leakage, electric shock, or fire.
• Use only attached accessories and specified parts.
• Install in a strong and firm location capable of withstanding the unit's weight.
• For electrical work, follow national regulations and these instructions. Use an independent circuit and a single outlet.
• Do not use joint cables for indoor/outdoor connections. Use specified cables and connect tightly. Clamp cables to prevent external force on terminals. Improper connection/fixing can cause overheating or fire.
• Wire routing must be arranged properly to ensure the control board cover is fixed correctly. Improperly fixed covers can cause fire or electric shock.
• Strongly recommended to install with an Earth Leakage Circuit Breaker (ELCB) or Residual Current Device (RCD) with sensitivity of 30 mA at 0.1 sec or less.
• During installation, install refrigerant piping properly before running the compressor.
• During pump down operation, stop the compressor before removing refrigeration piping.
• Tighten flare nuts with a torque wrench according to the specified method. Overtightening can cause refrigerant gas leakage over time.
• After installation, confirm no refrigerant gas leakage. Refrigerant contacting fire may generate toxic gas.
• Ventilate if refrigerant gas leaks during operation.
• Refrigerants may not contain an odor.
• The equipment must be properly earthed. Earth line must not be connected to gas pipe, water pipe, lightning rod earth, or telephone.

Cautions:

• Do not install the unit where flammable gas may leak. Gas accumulation can cause fire.
• Prevent liquid or vapor from entering sumps or sewers, as vapor is heavier than air and may form suffocating atmospheres.
• Do not release refrigerant during piping work. Handle liquid refrigerant carefully to avoid frostbite.
• Do not install in laundry rooms or other locations where water may drip from the ceiling.
• Do not touch sharp aluminum fins; they can cause injury.
• Carry out drainage piping correctly; improper drainage can cause water entry and furniture damage.
• Select an installation location that is easy for maintenance.
• Incorrect installation, service, or repair can increase the risk of rupture, leading to damage or injury.

Power Supply Connection:

• Use power supply cord 3 x 1.5 mm² (3/4 ~ 1.75HP) or 3 x 2.5 mm² (2.0 ~ 2.5HP), type 60245 IEC 57 or heavier.
• Power supply point should be easily accessible for emergency disconnection.
• In some countries, permanent connection to the power supply is prohibited.
• 1) Power supply connection to receptacle using power plug: Use an approved 15/16 A (3/4 ~ 1.75HP), 16 A (2.0 ~ 2.25HP), or 20 A (2.5HP) power plug with earth pin.
• 2) Power supply connection to a circuit breaker for permanent connection: Use an approved 16 A (3/4 ~ 2.25HP), or 20 A (2.5HP) circuit breaker. It must be a double pole switch with a minimum 3.0 mm contact gap.

Precautions for Using R32 Refrigerant

WARNING: The appliance shall be stored, installed, and operated in a well-ventilated room with indoor floor area larger than Amin (m²) [refer Table A] and without any continuously operating ignition source. Keep away from open flames, any operating gas appliances, or any operating electric heater. Otherwise, it may explode and cause injury or death.

• Mixing of different refrigerants within a system is prohibited.
• Models using R32 and R410A have different charging port thread diameters to prevent erroneous charging with R22 and for safety. Check beforehand. [Charging port thread diameter for R32 and R410A is 12.7 mm (1/2 inch).]
• Ensure foreign matter (oil, water, etc.) does not enter the piping. Seal piping openings securely when storing.
• Operation, maintenance, repair, and refrigerant recovery must be carried out by trained and certified personnel.
• No part of the refrigerating circuit or piping should be located near heat sources, open flames, operating gas appliances, or operating electric heaters.
• The user/owner or their authorized representative must regularly check alarms, mechanical ventilation, and detectors at least once a year, as required by national regulations.
• A logbook shall be maintained, recording the results of these checks.
• Ventilation in occupied spaces must be checked for obstructions.
• Before a new refrigerating system is put into service, the person responsible must ensure that trained and certified personnel are instructed on the system's construction, supervision, operation, maintenance, safety measures, and refrigerant handling.
• Personnel qualifications include knowledge of flammable refrigerant legislation, safe handling skills, PPE use, leak prevention, cylinder handling, charging, leak detection, recovery, disposal, understanding national legislation, and continuous training.
• Air-conditioner piping in occupied spaces must be installed to protect against accidental damage.
• Take precautions to avoid excessive vibration or pulsation to refrigerating piping.
• Ensure protection devices, piping, and fittings are protected against adverse environmental effects.
• Expansion and contraction of long runs of piping must be designed and installed securely to minimize the likelihood of hydraulic shock damage.
• Protect the system from accidental rupture due to moving furniture or reconstruction.
• Field-made refrigerant joints must be tightness tested with a sensitivity of 5 grams per year or better.

Installation Work

Installation may require two people. Keep ventilation openings clear of obstructions.

Outdoor Unit Installation

1. Select the Best Location

• Avoid direct sunlight or rain obstruction for heat radiation.
• Ensure hot air discharge does not affect animals or plants.
• Maintain minimum clearances indicated by arrows from walls, ceilings, fences, or other obstacles.
• Do not place obstacles that may cause short-circuiting of discharged air.
• If piping length exceeds the specified length for additional gas, add refrigerant as per the table.

Table A: Specifications and Additional Refrigerant Calculation

(*) Systems with total refrigerant charge, mc, lower than 1.84 kg are not subjected to any room area requirements.

Example for TZ20***: If installed at 10 m distance, additional refrigerant needed is 25 g (calculated as (10-7.5) m x 10 g/m).

Minimum Room Area (Amin) Calculation: Amin = (mc / (2.5 x (LFL)(5/4) x h0))² or Amin = mc / (SF x LFL x h0), where LFL=0.307 kg/m³, h0=1.8m, SF=0.75. Use the higher value.

2. Install the Outdoor Unit

Fix the unit firmly and horizontally on concrete or a rigid frame using bolts (ø10 mm). Ensure it is level for proper drainage. Consider wind and earthquake resistance when installing on a roof. Fasten the installation stand securely.

Dimensions (Model A B C D):

• TZ20***, TZ25***, RZ25***, TZ35***, RZ35***, TZ42***: 570 mm (A), 105 mm (B), 18.5 mm (C), 320 mm (D)
• TZ50***, RZ50***, TZ60***: 540 mm (A), 160 mm (B), 18.5 mm (C), 330 mm (D)
• TZ71***: 613 mm (A), 131 mm (B), 24 mm (C), 360.5 mm (D)

3. Connect the Piping

• Connecting to Indoor Unit: For outdoor joints, make a flare after inserting the flare nut onto the copper pipe. Align the pipe center and tighten the flare nut finger-tight, then with a torque wrench to the specified torque.
• Connecting to Outdoor Unit: Decide piping length, cut, remove burrs, and make the flare after inserting the flare nut onto the valve. Align pipe center to valve and tighten with a torque wrench to the specified torque. Do not overtighten.
• Piping Size and Torque:
  • 6.35 mm (1/4"): [18 N•m (1.8 kgf•m)]
  • 9.52 mm (3/8"): [42 N•m (4.3 kgf•m)]
  • 12.7 mm (1/2"): [55 N•m (5.6 kgf•m)]
  • 15.88 mm (5/8"): [65 N•m (6.6 kgf•m)]
  • 19.05 mm (3/4"): [100 N•m (10.2 kgf•m)]

4. Air Tightness Test on the Refrigerating System

Note: Air purging method is prohibited for R32 systems. Use a vacuum pump.

Procedure:

1. Connect charging hose with push pin to the low side of charging set and service port of 3-way valve.
2. Attach gauge manifold set correctly and tightly. Ensure both manifold gauge valves (low and high pressure) are closed.
3. Connect the center hose of the manifold gauge to a vacuum pump.
4. Turn on the vacuum pump, open the low side manifold gauge valve, and ensure the gauge needle moves to –76 cmHg (–0.1 MPa) or vacuum until 500 microns is achieved (approx. 10 minutes). Then close the valve.
5. Remove the vacuum pump and connect the center hose to an inert gas cylinder (test gas).
6. Charge test gas into the system until pressure reaches min. 1.04 MPa (10.4 barg).
7. Monitor pressure reading. Check for pressure drop.
8. If pressure drops, perform leak detection (using equipment with 5 g/year sensitivity or better), mark leaks, repair, and repeat evacuation (steps 3-4) and tightness test (steps 5-7).
9. If no pressure drop, recover test gas, perform evacuation (steps 3-4), then proceed to step 14.
10. Disconnect charging hose. Tighten service port caps to 18 N•m with a torque wrench.
11. Remove valve caps. Open both 2-way and 3-way valves. (Recommended: allow refrigerant to flow slowly, repeat opening/closing 2-way valve 3 times, then fully open).

5. Connect the Cable to the Outdoor Unit

WARNING: This equipment must be properly earthed.

• Remove the control board cover by loosening the screw.
• Use approved polychloroprene sheathed flexible cord (4 x 1.5 mm² or 4 x 2.5 mm²) for indoor/outdoor connection. Replace wire if existing wire is too short.
• Secure the cable onto the control board with the holder (clamper).
• Attach the control board cover back.
• Refer to indoor unit instructions for wire stripping and connection.
• Earth wire should be Yellow/Green (Y/G) and longer than other AC wires for safety.

6. Piping Insulation

• Insulate pipe connections as shown in the installation diagram. Wrap the insulated pipe end to prevent water ingress.
• If drain hose or connecting piping is in a room where dew may form, increase insulation with 6 mm or thicker POLY-E FOAM.

In Case of Reusing Existing Refrigerant Piping

Do not reuse existing refrigerant piping if:

• Heat insulation is missing for liquid or gas pipes.
• The pipe was left open.
• Diameter and thickness do not meet requirements.
• Piping length and elevation do not meet requirements.

Clean thoroughly before reuse if:

• Pump down operation cannot be performed for the existing air conditioner.
• The compressor has a history of failure.
• Oil color is dark (ASTM 4.0 and above).
• The existing air-conditioner is a gas/oil heat pump type.

Important:

• Do not reuse flare nuts to prevent gas leaks; install new ones.
• If existing refrigerant piping has welded parts, conduct a gas leak check on the welded part.
• Replace deteriorated heat insulating material with new material. Heat insulating material is required for both liquid and gas pipes.

Proper Pump Down Method:

1. Operate the air conditioner in cooling mode for 10-15 minutes.
2. After 10-15 minutes, close the 2-way valve. After 3 minutes, close the 3-way valve.
3. Take out the air conditioner unit.
4. Install the new refrigerant air conditioner.

Purpose: To mix oil and refrigerant. They are separated when the air conditioner is stopped. Mixed refrigerant & oil will be collected into the outdoor unit. Only a very small amount of oil remains inside piping, which is acceptable.

Check Items

• Is there any gas leakage at flare nut connections?
• Has heat insulation been carried out at flare nut connection?
• Is the connection cable fixed firmly to the terminal board?
• Is the connection cable clamped firmly?
• Is the earth wire connection properly done?
• Does the power supply voltage comply with the rated value?
• Is there any abnormal sound?
• Is the cooling/heating operation normal?
• Is the thermostat operation normal?

Disposal of Outdoor Unit Drain Water

• If a drain elbow is used, the unit should be placed on a stand taller than 3 cm.
• If the unit is used in an area where the temperature falls below 0 °C for 2 or 3 consecutive days, it is recommended not to use a drain elbow, as the drain water freezes and the fan will not rotate.
• Install the hose at an angle so that water flows out smoothly.

Required Tools for Installation Works

• Phillips screwdriver
• Level gauge
• Electric drill, hole core drill (ø70 mm)
• Hexagonal wrench (4 mm)
• Spanner
• Pipe cutter
• Reamer
• Knife
• Gas leak detector
• Measuring tape
• Thermometer
• Megameter
• Multimeter
• Torque wrench (with specified values: 18 N•m, 42 N•m, 55 N•m, 65 N•m, 100 N•m)
• Vacuum pump
• Gauge manifold

Explanation of Symbols

WARNING: Indicates use of flammable refrigerant. Leakage plus ignition source may cause ignition.

CAUTION: Read Installation Manual carefully.

CAUTION: Service personnel should handle equipment with reference to Installation Manual.

CAUTION: Information included in Operation Manual and/or Installation Manual.