Mitsubishi Electric Mr.Slim PUHZ-SHW-HA Installation manual

Air-Conditioners
PUHZ-BP·HA
INSTALLATION MANUAL
FOR INSTALLER
For safe and correct use, read this manual and the indoor unit installation manual thoroughly before installing
the air-conditioner unit.
English
Contents
1.
2.
3.
4.
5.
Safety precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the outdoor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the refrigerant piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drainage piping work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
3
4
5
7
6.
7.
8.
9.
Electrical work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Test run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
System control (Fig. 9-1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1. Safety precautions
► Before installing the unit, make sure you read all the “Safety
precautions”.
► Please report to or take consent by the supply authority before
connection to the system.
Warning:
Describes precautions that must be observed to prevent danger of injury or
death to the user.
Caution:
Describes precautions that must be observed to prevent damage to the unit.
Warning:
• The unit must not be installed by the user. Ask a dealer or an authorized
technician to install the unit. If the unit is installed incorrectly, water leakage, electric shock, or fire may result.
• For installation work, follow the instructions in the Installation Manual and
use tools and pipe components specifically made for use with R410A refrigerant. The R410A refrigerant in the HFC system is pressurized 1.6 times
the pressure of usual refrigerants. If pipe components not designed for
R410A refrigerant are used and the unit is not installed correctly, the pipes
may burst and cause damage or injuries. In addition, water leakage, electric shock, or fire may result.
• The unit must be installed according to the instructions in order to minimize the risk of damage from earthquakes, typhoons, or strong winds. An
incorrectly installed unit may fall down and cause damage or injuries.
• 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
and cause damage or injuries.
• If the air conditioner is installed in a small room, measures must be taken
to prevent the refrigerant concentration in the room from exceeding the
safety limit in the event of refrigerant leakage. Consult a dealer regarding
the appropriate measures to prevent the allowable concentration from being exceeded. Should the refrigerant leak and cause the concentration limit
to be exceeded, hazards due to lack of oxygen in the room may result.
• Ventilate the room if refrigerant leaks during operation. If refrigerant comes
into contact with a flame, poisonous gases will be released.
• All electric work must be performed by a qualified technician according to
local regulations and the instructions given in this manual. The units must
be powered by dedicated power lines and the correct voltage and circuit
breakers must be used. Power lines with insufficient capacity or incorrect
electrical work may result in electric shock or fire.
After installation work has been completed, explain the “Safety Precautions,” use,
and maintenance of the unit to the customer according to the information in the
Operation Manual and perform the test run to ensure normal operation. Both the
Installation Manual and Operation Manual must be given to the user for keeping.
These manuals must be passed on to subsequent users.
: Indicates a part which must be grounded.
Warning:
Carefully read the labels affixed to the main unit.
• Use C1220 copper phosphorus, for copper and copper alloy seamless
pipes, to connect the refrigerant pipes. If the pipes are not connected correctly, the unit will not be properly grounded and electric shock may result.
• Use only specified cables for wiring. The connections must be made securely without tension on the terminals. If the cables are connected or
installed incorrectly, overheating or fire may result.
• The terminal block cover panel of the outdoor unit must be firmly attached.
If the cover panel is mounted incorrectly and dust and moisture enter the
unit, electric shock or fire may result.
• When installing or moving the air conditioner, use only the specified refrigerant (R410A) to charge the refrigerant lines. Do not mix it with any other
refrigerant and do not allow air to remain in the lines. Air enclosed in the
lines can cause pressure peaks resulting in a rupture and other hazards.
• Use only accessories authorized by Mitsubishi Electric and ask a dealer
or an authorized technician to install them. If accessories are incorrectly
installed, water leakage, electric shock, or fire may result.
• Do not alter the unit. Consult a dealer for repairs. If alterations or repairs
are not performed correctly, water leakage, electric shock, or fire may result.
• The user should never attempt to repair the unit or transfer it to another
location. If the unit is installed incorrectly, water leakage, electric shock,
or fire may result. If the air conditioner must be repaired or moved, ask a
dealer or an authorized technician.
• After installation has been completed, check for refrigerant leaks. If refrigerant leaks into the room and comes into contact with the flame of a heater
or portable cooking range, poisonous gases will be released.
1.1. Before installation
Caution:
• Do not use the unit in an unusual environment. If the air conditioner is
installed in areas exposed to steam, volatile oil (including machine oil), or
sulfuric gas, areas exposed to high salt content such as the seaside, or
areas where the unit will be covered by snow, the performance can be significantly reduced and the internal parts can be damaged.
• Do not install the unit where combustible gases may leak, be produced,
flow, or accumulate. If combustible gas accumulates around the unit, fire
or explosion may result.
• The outdoor unit produces condensation during the heating operation.
Make sure to provide drainage around the outdoor unit if such condensation is likely to cause damage.
• When installing the unit in a hospital or communications office, be prepared for noise and electronic interference. Inverters, home appliances,
high-frequency medical equipment, and radio communications equipment
can cause the air conditioner to malfunction or breakdown. The air conditioner may also affect medical equipment, disturbing medical care, and
communications equipment, harming the screen display quality.
1.2. Before installation (relocation)
Caution:
• Be extremely careful when transporting the units. Two or more persons
are needed to handle the unit, as it weighs 20 kg or more. Do not grasp
the packaging bands. Wear protective gloves to remove the unit from the
packaging and to move it, as you can injure your hands on the fins or
other parts.
• Be sure to safely dispose of the packaging materials. Packaging materials,
such as nails and other metal or wooden parts may cause stabs or other
injuries.
2
• The base and attachments of the outdoor unit must be periodically
checked for looseness, cracks or other damage. If such defects are left uncorrected, the unit may fall down and cause damage or injuries.
• Do not clean the air conditioner unit with water. Electric shock may result.
• Tighten all flare nuts to specification using a torque wrench. If tightened
too much, the flare nut can break after an extended period and refrigerant
can leak out.
1. Safety precautions
1.3. Before electric work
Caution:
• Be sure to install circuit breakers. If not installed, electric shock may result.
• For the power lines, use standard cables of sufficient capacity. Otherwise,
a short circuit, overheating, or fire may result.
• When installing the power lines, do not apply tension to the cables. If the
connections are loosened, the cables can snap or break and overheating
or fire may result.
• Be sure to ground the unit. Do not connect the ground wire to gas or water
pipes, lightning rods, or telephone grounding lines. If the unit is not properly grounded, electric shock may result.
• Use circuit breakers (ground fault interrupter, isolating switch (+B fuse),
and molded case circuit breaker) with the specified capacity. If the circuit
breaker capacity is larger than the specified capacity, breakdown or fire
may result.
1.4. Before starting the test run
Caution:
• Turn on the main power switch more than 12 hours before starting operation. Starting operation just after turning on the power switch can severely
damage the internal parts. Keep the main power switch turned on during
the operation season.
• 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 any switch with wet hands. Electric shock may result.
• Do not touch the refrigerant pipes with bare hands during operation. The
refrigerant pipes are hot or cold depending on the condition of the flowing
refrigerant. If you touch the pipes, burns or frostbite may result.
• After stopping operation, be sure to wait at least five minutes before turning off the main power switch. Otherwise, water leakage or breakdown may
result.
1.5. Using R410A refrigerant air conditioners
Caution:
• Use new refrigerant pipes.
Note the following if reusing existing pipes that carried R22 refrigerant.
- Be sure to clean the pipes and make sure that the insides of the pipes are clean.
- Replace the existing flare nuts and flare the flared sections again.
- Do not use thin pipes. (Refer to page 5)
• Use C1220 copper phosphorus, for copper and copper alloy seamless
pipes, to connect the refrigerant pipes. Make sure the insides of the pipes
are clean and do not contain any harmful contaminants such as sulfuric
compounds, oxidants, debris, or dust. Use pipes with the specified thickness. (Refer to page 5)
• Store the pipes to be used during installation indoors and keep both ends
of the pipes sealed until just before brazing. (Leave elbow joints, etc. in
their packaging.) If dust, debris, or moisture enters the refrigerant lines, oil
deterioration or compressor breakdown may result.
• Use ester oil, ether oil, alkylbenzene oil (small amount) as the refrigeration
oil applied to the flared sections. If mineral oil is mixed in the refrigeration
oil, oil deterioration may result.
• Do not use refrigerant other than R410A refrigerant. If another refrigerant
is used, the chlorine will cause the oil to deteriorate.
• Use a vacuum pump with a reverse flow check valve.
If the vacuum pump oil flows backward into the refrigerant lines, refrigerant oil deterioration may result.
• Use the following tools specifically designed for use with R410A refrigerant. The following tools are necessary to use R410A refrigerant. Contact
your nearest dealer for any questions.
Tools (for R410A)
Gauge manifold
Charge hose
Gas leak detector
Torque wrench
Flare tool
Size adjustment gauge
Vacuum pump adapter
Electronic refrigerant charging scale
• Be sure to use the correct tools. If dust, debris, or moisture enters the refrigerant lines, refrigeration oil deterioration may result.
• Do not use a charging cylinder. If a charging cylinder is used, the composition of the refrigerant will change and the efficiency will be lowered.
1.6. Accessories of outdoor unit (Fig. 1-1)
1
<BP170-BP250 only>
The parts show in the left are the accessories of this unit, which are affixed to
the inside of the service panel.
1 Joint pipe.........×1
Fig. 1-1
2. Installation location
2.1. Refrigerant pipe (Fig. 2-1)
► 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.
B
E
Models
C
Fig. 2-1
F
D
A
A Pipe size(mm) B Pipe length
Gas side Liquid side
(one way)
C Height
DNumber of bends
difference
(one way)
P100
P125
P140
Ø15.88
Ø9.52
Max. 50 m
Max. 30m
Max. of 15
BP170
BP200
Ø25.4
Ø9.52
Max. 70 m
Max. 30m
Max. of 15
BP250
Ø25.4
Ø12.7
Max. 70 m
Max. 30m
Max. of 15
• Height difference limitations are binding regardless of which unit, indoor or outdoor, is positioned higher.
E Indoor unit
F Outdoor unit
■BP100-BP140
■BP170-BP250
(mm)
2.2. Choosing the outdoor unit installation location
• Avoid locations exposed to direct sunlight or other sources of heat.
• Select a location from which noise emitted by the unit will not inconvenience
neighbors.
• Select a location permitting easy wiring and pipe access to the power source and
indoor unit.
• Avoid locations where combustible gases may leak, be produced, flow, or accumulate.
• Note that water may drain from the unit during operation.
• Select a level location that can bear the weight and vibration of the unit.
• Avoid locations where the unit can be covered by snow. In areas where heavy
snow fall is anticipated, special precautions such as raising the installation location or installing a hood on the air intake and air outlet must be taken to prevent
the snow from blocking the air intake or blowing directly against it. This can reduce the airflow and a malfunction may result.
• Avoid locations exposed to oil, steam, or sulfuric gas.
• Use the transportation handles of the outdoor unit to transport the unit. If the unit
is carried from the bottom, hands or fingers may be pinched.
Fig. 2-2
2.3. Outline dimensions(Outdoor unit) (Fig.2-2)
3
2. Installation location
2.4.2. When installing a single outdoor unit (Refer to the last page)
Minimum dimensions are as follows, except for Max., meaning Maximum dimensions, indicated.
The figures in parentheses are for BP125- BP250 models.
1 Obstacles at rear only (Fig. 2-6)
2 Obstacles at rear and above only (Fig. 2-7)
3 Obstacles at rear and sides only (Fig. 2-8)
4 Obstacles at front only (Fig. 2-9)
5 Obstacles at front and rear only (Fig. 2-10)
Fig. 2-3
• When using an optional air outlet guide, the clearance for BP125-BP250 models is
500 mm or more.
6 Obstacles at rear, sides, and above only (Fig. 2-11)
• Do not install the optional air outlet guides for upward airflow.
Fig. 2-4
2.4.3. When installing multiple outdoor units (Refer to the last page)
Leave 10 mm space or more between the units.
1 Obstacles at rear only (Fig. 2-12)
2 Obstacles at rear and above only (Fig. 2-13)
• No more than 3 units must be installed side by side. In addition, leave space as
shown.
• Do not install the optional air outlet guides for upward airflow.
3 Obstacles at front only (Fig. 2-14)
Fig. 2-5
• When using an optional air outlet guide, the clearance for BP125-BP250 models is
1000 mm or more.
4 Obstacles at front and rear only (Fig. 2-15)
2.4. Ventilation and service space
2.4.1. Windy location installation
When installing the outdoor unit on a rooftop or other location unprotected
from the wind, situate the air outlet of the unit so that it is not directly exposed
to strong winds. Strong wind entering the air outlet may impede the normal
airflow and a malfunction may result.
The following shows 3 examples of precautions against strong winds.
1 Face the air outlet towards the nearest available wall about 50 cm away
from the wall. (Fig. 2-3) [for BP170-BP250 models : 100cm]
2 Install an optional air guide if the unit is installed in a location where strong
winds from a typhoon, etc. may directly enter the air outlet. (Fig. 2-4)
A Air outlet guide
• When using an optional air outlet guide, the clearance for BP125-BP250 models is
1000 mm or more.
• When using an optional air outlet guide installed for upward airflow, the clearance is
500 (1000) mm or more.
6 Multiple parallel unit arrangement (Fig. 2-17)
• When using an optional air outlet guide installed for upward airflow, the clearance is
1000 (1500) mm or more.
7 Stacked unit arrangement (Fig. 2-18)
• The units can be stacked up to 2 units high.
• No more than 2 stacked units must be installed side by side. In addition, leave
space as shown.
3 Position the unit so that the air outlet blows perpendicularly to the seasonal
wind direction, if possible. (Fig. 2-5)
B Wind direction
3. Installing the outdoor unit
(mm)
• Be sure to install the unit in a sturdy, level surface to prevent rattling noises during operation. (Fig. 3-1)
<Foundation specifications>
Foundation bolt
Thickness of concrete
Length of bolt
Weight-bearing capacity
B
Max. 30
D
Min. 360
600
Min. 10
175
175
950
25
330
370
600
4
• Make sure that the length of the foundation bolt is within 30 mm of the bottom
surface of the base.
• Secure the base of the unit firmly with 4-M10 foundation bolts in sturdy locations.
Installing the outdoor unit
• Do not block the vent. If the vent is blocked, operation will be hindered and
breakdown may result.
• In addition to the unit base, use the installation holes it fixes top panel on the
back of the unit to attach wires, etc., if necessary to install the unit. Use selftapping screws (ø5 × 15 mm or less) and install on site.
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
and cause damage or injuries.
• The unit must be installed according to the instructions in order to minimize the risk of damage from earthquakes, typhoons, or strong winds. An
incorrectly installed unit may fall down and cause damage or injuries.
A M10 (3/8") bolt
B Base
C As long as possible.
D Vent
E Set deep in the ground.
Fig. 3-1
M10 (3/8")
120 mm
70 mm
320 kg
4. Installing the refrigerant piping
4.1. Precautions for devices that use R410A refrigerant
• Refer to page 3 for precautions not included below on using air conditioners with R410A refrigerant.
• Use ester oil, ether oil, alkylbenzene oil (small amount) as the refrigeration
oil applied to the flared sections.
• Use C1220 copper phosphorus, for copper and copper alloy seamless
pipes, to connect the refrigerant pipes. Use refrigerant pipes with the
thicknesses specified in the table to the below. Make sure the insides of
the pipes are clean and do not contain any harmful contaminants such as
sulfuric compounds, oxidants, debris, or dust.
Always apply no-oxidation brazing when brazing the pipes,otherwise,the
compressor will be damaged.
Warning:
When installing or moving the air conditioner, use only the specified refrigerant (R410A) to charge the refrigerant lines. Do not mix it with any other refrigerant and do not allow air to remain in the lines. Air enclosed in the lines can
cause pressure peaks resulting in a rupture and other hazards.
Pipe size(mm) Ø6.35 Ø9.52 Ø12.7 Ø15.88 Ø19.05 Ø22.2 Ø25.4 Ø28.58
Thickness(mm) 0.8
0.8
0.8
1.0
1.0
1.0
1.0
1.0
• Do not use pipes thinner than those specified above.
4.2. Connecting pipes
B
45° ± 2°
øA
• When commercially available copper pipes are used, wrap liquid and gas pipes
with commercially available insulation materials (heat-resistant 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 0.03, thickness of 9 mm or more).
• Apply thin layer of refrigerant oil to pipe and joint seating surface before tightening flare nut. A (Fig.4-1)
• Use 2 wrenches to tighten piping connections. B (Fig.4-1)
• Use leak detector or soapy water to check for gas leaks after connections are
completed.
• Apply refrigerating machine oil over the entire flare seat surface. C (Fig.4-1)
• Use the flare nuts for the following pipe size. D (Fig.4-1)
.8
R0
.4~
R0
90° ± 0.5°
A
A Flare cutting dimensions
B Flare nut tightening torque
C
Indoor unit model
Gas side
Pipe size(mm)
Liquid side
Pipe size(mm)
Fig. 4-1
Copper pipe O.D.
(mm)
ø6.35
ø9.52
ø12.7
ø15.88
ø19.05
RP60,71
Ø15.88
Ø9.52
RP100-140
Ø15.88
Ø9.52
• When bending the pipes, be careful not to break them. Bend radii of 100 mm to
150 mm are sufficient.
• Make sure the pipes do not contact the compressor. Abnormal noise or vibration
may result.
D
A (Fig. 4-1)
RP50
Ø12.7
Ø6.35
Flare dimensions
øA dimensions (mm)
8.7 - 9.1
12.8 - 13.2
16.2 - 16.6
19.3 - 19.7
23.6 - 24.0
1 Pipes must be connected starting from the indoor unit.
Flare nuts must be tightened with a torque wrench.
2 Flare the liquid pipes and gas pipes and apply a thin layer of refrigeration oil
(Applied on site).
• When usual pipe sealing is used, refer to Table 1 for flaring of R410A refrigerant
pipes.
The size adjustment gauge can be used to confirm B measurements.
B (Fig. 4-1)
Table 1 (Fig. 4-2)
Copper pipe O.D.
(mm)
ø6.35
ø6.35
ø9.52
ø12.7
ø12.7
ø15.88
ø15.88
ø19.05
Flare nut O.D.
(mm)
17
22
22
26
29
29
36
36
Tightening torque
(N·m)
14 - 18
34 - 42
34 - 42
49 - 61
68 - 82
68 - 82
100 - 120
100 - 120
Copper pipe O.D.
(mm)
ø6.35 (1/4")
ø9.52 (3/8")
ø12.7 (1/2")
ø15.88 (5/8")
ø19.05 (3/4")
B (mm)
Flare tool for R410A
Flare tool for R22·R407C
Clutch type
0 - 0.5
1.0 - 1.5
0 - 0.5
1.0 - 1.5
0 - 0.5
1.0 - 1.5
0 - 0.5
1.0 - 1.5
0 - 0.5
1.0 - 1.5
3 Use the following procedure for connecting the gas-side piping. (Fig. 4-3)
[For BP170-BP250]
1 Braze the E Joint pipe provided to the outdoor unit using locally procured brazing materials and C Local piping without oxygen.
2 Connect the E Joint pipe to the gas-side Stop valve.
Use two wrenches to tighten the flare nut.
B
*
If order is reversed, refrigerant leak occures because of the part damaging by brazing fire.
A
• For PEA-RP170-250WGA
The method of pipe connection is brazing connection.
B
A Die
B Copper pipe
Fig. 4-2
A Stop valve (gas-side)
B Seal section
C Local piping
D Double spanner section
E Joint pipe
F Pipe cover
PEA-RP170WGA PEA-RP200WGA PEA-RP250WGA
Gas side Pipe size(mm)
Liquid side Pipe size(mm)
Ø25.4
Ø9.52
Ø25.4
Ø9.52
Ø25.4
Ø12.7
Fig. 4-3
5
4. Installing the refrigerant piping
4.3. Refrigerant piping (Fig. 4-4)
A Front piping cover
B Piping cover
C Stop valve
D Service panel
E Bend radius : 100 mm-150 mm
Fig. 4-4
Fig. 4-5
A Stop valve <Liquid side>
G Pipe cover
B Stop valve <Gas side>
H Do not use a wrench here.
Refrigerant leakage may result.
C Service port
I Double spanner section
D Open/Close section
(Do not apply a spanner other than to
this section. Doing so would cause
refrigerant leaks.)
E Local pipe
F Seal section
(Seal the end of the heat insulation
material at the pipe connection section
with whatever seal material you have on
hand so that water does not infiltrate the
heat insulation material.)
(1)
A Valve
B Unit side
C Operation section
D Cap
E Local pipe side
F Pipe cover
G Service port
4.4. Refrigerant pipe airtight testing method(Fig.4-5)
(1) Connect the testing tools.
• Make sure the stop valves A B are closed and do not open them.
• Add pressure to the refrigerant lines through the service port C of the liquid
stop valve A.
(2) Do not add pressure to the specified pressure all at once; add pressure little by little.
1 Pressurize to 0.5 MPa (5 kgf/cm2G), wait 5 minutes, and make sure the pressure does not decrease.
2 Pressurize to 1.5 MPa (15 kgf/cm2G), wait 5 minutes, and make sure the
pressure does not decrease.
3 Pressurize to 4.15 MPa (41.5 kgf/cm2G) and measure the surrounding temperature and refrigerant pressure.
(3) If the specified pressure holds for about one day and does not decrease, the
pipes have passed the test and there are no leaks.
• If the surrounding temperature changes by 1 °C, the pressure will change by
about 0.01 MPa (0.1 kgf/cm2G). Make the necessary corrections.
(4) If the pressure decreases in steps (2) or (3), there is a gas leak. Look for the
source of the gas leak.
4.5. Stop valve opening method
(2)
Fig. 4-6
Remove the service panel D (3 screws) and the front piping cover A (2 screws)
and rear piping cover B (2 screws).
1 Perform refrigerant piping connections for the indoor/outdoor unit when the outdoor unit’s stop valve is completely closed.
2 Vacuum-purge air from the indoor unit and the connection piping.
3 After connecting the refrigerant pipes, check the connected pipes and the indoor
unit for gas leaks. (Refer to 4.4 Refrigerant pipe airtight testing method)
4 A high-performance vacuum pump is used at the stop valve service port to maintain a vacuum for an adequate time (at least 1 hour after reaching –101 kPa (5
Torr)) in order to vacuum dry the inside of the pipes. Always check the degree
of vacuum at the gauge manifold. If there is any moisture left in the pipe, the degree of vacuum is sometimes not reached with short-time vacuum application.
After vacuum drying, completely open the stop valves (both liquid and gas) for
the outdoor unit. This completely links the indoor and outdoor refrigerant circuits.
• If the vacuum drying is inadequate, air and water vapor remain in the refrigerant circuits and can cause abnormal rise of high pressure, abnormal drop of
low pressure, deterioration of the refrigerating machine oil due to moisture,
etc.
• If the stop valves are left closed and the unit is operated, the compressor and
control valves will be damaged.
• Use a leak detector or soapy water to check for gas leaks at the pipe connection sections of the outdoor unit.
• Do not use the refrigerant from the unit to purge air from the refrigerant lines.
• After the valve work is completed, tighten the valve caps to the correct torque:
20 to 25 N·m (200 to 250 kgf·cm).
Failure to replace and tighten the caps may result in refrigerant leakage. In
addition, do not damage the insides of the valve caps as they act as a seal to
prevent refrigerant leakage.
5 Use sealant to seal the ends of the pipe cover around the pipe connection sections to prevent water from entering the thermal insulation.
Fig. 4-7
I Double spanner section
(Do not apply a spanner other than to this section. Doing
so would cause refrigerant leaks.)
J Seal section
(Seal the end of the heat insulation material at the pipe connection
section with whatever seal material you have on hand
so that water does not infiltrate the heat insulation material.)
K Handle
H Wrench hole
The stop valve opening method varies according to the outdoor unit model. Use the
appropriate method to open the stop valves.
(1) Gas side(Fig. 4-6)
1 Remove the cap, pull the handle toward you and rotate 1/4 turn in a counterclockwise direction to open.
2 Make sure that the stop valve is open comletely,push in the handle and rotate
the cap back to its original position.
(2) Liquid side(Fig. 4-7)
1 Remove the cap and turn the valve rod counterclockwise as far as it will go
with the use of a 4 mm hexagonal wrench. Stop turning when it hits the stopper.
(ø9.52: Approximately 10 revolutions)
2 Make sure that the stop valve is open completely and rotate the cap back to
its original position.
Refrigerant pipes are protectively wrapped
• The pipes can be protectively wrapped up to a diameter of ø90 before or after
connecting the pipes. Cut out the knockout in the pipe cover following the
groove and wrap the pipes.
Pipe inlet gap
• Use putty or sealant to seal the pipe inlet around the pipes so that no gaps remain. (If the gaps are not closed, noise may be emitted or water and dust will
enter the unit and breakdown may result.)
4.6. Addition of refrigerant
• Additional charging is not necessary if the pipe length does not exceed 20 m for
BP100-BP140 and 30 m for BP170-BP250.
• If the pipe length is exceeded, charge the unit with additional R410A refrigerant
according to the permitted pipe lengths in the following table.
* When the unit is stopped, charge the unit with the additional refrigerant
through the liquid stop valve after the pipe extensions and indoor unit have
been vacuumized.
When the unit is operating, add refrigerant to the gas check valve using a
safety charger. Do not add liquid refrigerant directly to the check valve.
* After charging the unit with refrigerant, note the added refrigerant amount
on the service label (attached to the unit).
Refer to the “1.5. Using R410A refrigerant air conditioners” for more information.
6
• Be careful when installing multiple units. Connecting to an incorrect indoor unit
can lead to abnormally high pressure and have a serious effect on operation
performance.
Models
BP100
BP125
BP140
BP170
BP200
BP250
Permitted
pipe
length
Permitted
vertical
difference
~50m
~30m
~70m
~30m
Additional refrigerant charging amount
21-30m
31-40m
41-50m
51-60m
61-70m
0.6kg
1.2kg
1.8kg
0.9kg
1.8kg
2.7kg
3.6kg
1.2kg
2.4kg
3.6kg
4.8kg
4. Installing the refrigerant piping
<Limits of refrigerant piping installation>
4.7. For twin/triple/quadruple combination (Fig. 4-8)
• When this unit is used as a FREE COMPO MULTI unit, install the refrigerant
piping with the restrictions indicated in the drawing on the left. In addition, if the
restrictions are going to be exceeded, or if there are going to be combinations of
indoor and outdoor units, refer to installation instructions for the indoor unit for
details about the installation.
E : BP170-250 only
A Indoor unit
B Outdoor unit
C Multidistribution pipe (option)
D Height difference (Indoor unitOutdoor unit) Max. 30 m
E Height difference (Indoor unit-
Outdoor unit
BP100
BP125
BP140
BP170
BP200
BP250
Indoor unit) Max. 1 m
A: Main piping
B, C, D, E: Branch piping
Outdoor unit
BP100-140:
A+B+C(+D) { 50 m
BP170-250:
A+B+C(+D)(+E) { 70 m
*“D” is for triple.
*“E” is for four (quadruple).
| B–C |
| B–D |
| C–D |
BP100, 125, 140,
170, 200, 250
{ 8m
Permissible total
piping length
A+B+C+D+E
Charge-less
piping length
A+B+C+D+E
50m and less
20m and less
70m and less
30m and less
| B-C | or | B-D | or
| B-E | or | C-D | or
| C-E | or | D-E |
No. of bends
8 m and less
Within 15
E, | C-E | | D-E |:BP170- 250 only
Fig. 4-8
5. Drainage piping work
Outdoor unit drainage pipe connection
When drain piping is necessary, use the drain socket or the drain pan (option).
Drain socket
PAC-SG61DS-E
Darin pan
PAC-SG64DP-E
6. Electrical work
6.1. Outdoor unit (Fig. 6-1)
■ BP170-BP250
(1) Remove the service panel.
(2) Wire the cables referring to the Fig. 6-1.
Note: If the protective sheet for the
electrical box is removed during
servicing, be sure to reinstall it.
■ BP100-BP140
F
G
H
I
Power supply terminal block (L, N,
)
Indoor/outdoor connection terminal block (S1, S2, S3)
Service panel
Clamp
* Clamp the cables so that they do not contact the center of the service panel or the gas valve.
*
Except PEA-RP170-250WGA
F Power supply terminal block : (L1, L2, L3, N,
)
G Indoor/outdoor connection terminal block (S1, S2, S3)
H Service panel
I Clamp
* Clampthe cables so that they do not contact the center of the service panel
or the gas valve.
* In case of PEA-RP170-250WGA
*With Heater
model only
For Heater
PUHZ-170 - 250
A Indoor unit
B Outdoor unit
C Remote controller
D Main switch (Breaker)
E Earth
For Power
For Heater
For Heater
For Heater
A Power supply
B Earth leakage breaker
C Circuit breaker or local switch
D LCD remote controller
E Outdoor unit
PEA-170 - 250
F Indoor unit
G Power cable wiring
H Indoor/Outdoo rconnection wiring
I Grounding
A Outdoor unit
B Indoor unit
C Main remote controller
D Subordinate remote con-
For Heater
troller
For Power
E Standard
(Refrigerant address = 00)
F Refrigerantaddress = 01
G Refrigerantaddress = 02
H Refrigerantaddress = 15
Fig. 6-1
BP170-BP250 only
7
6. Electrical work
6.2. Field electrical wiring
• If the wiring connecting the indoor and outdoor units is longer than 80 m, use separate indoor/outdoor unit power supplies. (Refer to the installation manuals of the
indoor units for more information.)
■ BP100-BP140
Outdoor unit model
BP100V
BP125V
BP140V
~/N (single), 50 Hz,
230 V
~/N (single), 50 Hz,
230 V
*2
*2
25A
3 × Min. 2.5
3 × 1.5 (Polar)
1 × Min. 1.5
32A
3 × Min. 4
3 × 1.5 (Polar)
1 × Min. 1.5
40A
3 × Min. 6
3 × 1.5 (Polar)
1 × Min. 1.5
*3
2 × 0.3 (Non-polar)
2 × 0.3 (Non-polar)
2 × 0.3 (Non-polar)
~/N (single), 50 Hz,
230 V
outdoor unit power supply
outdoor unit input capacity Main switch(breaker)
Outdoor unit power supply
Wiring
Indoor unit-Outdoor unit
Wire No. ×
Indoor unit-Outdoor unit earth
size (mm²)
Remote controller-Indoor unit
Outdoor unit L-N (single)
Circuit rating Indoor unit-Outdoor unit S1-S2
Indoor unit-Outdoor unit S2-S3
Remote controller-Indoor unit
*1
*4
AC230V
AC230V
AC230V
*4
*4
*4
AC230V
DC24V
DC12V
AC230V
DC24V
DC12V
AC230V
DC24V
DC12V
*1. A breaker with at least 3.0 mm contact separation in each poles shall be provided. Use earth leakage breaker (NV).
*2. Max.45 m
If 2.5 mm² used, Max. 50 m
If 2.5 mm² used and S3 separated, Max. 80 m
*3. The10 m wire is attached in the remote controller accessory.
*4. The figures are NOT always against the ground.
S3 terminal has DC 24 V against S2 terminal. However between S3 and S1, these terminals are NOT electrically insulated by the transformer or other device.
■ BP170-BP250
Outdoor unit model
Outdoor unit
Phase
Power supply
Frequency & Voltage
Outdoor unit input capacity
Main switch (Breaker)
Outdoor unit power supply
Wiring
Indoor unit-Outdoor unit
Wire No. × size
Indoor unit-Outdoor unit earth
(mm²)
Remote controller-Indoor unit
Outdoor unit L1-N, L2-N, L3-N
Indoor unit-Outdoor unit S1-S2
Circuit rating
Indoor unit-Outdoor unit S2-S3
Remote controller-Indoor unit
BP170, 200, 250
3N~(3ph 4-wires), 50 Hz,
380 - 400 - 415 V
*1
*2
*3
*4
*4
*4
32 A
5 × Min. 4
Cable length 50 m : 3 × 4 (Polar)/Cable length 80 m : 3 × 6 (Polar)
1 × Min. 2.5
2 × 0.3 (Non-polar)
AC 220 - 230 - 240 V
AC 220 - 230 - 240 V
DC 24 V
DC 12 V
*1. A breaker with at least 3 mm contact separation in each pole shall be provided. Use earth leakage breaker(NV).
*2. Max.80 m Total Max. including all indoor/indoor connection is 80 m.
•Use one cable for S1 and S2 and another for S3 as shown in the picture.
•Max. 50 m Total Max. for PEA. Wiring size 3 × 1.5 (Polar).
*3. The 10 m wire is attached in the remote controller accessory.
*4. The figures are NOT against the ground.
S3 terminal has DC 24 V against S2 terminal. However between S3 and S1, these terminals are not electrically insulated by the transformer or other device.
Notes : 1. Wiring size must comply with the applicable local and national code.
2. Power supply cords and Indoor unit/Outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord.
(Design 60245 IEC 57)
3. Use an earth wire which is longer than the other cords so that it will not become disconnected when tension is applied.
Power supply
Isolator (Switch)
“A-Control”
Outdoor Unit
3 poles isolator (Switch)
“A-Control”
Indoor Unit
Warning:
In case of A-control wiring, there is high voltage potential on the S3 terminal caused by electrical circuit design that has no electrical insulation between
power line and communication signal line. Therefore, please turn off the main power supply when servicing. And do not touch the S1, S2, S3 terminals
when the power is energized. If isolator should be used between indoor unit and outdoor unit, please use 3-pole type.
8
6. Electrical work
■ BP170-BP250
WIRING SPECIFICATIONS FOR 220-240 V 50 Hz
(INDOOR-OUTDOOR CONNECTING CABLE)
Cross section of cable
Round
Wire size (mm²)
Number of wires
Polarity
2.5
3
Clockwise : S1-S2-S3
* Pay attention to stripe of yellow and green
2.5
3
Not applicable
(Because center wire has no cover finish)
1.5
4
2.5
4
Flat
Flat
Round
L (m)*6
(30)
*2
Not applicable
*5
From left to right : S1-Open-S2-S3
(18)
*3
Clockwise : S1-S2-S3-Open
*Connect S1 and S3 to the opposite angle
(30)
*4
*1 : Power supply cords of appliances shall not be lighter than design 60245 IEC or
227 IEC.
*2 : In case that cable with stripe of yellow and green is available.
*3 : In case of regular polarity connection (S1-S2-S3), wire size is 1.5 mm2.
*4 : In case of regular polarity connection (S1-S2-S3).
*5 : In the flat cables are connected as this picture, they can be used up to 30 m.
(3C Flat cable × 2)
*6 : Mentioned cable length is just a reference value.
It may be different depending on the condition of installation, Humidity or
materials, etc.
Be sure to connect the indoor-outdoor connecting cables directly to the units (no intermediate connections).
Intermediate connections can lead to communication errors if water enters the cables and causes insufficient insulation to ground or a poor
electrical contact at the intermediate connection point.
7. Test run
7.1. Before test run
• After completing installation and the wiring and piping of the indoor and
outdoor units, check for refrigerant leakage, looseness in the power supply
or control wiring, wrong polarity, and no disconnection of one phase in the
supply.
• Use a 500-volt megohmmeter to check that the resistance between the
power supply terminals and ground is at least 1.0 MΩ.
• Do not carry out this test on the control wiring (low voltage circuit) terminals.
Warning:
Do not use the air conditioner if the insulation resistance is less than 1.0 MΩ.
• The insulation resistance drops due to accumulation of refrigerant in the compressor. The resistance will rise above 1 MΩ after the compressor is warmed
up for 4 hours.
(The time necessary to warm up the compressor varies according to atmospheric conditions and refrigerant accumulation.)
• To operate the compressor with refrigerant accumulated in the compressor,
the compressor must be warmed up at least 12 hours to prevent breakdown.
4. If the insulation resistance rises above 1 MΩ, the compressor is not faulty.
Caution:
• The compressor will not operate unless the power supply phase connection
Insulation resistance
After installation or after the power source to the unit has been cut for an extended
period, the insulation resistance will drop below 1 MΩ due to refrigerant accumulating in the compressor. This is not a malfunction. Perform the following procedures.
1. Remove the wires from the compressor and measure the insulation resistance
of the compressor.
2. If the insulation resistance is below 1 MΩ, the compressor is faulty or the resistance dropped due the accumulation of refrigerant in the compressor.
3. After connecting the wires to the compressor, the compressor will start to warm
up after power is supplied. After supplying power for the times indicated below,
measure the insulation resistance again.
is correct.
• Turn on the power at least 12 hours before starting operation.
- Starting operation immediately after turning on the main power switch can result
in severe damage to internal parts. Keep the power switch turned on during the
operational season.
• The followings must be checked as well.
• The outdoor unit is not faulty. LED1 and LED2 on the control board of the outdoor
unit flash when the outdoor unit is faulty.
• Both the gas and liquid stop valves are completely open.
• A protective sheet covers the surface of the DIP switch panel on the control
board of the outdoor unit. Remove the protective sheet to operate the DIP
switches easily.
7.2. Test run
7.2.1. Using SW4 in outdoor unit
SW4-1
SW4-2
ON
OFF
SW4-1
ON
SW4-2
ON
Cooling operation
Heating operation
• A few seconds after the compressor starts, a clanging noise may be heard from
the inside of the outdoor unit. The noise is coming from the check valve due to
the small difference in pressure in the pipes. The unit is not faulty.
The test run operation mode cannot be changed by DIP switch SW4-2 during
* After performing the test run, set SW 4 -1 to OFF.
the test run. (To change the test run operation mode during the test run,
• After power is supplied, a small clicking noise may be heard from the inside of
stop the test run by DIP switch SW4-1. After changing the test run operation
the outdoor unit. The electronic expansion valve is opening and closing. The unit
mode, resume the test run by switch SW4-1.)
is not faulty.
7.2.2. Using remote controller
Refer to the indoor unit installation manual.
9
8. Special Functions
B
A
C
8.1. Low noise mode (on-site modification) (Fig. 8-1)
D
Red
Brown
Orange
3
1
SW1
Fig. 8-1
CNDM
E
A Circuit diagram example (low noise
mode)
B On-site arrangement
C External input adapter (PAC-SC36NA)
A
B
D Outdoor unit control board
E Max. 10 m
C
8.2. Demand function (on-site modification) (Fig. 8-2)
D
Red
Brown
Orange
3
1
SW2
Fig. 8-2
CNDM
E
A Circuit diagram example (Demand
function)
B On-site arrangement
C External input adapter (PAC-SC36NA)
By performing the following modification, operation noise of the outdoor unit can be
reduced by about 3-4 dB.
The low noise mode will be activated when a commercially available timer or the
contact input of an ON/OFF switch is added to the CNDM connector (option) on the
control board of the outdoor unit.
• The ability varies according to the outdoor temperature and conditions, etc.
1 Complete the circuit as shown when using the external input adapter
(PAC-SC36NA). (Option)
2 SW1 ON: Low noise mode
SW1 OFF: Normal operation
D Outdoor unit control board
E Max. 10 m
By performing the following modification, energy consumption can be reduced to 0
–100% of the normal consumption.
The demand function will be activated when a commercially available timer or the
contact input of an ON/OFF switch is added to the CNDM connector (option) on the
control board of the outdoor unit.
1 Complete the circuit as shown when using the external input adapter
(PAC-SC36NA). (Option)
2 By setting SW 7-1 and SW 7-2 on the control board of the outdoor unit, the energy consumption (compared to the normal consumption) can be limited as shown
below.
SW7-1
OFF
ON
OFF
SW7-2
OFF
OFF
ON
Energy consumption (SW2 ON)
0% (Stop)
50%
75%
8.3. Refrigerant collecting (pump down)
Perform the following procedures to collect the refrigerant when moving the indoor
unit or the outdoor unit.
1 Supply power (circuit breaker).
* When power is supplied, make sure that “CENTRALLY CONTROLLED” is not
displayed on the remote controller. If “CENTRALLY CONTROLLED” is displayed, the refrigerant collecting (pump down) cannot be completed normally.
2 After the gas stop valve is closed, set the SWP switch on the control board of the
outdoor unit to ON. The compressor (outdoor unit) and ventilators (indoor and
outdoor units) start operating and refrigerant collecting operation begins. LED1
and LED2 on the control board of the outdoor unit are lit.
* Only set the SWP switch (push-button type) to ON if the unit is stopped. However, even if the unit is stopped and the SWP switch is set to ON less than
three minutes after the compressor stops, the refrigerant collecting operation
cannot be performed. Wait until compressor has been stopped for 3 minutes
and then set the SWP switch to ON again.
3 Because the unit automatically stops in about 2 to 3 minutes after the refrigerant
collecting operation (LED1 and LED2 are lit), be sure to quickly close the gas
stop valve. When LED1 and LED2 are lit and the outdoor unit is stopped, open
the liquid stop valve completely, and then repeat step 2 after 3 minutes have
passed.
* If the refrigerant collecting operation has been completed normally (LED1 and
LED2 are lit), the unit will remain stopped until the power supply is turned off.
4 Turn off the power supply (circuit breaker).
* Note that when the length of the extension piping is long, it may no be possible to perform a pump-down operation.When performing the pump-down
operation,make sure that the low pressure is lowered to near 0 MPa( gauge).
9. System control (Fig. 9-1)
E SW 1 - 3 ~ 6
ON
OFF
F SW 1 - 3 ~ 6
ON
OFF
G SW 1 - 3 ~ 6
ON
OFF
3
4
5
6
3
4
5
6
3
4
5
6
A E
TB1
TB4
TB4
TB5
Outdoor unit
Indoor unit
Master remote controller
Subordinate remote controller
Standard 1:1 (Refrigerant address = 00)
Simultaneous twin (Refrigerant address = 01)
Simultaneous triple (Refrigerant address = 02)
A F
TB1
B
A
B
C
D
E
F
G
TB4
2
2 TB5
B
SW1
Function table
G
TB4
B
TB4
B
TB4
<SW1>
B
ON
OFF
1 2 3 4 5 6
D
1
Fig. 9-1
10
A
TB5
1
C
Note:
In single refrigerant system (twin/triple), there is no need of wiring 2.
TB1
B
* Set the refrigerant address using the DIP switch of the outdoor unit.
1 Wiring from the Remote Control
This wire is connected to TB5 (terminal board for remote controller) of the indoor
unit (non-polar).
2 When a Different Refrigerant System Grouping is Used.
Up to 16 refrigerant systems can be controlled as one group using the slim MA remote controller.
Function
Operation according to switch setting
ON
OFF
1 Compulsory
Start
Normal
defrosting
2 Error history
Clear
Normal
SW1
clear
function
3 Refrigerant Settings for outdoor unit addresses
settings
4 system ad- 0 to 15
5 dress setting
6
Fig. 2-6
Fig. 2-7
Fig. 2-8
Fig. 2-9
Fig. 2-10
Fig. 2-11
Fig. 2-12
Fig. 2-13
Fig. 2-14
Fig. 2-15
Fig. 2-16
Fig. 2-17
Fig. 2-18
11
This product is designed and intended for use in the residential,
commercial and light-industrial environment.
Please be sure to put the contact address/telephone number on
this manual before handing it to the customer.
HEAD OFFICE: TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN
BH79D068K03
Printed in Japan