SPW CR365-CR485 GXH56 GXH8 (MINI ECO 2 PIPE VRF) INSTALLATION

SPW CR365-CR485 GXH56 GXH8 (MINI ECO 2 PIPE VRF) INSTALLATION
05-194
5/27/05
5:06 PM
Page a
INSTALLATION INSTRUCTIONS
– Mini ECO-i System Air Conditioner –
for Refrigerant R410A
■ R410A Models
Indoor Units
Indoor Unit Type
AS
S
X
T
SPW-
12
16
18
25
36
SPW-
SPW-
Semi-Concealed Slim
LDR94GXH56(A/B) LDR124GXH56(A/B)
SPW-
SPW-
SPW-
LDR184GXH56(A/B) LDR254GXH56(A/B)
2-Way Air Discharge SPW-
SPW-
SPW-
SPW-
SPW-
Semi-Concealed
SR94GXH56(A/B)
SR124GXH56(A/B)
SR164GXH56(A/B)
SR184GXH56(A/B)
SR254GXH56(A/B)
SPW-
SPW-
SPW-
SPW-
SPW-
SR74GXH56(A/B)
4-Way Air Discharge SPW-
Wall-Mounted
48
ASR74GXH56(A/B) ASR94GXH56(A/B) ASR124GXH56(A/B)
1-Way Air Discharge
Semi-Concealed*
K
9
1-Way Air Discharge SPWSemi-Concealed
LD
7
SPW-
SPW-
SPW-
XDR74GXH56(A/B) XDR94GXH56(A/B) XDR124GXH56(A/B) XDR164GXH56(A/B) XDR184GXH56(A/B) XDR254GXH56(A/B) XDR364GXH56(A/B) XDR484GXH56(A/B)
SPW-
SPW-
SPW-
SPW-
SPW-
SPW-
KR74GXH56(A/B)
KR94GXH56(A/B)
KR124GXH56(A/B)
KR164GXH56(A/B)
KR184GXH56(A/B)
KR254GXH56(A/B)
SPW-
SPW-
SPW-
SPW-
Ceiling-Mounted
SPW-
SPW-
TDR124GXH56(A/B) TDR164GXH56(A/B) TDR184GXH56(A/B) TDR254GXH56(A/B) TDR364GXH56(A/B) TDR484GXH56(A/B)
U
D
F
FM
Concealed-Duct
SPW-
SPW-
UR254GXH56(A/B)
UR364GXH56(A/B) UR484GXH56(A/B)
Concealed-Duct
SPW-
SPW-
High Static Pressure*
DR254GXH56(A/B)
DR364GXH56(A/B) DR484GXH56(A/B)
Floor-Standing
SPW-
SPW-
SPW-
SPW-
UR74GXH56(A/B)
UR94GXH56(A/B)
UR124GXH56(A/B)
UR164GXH56(A/B) UR184GXH56(A/B)
SPW-
SPW-
SPW-
SPW-
SPW-
SPW-
FR74GXH56(A/B)
FR94GXH56(A/B)
FR124GXH56(A/B)
FR164GXH56(A/B)
FR184GXH56(A/B)
FR254GXH56(A/B)
Concealed-Floor-
SPW-
SPW-
SPW-
SPW-
SPW-
SPW-
Standing
FMR74GXH56(A/B) FMR94GXH56(A/B) FMR124GXH56(A/B) FMR164GXH56(A/B) FMR184GXH56(A/B) FMR254GXH56(A/B)
SPW-
SPW-
SPW-
* SPW-XDR604GXH56(A/B) is also available.
* SPW-DR764GXH56(A/B) and DR964GXH56(A/B) are also available.
Outdoor Units
C
Heat Pump Unit
SPW-CR365GXH56, SPW-CR485GXH56, SPW-CR605GXH56
Cooling Unit
SPW-CR365GX56, SPW-CR485GX56, SPW-CR605GX56
* Refrigerant R410A is used in the outdoor units.
Optional Controllers
Remote Controller
RCS-SH80AG
Wireless Remote Controller (For X type)
RCS-SH80AG.WL
Wireless Remote Controller (For S, LD type)
RCS-TH80AG.WL
Wireless Remote Controller (For T type)
RCS-TRP80ANG.WL
RC Wireless Remote Controller (For AS, U, D, F, FM type)
RCS-BH80AG.WL
Wireless Remote Controller (For K type)
RCS-SH1AG
Simplified Remote Controller
RCS-KR1AG
Remote Sensor
ART-K45AG
System Controller
SHA-KC64AG
Schedule Timer
SHA-TM64AG
C
RC
WT
85464359780000 ©SANYO 2005
SANYO Electric Co., Ltd.
Gunma, Japan
W
05-194
5/27/05
5:06 PM
Page 2
IMPORTANT!
Please Read Before Starting
When Installing…
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.
…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.
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.
● This product is intended for professional use.
Permission from the power supplier is required when
installing an outdoor unit that is connected to a 16 A
distribution network.
● 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
WARNING
in severe personal injury or death.
…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.
CAUTION
…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
• Ventilate the room well, in the event that is refrigerant
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.
This symbol refers to a hazard or
unsafe practice which can result
in personal injury or product or
property damage.
• Keep all tubing runs as short as possible.
If Necessary, Get Help
• Use the flare method for connecting tubing.
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.
• Apply refrigerant lubricant to the matching surfaces of
the flare and union tubes before connecting them, then
tighten the nut with a torque wrench for a leak-free connection.
In Case of Improper Installation
• Check carefully for leaks before starting the test run.
The manufacturer shall in no way be responsible for
improper installation or maintenance service, including failure to follow the instructions in this document.
When Servicing
• Turn the power OFF at the main power box (mains)
before opening the unit to check or repair electrical parts
and wiring.
SPECIAL PRECAUTIONS
WARNING
• Keep your fingers and clothing away from any moving
parts.
When Wiring
• Clean up the site after you finish, remembering to check
that no metal scraps or bits of wiring have been left
inside the unit being serviced.
ELECTRICAL SHOCK CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH.
ONLY A QUALIFIED, EXPERIENCED
ELECTRICIAN SHOULD ATTEMPT TO
WIRE THIS SYSTEM.
CAUTION
• Do not supply power to the unit until all wiring and tubing
are completed or reconnected and checked.
• Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and inadequate grounding can cause accidental injury or death.
Ventilate any enclosed areas when installing or testing
the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously toxic
gas.
• Ground the unit following local electrical codes.
• Confirm after installation that no refrigerant gas is leaking. If the gas comes in contact with a burning stove, gas
water heater, electric room heater or other heat source,
it can cause the generation of poisonous gas.
• Connect all wiring tightly. Loose wiring may cause overheating at connection points and a possible fire hazard.
When Transporting
Be careful when picking up and moving the indoor and outdoor
units. Get a partner to help, and bend your knees when lifting
to reduce strain on your back. Sharp edges or thin aluminum
fins on the air conditioner can cut your fingers.
2
5/27/05
5:06 PM
Page 3
2. The standards for minimum room volume are as
follows.
Check of Density Limit
The room in which the air conditioner is to be
installed requires a design that in the event of
refrigerant gas leaking out, its density will not
exceed a set limit.
The refrigerant (R410A), which is used in the air conditioner, is safe, without the toxicity or combustibility of
ammonia, and is not restricted by laws imposed to protect the ozone layer. However, since it contains more
than air, it poses the risk of suffocation if its density
should rise excessively. Suffocation from leakage of
refrigerant is almost non-existent. With the recent
increase in the number of high density buildings, however, the installation of multi air conditioner systems is
on the increase because of the need for effective use
of floor space, individual control, energy conservation
by curtailing heat and carrying power, etc.
Most importantly, the multi air conditioner system is
able to replenish a large amount of refrigerant compared to conventional individual air conditioners. If a
single unit of the multi air conditioner system is to be
installed in a small room, select a suitable model and
installation procedure so that if the refrigerant accidentally leaks out, its density does not reach the limit
(and in the event of an emergency, measures can be
made before injury can occur).
In a room where the density may exceed the limit,
create an opening with adjacent rooms, or install
mechanical ventilation combined with a gas leak
detection device. The density is as given below.
(1) No partition (shaded portion)
(2) When there is an effective opening with the adjacent room for ventilation of leaking refrigerant gas
(opening without a door, or an opening 0.15% or
larger than the respective floor spaces at the top
or bottom of the door).
Outdoor unit
Refrigerant tubing
Indoor unit
(3) If an indoor unit is installed in each partitioned
room and the refrigerant tubing is interconnected,
the smallest room of course becomes the object.
But when mechanical ventilation is installed interlocked with a gas leakage detector in the smallest
room where the density limit is exceeded, the volume of the next smallest room becomes the object.
Refrigerant tubing
Total amount of refrigerant (kg)
Outdoor unit
Min. volume of the indoor unit installed room (m3)
≤ Density limit (kg/m3)
Very
small
room
The density limit of refrigerant which is used in multi air conditioners is 0.3 kg/m3 (ISO 5149).
Indoor unit
Small
room
NOTE
Medium
room
Large room
Mechanical ventilation device – Gas leak detector
1. If there are 2 or more refrigerating systems in a single refrigerating device, the amount of refrigerant
should be as charged in each independent device.
3. The minimum indoor floor space compared with the
amount of refrigerant is roughly as follows (when
the ceiling is 2.7 m high):
For the amount of charge in this example:
Outdoor unit
e.g., charged
amount (10 kg)
40
e.g., charged
amount (15 kg)
m2 35
30
Indoor unit
Min. indoor floor space
05-194
Room A Room B Room C Room D Room E Room F
The possible amount of leaked refrigerant gas in rooms
A, B and C is 10 kg.
The possible amount of leaked refrigerant gas in rooms
D, E and F is 15 kg.
25
20
15
10
5
0
3
Range below the
density limit
of 0.3 kg/m3
(countermeasures
not needed)
Range above
the density limit
of 0.3 kg/m3
(countermeasures
needed)
10
20
30
Total amount of refrigerant
kg
05-194
5/27/05
5:06 PM
Page 4
Precautions for Installation Using New Refrigerant
1. Care regarding tubing
1-1. Process tubing
●
Material: Use C1220 phosphorous deoxidized copper specified in JIS H3300 “Copper and Copper Alloy Seamless Pipes and Tubes.”
●
Tubing size: Be sure to use the sizes indicated in the table below.
●
Use a tube cutter when cutting the tubing, and be sure to remove any flash. This also applies to distribution
joints (optional).
●
When bending tubing, use a bending radius that is 4 times the outer diameter of the tubing or larger.
CAUTION
Use sufficient care in handling the tubing. Seal the tubing ends with
caps or tape to prevent dirt, moisture, or other foreign substances
from entering. These substances can result in system malfunction.
Unit: mm
Material
Copper tube
O
Outer diameter
6.35
9.52
12.7
15.88
19.05
Wall thickness
0.8
0.8
0.8
1.0
1.0
1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A
refrigerant deterioration and compressor defects. Due to the features of the refrigerant and refrigerating
machine oil, the prevention of water and other impurities becomes more important than ever.
2. Be sure to recharge the refrigerant only in liquid form.
2-1. Since R410A is a non-azeotrope, recharging the refrigerant in gas form can lower performance and cause
defects of the unit.
2-2. Since refrigerant composition changes and performance decreases when gas leaks, collect the remaining
refrigerant and recharge the required total amount of new refrigerant after fixing the leak.
3. Different tools required
3-1. Tool specifications have been changed due to the characteristics of R410A.
Some tools for R22- and R407C-type refrigerant systems cannot be used.
Item
R407C tools
New compatible
tool? with R410A?
Manifold gauge
Remarks
Manifold gauge
Yes
No
Types of refrigerant, refrigerating machine oil, and
pressure gauge are different.
Charge hose
Yes
No
To resist higher pressure, material must be changed.
Vacuum pump
Yes
Yes
Use a conventional vacuum pump if it is equipped
with a check valve. If it has no check valve,
purchase and attach a vacuum pump adapter.
Leak detector
Yes
No
Leak detectors for CFC and HCFC that
react to chlorine do not function because
R410A contains no chlorine. Leak detector
for HFC134a can be used for R410A.
Flaring oil
Yes
No
For systems that use R22, apply mineral oil (Suniso oil)
to the flare nuts on the tubing to prevent refrigerant
leakage. For machines that use R407C or R410A, apply
synthetic oil (ether oil) to the flare nuts.
* Using tools for R22 and R407C and new tools for R410A together can cause defects.
4
Vacuum pump
Outlet
Inlet
05-194
5/27/05
5:06 PM
Page 5
3-2. Use R410A exclusive cylinder only.
Valve
Single-outlet valve
(with siphon tube)
Liquid refrigerant should be recharged
with the cylinder standing on end as
shown.
Liquid
5
05-194
5/27/05
5:06 PM
Page 6
CONTENTS
Page
Page
6. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . .34
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please Read Before Starting
Check of Density Limit
Precautions for Installation Using New Refrigerant
■ Air Purging with a Vacuum Pump (for Test Run)
Preparation
7. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7-1. Preparing for Test Run
7-2. Test Run Procedure
7-3. Main Outdoor Unit PCB Setting
7-4. Auto Address Setting
7-5. Caution for Pump Down
7-6. Meaning of Alarm Messages
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Type of Copper Tube and Insulation Material
1-4. Additional Materials Required for Installation
1-5. Tubing Size
1-6. Straight Equivalent Length of Joints
1-7. Additional Refrigerant Charge
1-8. System Limitations
1-9. Tubing Length
1-10. Check of Limit Density
1-11. Installing Distribution Joint
1-12. Optional Distribution Joint Kit
1-13. Optional Ball Valve Kit
1-14. Recommended Location of Ball Valves
1-15. Example of Tubing Size Selection and
Refrigerant Charge Amount
2. SELECTING THE INSTALLATION SITE . . . . .17
2-1. Indoor Unit
2-2. Outdoor Unit
2-3. Air-Discharge Chamber for Top Discharge
2-4. Installing the Unit in Heavy Snow Areas
2-5. Precautions for Installation in Heavy Snow
Areas
2-6. Dimensions of Air-Discharge Chamber
2-7. Dimensions of Outdoor Unit with
Air-Discharge Chamber (field supply)
2-8. Dimensions of Snow Ducting
2-9. Dimensions of Outdoor Unit with Snow-Proof
Vents (field supply)
3. HOW TO INSTALL THE OUTDOOR UNIT . . .25
3-1. Installing the Outdoor Unit
3-2. Drainage Work
3-3. Routing the Tubing and Wiring
4. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . .26
4-1. General Precautions on Wiring
4-2. Recommended Wire Length and Wire
Diameter for Power Supply System
4-3. Wiring System Diagrams
5. HOW TO PROCESS TUBING . . . . . . . . . . . . .30
5-1. Connecting the Refrigerant Tubing
5-2. Connecting Tubing Between Indoor and
Outdoor Units
5-3. Insulating the Refrigerant Tubing
5-4. Taping the Tubes
5-5. Finishing the Installation
6
05-194
5/27/05
5:06 PM
Page 7
1. GENERAL
This booklet briefly outlines where and how to install
the air conditioning system. Please read over the
entire set of instructions for the outdoor unit and make
sure all accessory parts listed are with the system
before beginning.
1-4. Additional Materials Required for Installation
1-1.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
4. Refrigeration tubing lubricant
1. Refrigeration (armored) tape
2. Insulated staples or clamps for connecting wire
(See your local codes.)
3. Putty
Tools Required for Installation (not supplied)
Standard screwdriver
Phillips head screwdriver
Knife or wire stripper
Tape measure
Carpenter’s level
Sabre saw or key hole saw
Hacksaw
Core bits
Hammer
Drill
Tube cutter
Tube flaring tool
Torque wrench
Adjustable wrench
Reamer (for deburring)
5. Clamps or saddles to secure refrigerant tubing
6. Scale for weighing
1-2. Accessories Supplied with Outdoor Unit
See Table 1-1.
1-3. 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.
2. Foamed polyethylene insulation for copper tubes as
required to precise length of tubing. Wall thickness
of the insulation should be not less than 8 mm.
3. Use insulated copper wire for field wiring. Wire
size varies with the total length of wiring. Refer to
5. ELECTRICAL WIRING for details.
CAUTION
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions
or limitations.
7
05-194
5/27/05
5:06 PM
Page 8
Table 1-1 (Outdoor Unit)
Q ty
Part name
Figure
365 Model 485 Model 605 Model
(4 hp)
(5 hp)
(6 hp)
0
0
1
1
1
1
Tube Discharge
Assy
paper
Instruction manual
hp = horsepower
1-5. Tubing Size
Table 1-2 Main Tubing Size (LA)
kW
System
horsepower
11.2
14.0
15.5
4
5
6
Gas tubing
(mm)
ø15.88
Liquid tubing
(mm)
ø19.05
ø9.52
Unit: mm
Table 1-3 Main Tubing Size After Distribution (LB, LC...)
Below kW
Total capacity
after distribution
Tubing size
7.1
11.2
14.0
15.5
(2.5 hp)
(4 hp)
(5 hp)
(6 hp)
7.1
–
Over kW
Gas tubing (mm)
ø12.7
Liquid tubing (mm)
ø9.52
(2.5 hp)
ø15.88
ø19.05
ø9.52
Unit: mm
hp = horsepower
Note: In case the total capacity of connected indoor units exceeds the total capacity of the outdoor units, select the main
tubing size for the total capacity of the outdoor units.
Table 1-4 Indoor Unit Tubing Connection (
Indoor unit type
Gas tubing (mm)
Liquid tubing (mm)
7
9
12
ø12.7
ø6.35
16
1,
2...
n–1)
25
18
8
36
48
ø15.88
ø9.52
60
Unit: mm
05-194
5/27/05
5:06 PM
Page 9
1-6. Straight Equivalent Length of Joints
Design the tubing system by referring to the following table for the straight equivalent length of joints.
Table 1-5 Straight Equivalent Length of Joints
Gas tubing size (mm)
12.7
15.88
19.05
90° elbow
0.30
0.35
0.42
45° elbow
0.23
0.26
0.32
U-shape tube bend (R60 100 mm)
0.90
1.05
1.26
Trap bend
2.30
2.80
3.20
Y-branch distribution joint
Equivalent length conversion not needed.
Ball valve for service
Equivalent length conversion not needed.
Table 1-6 Required Copper Tubing Dimensions
Material
Copper tubing
Unit: mm
O
Outer diameter
6.35
9.52
12.7
15.88
19.05
Wall thickness
0.8
0.8
0.8
1.0
1.0
1-7. Additional Refrigerant Charge
Additional refrigerant charge amount is calculated from the liquid tubing total length as follows.
Table 1-7 Amount of Refrigerant Charge Per Meter, According to Liquid Tubing Size
Narrow tubing size
Amount of refrigerant
charge/m (g/m)
φ 6.35
26
Required amount of charge = (Amount of refrigerant
charge per meter of each size of liquid tube × its tube
length) + (...) + (...)
φ 9.52
56
*Always charge accurately using a scale for weighing.
Table 1-8 Refrigerant Charge Amount at Shipment (for outdoor unit)
Heat pump unit
SPW-CR365GXH56
(kg)
3.5
Cooling only unit
(kg)
SPW-CR365GX56
SPW-CR485GXH56
SPW-CR605GXH56
3.5
3.5
SPW-CR485GX56
3.5
SPW-CR605GX56
3.5
3.5
1-8. System Limitations
Table 1-9 System Limitations
Outdoor units (Type)
Number of max. connectable indoor units
Max. allowable indoor/outdoor capacity ratio
365
485
605
6
8
9
50
9
130%
05-194
5/27/05
5:06 PM
Page 10
1-9. Tubing Length
Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown
in the figure below.
L1
L2
LA
LB
Main tube of unit
LD
LC
n
H1
1st branch
L3
2
1
3
H2
n-1
Unit distribution tube
Note: Do not use commercially available T-joints for the liquid tubing.
* Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor
unit connections and tubing branches.
R410A distribution joint
APR-RP160AG (for indoor unit)
Table 1-10 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights
Items
Marks
Contents
L1
Max. tubing length
L (L2 – L3)
Allowable tubing
length
1
1
Allowable elevation
difference
, 2~
+ 2 +~
H1
H2
n
n–1
+L1
Actual length
Equivalent length
Length (m)
> 150
> 175
Difference between max. length and min.
length from the No.1 distribution joint
> 40
Max. length of each distribution tube
> 30
Total max. tubing length including length of
each distribution tube (only narrow tubing)
> 200
When outdoor unit is installed higher than indoor unit
> 50
When outdoor unit is installed lower than indoor unit
> 40
> 15
Max. difference between indoor units
L = Length, H = Height
10
Page 11
Always check the gas density limit for the room in
which the unit is installed.
Minimum indoor volume & floor area as against the
amount of refrigerant is roughly as given in the following table.
1-10. Check of Limit Density
When installing an air conditioner in a room, it is necessary to ensure that even if the refrigerant gas accidentally leaks out, its density does not exceed the limit
level for that room.
If the density could exceed the limit level, it is necessary to provide an opening between the unit and the
adjacent room, or to install mechanical ventilation
which is interlocked with the leak detector.
(Min. indoor volume where the indoor unit is installed: m3)
≤ Limit density 0.3 (kg/m3)
The limit density of refrigerant which is used in this unit
is 0.3 kg/m3 (ISO 5149).
The shipped outdoor unit comes charged with the
amount of refrigerant fixed for each type, so add it to
the amount that is charged in the field. (For the refrigerant charge amount at shipment, refer to the unit’s
nameplate.)
CAUTION
Pay special attention to any
location, such as a basement,
etc., where leaking refrigerant
can accumulate, since refrigerant gas is heavier than air.
m3
270.0
256.5
243.0
229.5
216.0
202.5
189.0
175.5
162.0
148.5
135.0
121.5
108.0
94.5
81.0
67.5
54.0
40.5
Range below the
density limit of
0.3 kg/m3
(Countermeasures
not needed)
Range above the
density limit of
0.3 kg/m3
(Countermeasures
needed)
20
30
40
50
60
70
Total amount of refrigerant
80 kg
Tube branching methods (horizontal use)
30
°
(Total refrigerant charged amount: kg)
m2
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
to
WARNING
15
5:06 PM
Min. indoor volume
5/27/05
Min. indoor floor area
(when the ceiling is 2.7 m high)
05-194
1-11. Installing Distribution Joint
B
(1) Refer to “HOW TO ATTACH DISTRIBUTION
JOINT” enclosed with the optional distribution joint
kit (APR-RP160AG).
Horizontal A
line
View as seen
from arrow
A
B
Arrow view
(2) In order to prevent accumulation of refrigerant oil in
stopped units, if the main tubing is horizontal then
each branch tubing length should be at an angle that
is greater than horizontal. If the main tubing is vertical, provide a raised starting portion for each branch.
Types of vertical trap specifications
(When using ball valve)
Main tubing
(3) If there are height differences between indoor units
or if branch tubing that follows a distribution joint is
connected to only 1 unit, a trap or ball valve must be
added to that distribution joint. (When adding the ball
valve, locate it within 40 cm of the distribution joint.)
(Consult with SANYO separately concerning the
ball valve.)
If a trap or ball valve is not added, do not operate
the system before repairs to a malfunctioning
unit are completed. (The refrigerant oil sent
through the tubing to the malfunctioning unit will
accumulate and may damage the compressor.)
Ball valve
(BV: purchased
separately)
Indoor unit (more than 2 units)
(If only 1 unit is connected, a ball
valve is also needed on this side.)
Indoor unit (1)
(When not using ball valve)
Main tubing
Horizontal
Indoor unit (Each unit is
connected to tubing
Branch tubing is
that is either level or
directed upward.
is directed
More than
downward.)
20 cm
Indoor unit is directed downward
11
5/27/05
5:06 PM
Page 12
1-12. Optional Distribution Joint Kit
See the installation instructions packaged with the distribution joint kit for the installation procedure.
Table 1-11
Model name
Cooling capacity after distribution
Remarks
APR-RP160AG
22.4 kW or less
For indoor unit
APR-RP160AG
Use: For indoor unit (Capacity after distribution joint is 22.4 kW or less.)
Example: (F below indicates inner diameter. F below indicates outer diameter.)
F
F F
H
F GH
HG
103
• When creating a tube of diameter G,
use a tube cutter and cut between F
and H. Cut at a point as close to H
as possible.
Liquid tube
50
185
H
IJ
JI
F
F
145
H
G
H
135
83
Gas tube
210
55
I
J
Insulator
Insulator
Table 1-12 Dimension for Connections of Each Part
Unit: mm
Position
A
B
C
D
E
F
G
H
I
J
Dimension
–
–
–
–
–
φ19.05
φ15.88
φ12.7
φ9.52
φ6.35
1-13. Optional Ball Valve Kit
Table 1-13
Valve connecting tube size (mm)
Model No.
Gas tube
Indoor unit where used
Total capacity of indoor units
after the valve
Liquid tube
BV-RXP160AG
15.88
9.52
16.0 kW or less
BV-RXP56AG
12.7
6.35
5.6 kW or less
NOTE
1. Because the diameter of this ball valve is approximately the same as the inner diameter of the connecting copper tube, correction for pressure loss is not necessary.
2. Airtightness must be 3.6 MPa or more.
It is recommended that the ball valve is installed at each outdoor unit (gas tube and liquid tube), in order to
prevent refrigerant from being released into the atmosphere if the outdoor unit is eventually replaced.
Dimensions
Unit: mm
Figure
Type with flare nut at each end
Size
A
Insulator
(divided in 2)
D
Service port
Dimensions
ø6.35 (1/4")
ø9.52 (3/8")
ø12.7 (1/2")
ø15.88 (5/8")
E
C
05-194
30˚
Note: Install the service port so that it faces the extension side.
12
A
72
76
89
108
B
42
42
42
51
C
54
54
58
68
D
16
16
20
22
E
44
44
51
56
05-194
5/27/05
5:06 PM
Page 13
Ball Valve Installation (for refrigerant R410A only)
Check the size of the ball valve set you separately purchased.
Model name
Size
BV-RXP56AG
φ6.35 • φ12.7
BV-RXP160AG
φ9.52 • φ15.88
1. Installing the ball valve
(1) If the ball valve is to be installed for indoor unit
extension, or near an indoor unit, install it so that
the service port faces the indoor unit side.
(This facilitates indoor unit leak testing and vacuum procedures.)
Install the ball valve as close as possible to the
distribution joint.
Outdoor unit
Indoor
Outdoor
Ball valve
CAUTION
This ball valve is for use
only in systems that utilize
refrigerant R410A. The service port connection size is
φ7.94. The face-to-face distance between the φ12.7 or
φ15.88 flare nuts is 26 mm
or 29 mm, respectively.
Be sure to use only the
supplied flare nuts. Be
careful to use the correct
tools and materials.
Service
port
Indoor unit
Indoor unit extension
2. Flare nut tightening
The flare nut on the service port side is fully tightened. Recommended tightening torque is
(8~10 N·m).
Valve cap
Tightening torque (19~21 N•m)
Fully tightened (this side only)
If the valve is used for extension, it can be used
as-is. In all other cases, use 2 monkey wrenches
in combination to loosen the flare nut.
Service port
Plug
Tightening torque
(8~10 N•m)
(this side only)
Service port
Cool with damp shopcloth or other
means when heating brazed plug
with torch.
13
05-194
5/27/05
5:06 PM
Page 14
3. Opening and closing the valve
This valve is open at the time of shipment from the
factory. If the valve is used for extension, be sure
to close it.
Valve opened
Valve closed
Spindle
Spindle
4. Installing thermal insulation
The thermal insulation used for a flare-nut type
valve is in the form of a bag. When the valve is
used for extension, it can be used as-is. If the
valve is used for any other purpose, use a box
cutter or similar tool to cut away the part shown in
the figure at right.
The insulation is divided into 2 parts. After performing the leak test, use vinyl tape or other
means to temporarily fasten the 2 parts together.
Then carry out final finishing.
Notch
Insulator
1-14. Recommended Location of Ball Valves
●
Select a valve location that allows service to be easily provided for each unit or each refrigerant system.
(1) When adding ball valve for indoor unit
Outdoor unit
Distribution joint
Distribution tube
Main tube
Main tube
Distribution tube
Ball valve (for extension)
Ball valve (for extension)
Less than 40 cm
Indoor unit for extension
Indoor unit for extension
1. Location: Install the ball valve at the distribution tube (not main tube).
2. Installation requirements
• Be sure to install the ball valve up-grade to prevent the inadvertent flow of oil.
• Install the ball valve at the shortest distance (within 40 cm) from the main tube. If the diameter of the ball valve
is smaller than that of the main tube, use a reducer or the like to reduce the size of the tubing at that location.
• Select a place where it is easy to operate, using careful consideration of the location in advance.
14
05-194
5/27/05
5:06 PM
Page 15
1-15. Example of Tubing Size Selection and Refrigerant Charge Amount
Additional refrigerant charging
Based on the values in Tables 1-2, 1-3, 1-4 and 1-7, use the liquid tubing size and length, and calculate the
amount of additional refrigerant charge using the formula below.
Required additional
–3
refrigerant charge (kg) = [56 × (a) + 26 × (b)] × 10
(a): Liquid tubing
●
Total length of φ9.52 (m)
(b): Liquid tubing
Total length of φ6.35 (m)
Charging procedure
Be sure to charge with R410A refrigerant in liquid form.
1. After performing a vacuum, charge with refrigerant from the liquid tubing side. At this time, all valves must be
in the “fully closed” position.
2. If it was not possible to charge the designated amount, operate the system in Cooling mode while charging
with refrigerant from the gas tubing side. (This is performed at the time of the test run. For this, all valves
must be in the “fully open” position.)
Charge with R410A refrigerant in liquid form.
With R410A refrigerant, charge while adjusting the amount being fed a little at a time in order to prevent
liquid refrigerant from backing up.
●
After charging is completed, turn all valves to the “fully open” position.
●
Replace the tubing covers as they were before.
1 Tightening torque: 68~82 N·m
Tightening torque for valve stem cap: 19~21 N·m 4
Tightening torque: 34~42 N·m 3
2 Tightening torque for valve stem cap: 28~32 N·m
1. R410A additional charging absolutely must be done through liquid charging.
CAUTION
2. The R410A refrigerant cylinder has a gray base color, and the top part is pink.
3. The R410A refrigerant cylinder includes a siphon tube. Check that the siphon
tube is present. (This is indicated on the label at the top of the cylinder.)
4. Due to differences in the refrigerant, pressure, and refrigerant oil involved in
installation, it is not possible in some cases to use the same tools for R22 and
for R410A.
15
5/27/05
5:06 PM
Page 16
Example:
L1
L2
LA
LB
Main tube of unit
LN
LC
n
1st branch
Unit distribution tube
1
model 74
2
3
model 94
model 184
n–1
model 124 model 164
●
Example of each tubing length
Main tubing
Distribution joint tubing
LA = 40 m
Indoor side
LB = 5 m
1=5m
4=6m
LC = 5 m
2=5m
5=5m
LD = 15 m
3=2m
●
Obtain charge amount for each tubing size
Note that the charge amounts per 1 meter are different for each liquid tubing size.
φ9.52 → LA + LB + LC + LD
: 65 m × 0.056 kg/m = 3.64 kg
φ6.35 →
1 + 2 + 3 + 4 + 5 : 23 m × 0.026 kg/m = 0.598 kg
Total
4.238 kg
Additional refrigerant charge amount is 4.238 kg.
CAUTION
Be sure to check the limit density for the room in which the
indoor unit is installed.
Checking of limit density
m3
108.0
94.5
40
m2
81.0
67.5
54.0
40.5
27.0
13.5
<Determination by calculation>
0
Overall refrigerant charge amount for the air conditioner: kg
(Minimum room volume for indoor unit: m3)
= 4.238 (kg) + 3.5 (kg) = 0.39 (kg/m3) ≥ 0.3 (kg/m3)
20.06 (m3)
Therefore, openings such as louvers are required for
this room.
16
(when the ceiling is 2.7 m high)
Density limit is determined on the basis of the size of a
room using an indoor unit of minimum capacity. For
instance, when an indoor unit is used in a room (floor
area 7.43 m2 × ceiling height 2.7 m = room volume
20.06 m3), the graph at right shows that the minimum
room volume should be 14.1 m3 (floor area 5.2 m2) for
refrigerant of 4.238 kg. Accordingly, openings such as
louvers are required for this room.
Min. indoor floor area
05-194
35
30
25
20
15
10
5
0
Range below the
density limit
of 0.3 kg/m3
(countermeasures
not needed)
Range above
the density limit
of 0.3 kg/m3
(countermeasures
needed)
10
20
30
Total amount of refrigerant
kg
5/27/05
5:06 PM
Page 17
Ceiling-Mounted Type
2. SELECTING THE INSTALLATION SITE
Ceiling
2-1. Indoor Unit
Wall
AVOID:
●
areas where leakage of flammable gas may be
expected.
●
places where large amounts of oil mist exist.
●
direct sunlight.
●
locations near heat sources which may affect the
performance of the unit.
min. 25 cm
Front view
min. 25 cm
NOTE
●
Air
discharge
locations where external air may enter the room
directly. This may cause “sweating” on the air discharge ports, causing them to spray or drip.
●
locations where the remote controller will be splashed
with water or affected by dampness or humidity.
●
installing the remote controller behind curtains or furniture.
●
The rear of the indoor unit can be installed flush
against the wall.
Air intake
min. 50 cm
Side view
Max. 25 cm
Obstacle
Fig. 2-1
locations where high-frequency emissions are generated.
Concealed-Duct Type
2-Way, 4-Way Semi-Concealed Type
DO:
●
●
select an appropriate position from which every corner of the room can be uniformly cooled.
select a location where the ceiling is strong enough
to support the weight of the unit.
●
select a location where tubing and drain pipe have
the shortest run to the outdoor unit.
●
allow room for operation and maintenance as well as
unrestricted air flow around the unit.
●
install the unit within the maximum elevation difference above or below the outdoor unit and within a
total tubing length (L) from the outdoor unit as
detailed in Table 1-10.
●
1m
1m
1m
1m
1m
Fig. 2-2
1-Way Semi-Concealed & Slim Type
Semi-Concealed Type
allow room for mounting the remote controller about
1m off the floor, in an area that is not in direct sunlight nor in the flow of cool air from the indoor unit.
min. 5 cm
Wall
Air
discharge
Air delivery will be degraded if the distance from the
floor to the ceiling is greater than 3 m (for SL type,
greater than 3.5 m).
20cm
Air
intake
cm
min. 5 cm
Side view
Fig. 2-3
Wall-Mounted Type
min. 100 cm
min.
15 cm
min. 100 cm
Horizontal view
100
Wall
Floor-Standing, Concealed Floor-Standing Type
min.
10 cm
20cm
100cm
Obstacle
NOTE
min.
10 cm
Semi-Concealed Slim Type
Ceiling
min. 1 m
05-194
min.15 cm min.
15 cm
Vertical view
Front View
Fig. 2-4
Fig. 2-5
17
20cm
05-194
5/27/05
5:06 PM
Page 18
2-2. Outdoor Unit
Exhaust fan
AVOID:
●
heat sources, exhaust fans, etc. (Fig. 2-6)
●
damp, humid or uneven locations
Hot air
Heat source
Outdoor
unit
DO:
●
choose a place as cool as possible.
●
choose a place that is well ventilated and outside
air temperature does not exceed maximum 45°C
constantly.
●
allow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 2-7)
●
use lug bolts or equal to bolt down unit, reducing
vibration and noise.
Fig. 2-6
Installation space
Distance between obstructions and the unit air inlet
and outlet must be as shown below.
(Obstruction above unit)
Air direction chamber
*3
(field supply)
Inlet side C
More than 1 cm
B
More than 1 cm
A
*2
*4
Outlet side
More than
100 cm
Inlet side
More than 20 cm
*1
(Obstruction on
inlet side)
*1
Fig. 2-7
(Ground)
Fig. 2-8
●
Concerning inlet-side distance “C” (Fig. 2-7)
The minimum for distance “C” is 15 cm if there are no obstructions on the outlet side
(wall *1 side) and *2 or *4 is not present. In all other cases, the minimum for distance
“C” is 20 cm.
●
If the unit is installed with the outlet side facing wall *1, then there must be no obstructions on 2 of the remaining 3 sides: *2, *3, *4.
●
If wall *1 is on the outlet side (Fig. 2-7), or if obstructions are present on all 3 sides *2,
*3, and *4 (Fig. 2-7), then the minimum distance for “A” and “B” is 2 m (Fig. 2-9). Even
if there is no wall on the outlet side, a minimum of 100 cm is required.
CAUTION
In case of multiple installations
●
●
provide a solid base (concrete block, 10 × 40 cm
beams or equal), a minimum of 15 cm above
ground level to reduce humidity and protect the unit
against possible water damage and decreased service life. (Fig. 2-9)
Anchor bolts
(4 pieces)
use lug bolts or equal to bolt down unit, reducing
vibration and noise.
Fig. 2-9
18
05-194
5/27/05
5:06 PM
Page 19
2-3. Air Discharge Chamber for Top Discharge
Be sure to install an air discharge chamber in the
field when:
●
it is difficult to keep a space of min. 50 cm between
the air discharge outlet and an obstacle.
●
the air discharge outlet is facing a sidewalk and
discharged hot air may annoy passers-by.
Refer to Fig. 2-10.
Air discharge
2-4. Installing the Unit in Heavy Snow Areas
In locations with strong wind, snow-proof ducting
should be fitted and direct exposure to the wind
should be avoided as much as possible.
Fig. 2-10
■ Countermeasures against snow and wind
In regions with snow and strong wind, the following
problems may occur when the outdoor unit is not provided with a platform and snow-proof ducting:
a) The outdoor fan may not run and damage to the
unit may occur.
b) There may be no air flow.
c) The tubing may freeze and burst.
d) The condenser pressure may drop because of
strong wind, and the indoor unit may freeze.
In regions with significant snowfall, the outdoor unit should
be provided with a platform and snow-proof duct.
2-5. Precautions for Installation in Heavy Snow
Areas
(1) The platform should be higher than the max. snow
depth. (Fig. 2-11)
(2) The 2 anchoring feet of the outdoor unit should be
used for the platform, and the platform should be
installed beneath the air intake side of outdoor
unit.
Without snowproof ducting
(Low platform)
(3) The platform foundation must be firm and the unit
must be secured with anchor bolts.
With snowproof ducting
(High platform)
Fig. 2-11
(4) In case of installation on a roof subject to strong
wind, countermeasures must be taken to prevent
the unit from being blown over.
Outdoor
Unit
Duct
Air
Intake
Fig. 2-12
19
5/27/05
5:06 PM
Page 20
1
Unit front, air discharge chamber
2
Unit left side, air discharge chamber
3
Unit light side, air discharge chamber
4
Reinforcement brackets, 4 locations
29.5
300
2-6. Dimensions of Air-Discharge Chamber
Reference diagram for air-discharge chamber (field supply)
STK-DRE140A for SPW-CR365/485/605GX(H)56
2
240
3
4
29.5
240
Rectangular
hole
1090
537
70
310
997
70
250
537
Rectangular
hole
317
250
35
35
1
Rectangular
hole
250
317
Rectangular
hole
569
544
25
Unit: mm
25
13
110
13
340
380
Win
dire d
ctio
n
405
660
Wind direction
20
170
10
2-7. Dimensions of Outdoor Unit with Air-Discharge Chamber (field supply)
SPW-CR365/485/605GX(H)56 with STK-DRE140A
15
300
108
20
300
13
68
Wind direction
544
940
Wind
direction
Wind
direction
Wind
direction
Wind
direction
997
Wind direction
18
1230
05-194
Unit: mm
20
5/27/05
5:06 PM
Page 21
Reference for air-discharge chamber (field supply)
Required space around outdoor unit
SPW-CR365/485/605GX(H)56
with STK-DRE140A
Required space around outdoor
unit
If an air discharge chamber is used, the space shown below must be secured around the outdoor unit.
If the unit is used without the required space, a protective device may activate, preventing the unit from operating.
Min. 200
(1) Single-unit installation
Min. 1000
CAUTION
The top and both sides must remain open.
If there are obstacles to the front and rear of the outdoor unit, Unit: mm
the obstacle at either the front or rear must be no taller than the
height of the outdoor unit.
(2) Multiple-unit installation
● Installation in lateral rows
More than 300
More than 300
More than 400
05-194
More than 200
CAUTION
The front and top must remain open.
Unit: mm
The obstacles must be no taller than the height of the outdoor unit.
● Installation in front-rear rows
Installation with intakes facing
intakes or outlets facing outlets
Installation with intakes facing outlets
More than 400
More than 2000
More than 1500
CAUTION
The front and both sides must remain open.
Unit: mm
21
5/27/05
5:06 PM
Page 22
2-8. Dimensions of Snow Ducting
Reference diagram for snow-proof vents (field supply)
STK-BDR140U for SPW-CR365/485/605GX(H)56
Fastened by screws at 13 locations
764
1
Unit top, snow-proof vent
2
Unit left side
3
Unit right side
4
Unit reverse side
5
Unit reverse side
6
Unit sides, reinforcement brackets for snow-proof vent
4
1
Unit: mm
645
302
500
338
732
732
Fastened by screw at
1 location (also on reverse side)
e
hol
hor
anc hole)
t
i
Un ø 7
–
(7
41
388
1209
500
500
Fastened by screws at
3 locations (also on reverse side)
16
46
730
778
2-9. Dimensions of Outdoor Unit with Snow-Proof Vents (field supply)
SPW-CR365/485/605GX(H)56 with STK-BDR140U
20
10
15
380
405
645
20
764
179
Wind direction Wind direction
Wind direction
Wind direction
Unit: mm
940
632
1209
732
302
Wind direction
1230
2
101
450
233
150
95
233
444
20
3
1209
05-194
Wind direction
22
5/27/05
5:06 PM
Page 23
Reference diagram for snow-proof vents – 1
Space requirements for setting – (1)
SPW-CR365/485/605GX(H)56 with STK-BDR140U
[Obstacle to the rear of unit]
[Obstacle to the front of unit]
●• Top is open:
●• Top is open:
(1) Single-unit installation
Min. D
Min. A
Min. H
(1) Single-unit installation (2) Obstacles on both sides
Min. B
(2) Multiple-unit installation (2 or more units)
Min. C
Min. I
Min. G
Min. I
Min. J
(3) Multiple-unit installation (2 or more units)
Min. E
Min. E
Min. E
Outdoor unit
H
SPW-CR365 / 485 / 605GX(H)56
500
I
J
300 1000
Min. F
A
B
C
D
E
F
G
150
300
200
300
150
200
• Top is blocked by an obstacle:
●
Note: In cases 2 and 3 the height of the obstacle
must be no taller than the height of the outdoor
unit.
• Top is blocked by an obstacle:
●
Min. M
Min. N
Outdoor unit
SPW-CR365 / 485 / 605GX(H)56 150
Min. L
Min. K
05-194
Outdoor unit
Outdoor unit
K
L
SPW-CR365 / 485 / 605GX(H)56
500
150
SPW-CR365 / 485 / 605GX(H)56
M
N
1000 1000
Unit: mm
23
5/27/05
5:06 PM
Page 24
Reference diagram for snow-proof vents – 2
Space requirements for setting – (2)
SPW-CR365/485/605GX(H)56 with STK-BDR140U
[Obstacles to the front and rear of unit]
●• The top and both sides must remain open. Either the obstacle to the front or
the obstacle to the rear must be no taller than the height of the outdoor unit.
Q
Min. P
(1) Single-unit installation
Min. O
Dimension Q
If a snow protection duct is attached after the unit is
installed, verify that dimension Q is 500 mm or more.
Outdoor unit
O
P
SPW-CR365 / 485 / 605GX(H)56 1000 150
Min. 300
Min. 200
Q
(2) Obstacles on both sides
Min. 1000
05-194
Min. 300
[Installation in front-rear rows]
●• The top and both sides must remain open. Either the obstacle to the front or the obstacle
to the rear must be no taller than the height of the outdoor unit.
0
Min. 300
Min. 1000
Min. 1500
Min. 200
Min. 2000
Dimension Q
If a snow protection duct is
attached after the unit is
installed, verify that dimension
Q is 500 mm or more.
Unit: mm
24
5/27/05
5:06 PM
Page 25
3. HOW TO INSTALL THE OUTDOOR UNIT
3-1. Installing the Outdoor Unit
Ordinarily, ensure a base height of 5 cm or more. If a
drain pipe is used, or for use in cold-weather regions,
ensure a height of 15 cm or more at the feet on both
sides of the unit.
(In this case, leave clearance below the unit for the
drain pipe, and to prevent freezing of drainage water
in cold-weather regions.)
●
Refer to the Fig. 3-1 for the anchor bolt dimensions.
●
Be sure to anchor the feet with the anchor bolts
(M10). In addition, use anchoring washers on the top
side. (Use large square 32 × 32 SUS washers with
JIS nominal diameters of 10.) (Field supply)
Drain port (2 locations)
171
660
219 150
13
111
13
20
10
●
13
380
405
Use concrete or a similar material to create the base,
and ensure good drainage.
19
15
●
341
296
05-194
13
3-2. Drainage Work
942
Follow the procedure below to ensure adequate draining for the outdoor unit.
●
For the drain port dimensions, refer to the figure at
right.
●
Ensure a base height of 15 cm or more at the feet on
both sides of the unit.
●
When using a drain pipe, install the drain socket
(optional part STK-DS25T) onto the drain port. Seal
the other drain port with the rubber cap supplied with
the drain socket.
●
For details, refer to the instruction manual of the
drain socket (optional part STK-DS25T).
Anchor bolt (M10)
Drain port
Fig. 3-1
3-3. Routing the Tubing and Wiring
●
The tubing and wiring can be extended out in 4 directions: front, rear, right, and down.
●
The service valves are housed inside the unit. To
access them, remove the inspection panel. (To
remove the inspection panel, remove the 3 screws,
then slide the panel downward and pull it toward you.)
Inter-unit control wiring outlet
Inspection panel
Rear
(1) If the routing direction is through the front, rear, or
right, use a nipper or similar tool to cut out the
knockout holes for the inter-unit control wiring outlet,
power wiring outlet, and tubing outlet from the
appropriate covers A and B.
Cover B
Cover A
Front
Down
(2) If the routing direction is down, use a nipper or similar tool to cut out the lower flange from cover A.
Tubing outlet
Fig. 3-2
●
Route the tubing so that it does
not contact the compressor,
panel, or other parts inside the
unit. Increased noise will result if
the tubing contacts these parts.
●
When routing the tubing, use a
tube bender to bend the tubes.
CAUTION
Right
Power wiring outlet
25
C
05-194
5/27/05
5:06 PM
Page 26
4. ELECTRICAL WIRING
4-1. General Precautions on Wiring
(1) Before wiring, confirm the rated voltage of the unit
as shown on its nameplate, then carry out the
wiring closely following the wiring diagram.
(7) Regulations on wire diameters differ from locality
to locality. For field wiring rules, please refer to
your LOCAL ELECTRICAL CODES before beginning.
(2) Provide a power outlet to be used exclusively for
each unit, and a power supply disconnect and circuit breaker for overcurrent protection should be
provided in the exclusive line.
You must ensure that installation complies with all
relevant rules and regulations.
(8) To prevent malfunction of the air conditioner
caused by electrical noise, care must be taken
when wiring as follows:
(3) To prevent possible hazards from insulation failure, the unit must be grounded.
(4) Each wiring connection must be done 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.
●
The remote control wiring and the inter-unit control
wiring should be wired apart from the inter-unit
power wiring.
●
Use shielded wires for inter-unit control wiring
between units and ground the shield on both sides.
(9) If the power supply cord of this appliance is damaged, it must be replaced by a repair shop
appointed by the manufacturer, because special
purpose tools are required.
(6) Unauthorized changes in the internal wiring can be
very dangerous. The manufacturer will accept no
responsibility for any damage or misoperation that
occurs as a result of such unauthorized changes.
4-2. Recommended Wire Length and Wire Diameter for Power Supply System
Outdoor unit
(A) Power supply
SPW-CR365GX(H)56
SPW-CR485GX(H)56
SPW-CR605GX(H)56
Wire size
4 mm 2
6 mm 2
6 mm 2
Time delay fuse or
Max. length circuit capacity
16 m
25 A
24 m
35 A
20 m
35 A
Indoor unit
Type
(B) Power supply Time delay fuse or
circuit capacity
2.5 mm2
Max. 150 m
10 ~ 16A
AS, SL, S, X, T, U, F, FM
Max. 130 m
10 ~ 16A
D
Max. 60 m
10 ~ 16A
K
Control wiring
(C) Inter-unit (between outdoor and
indoor units) control wiring
(D) Remote control wiring
(E) Control wiring for group control
0.75 mm 2 (AWG #18)
Use shielded wiring*
0.75 mm 2 (AWG #18)
Use shielded wiring
0.75 mm2 (AWG #18)
Use shielded wiring
Max. 1,000 m
Max. 500 m
Max. 500 m (Total)
NOTE
* With ring-type wire terminal.
26
05-194
5/27/05
5:06 PM
Page 27
4-3. Wiring System Diagram
Indoor
unit (No. 1)
L
Power supply
220-240V 50Hz N
1
Outdoor unit
INV unit
2
3
Ground
Remote
controller
WHT 1
BLK 2
B
C
U2
D
Ground
1
1
2
2
A
L1
L2
L3
N
1
2
3
4
5
U1
U2
U1
3
4
Power supply
380-415V-3N
50Hz
Power supply
380-415V-3N
50Hz
Ground
Ground
C
Indoor
unit (No. 2)
L
Power supply
220-240V 50Hz N
Ground
F
Inter-outdoor-unit control wiring
1
2
3
Ground
Remote
controller
WHT 1
BLK 2
B
Outdoor unit
CS unit
U1
U2
D
2
3
4
Ground
C
Indoor
unit (No. 3)
Group control:
L
Power supply
220-240V 50Hz N
A
L1
L2
L3
N
1
2
3
4
5
1
1
2
Ground
1
2
3
Ground
B
E
U1
U2
1
2
Ground
C
Indoor
unit (No. n)
L
Power supply
220-240V 50Hz N
1
2
3
Ground
Remote
controller
WHT 1
BLK 2
B
U1
U2
D
1
1
2
2
Ground
7P terminal board
NOTE
(1) Refer to Section 5-2. “Recommended Wire Length
and Wire Diameter for Power Supply System” for
the explanation of “A,” “B,” “C,” “D,” and “E,” in the
above diagram.
(2) The basic connection diagram of the indoor unit
shows the 7P terminal board, so the terminal
boards in your equipment may differ from the diagram.
U1 U2 R1 R2
Remote
Inter-unit
control wiring controller
1(L) 2(N)
Power
supply
S, X, T Type
(3) Refrigerant Circuit (R.C.) address should be set
before turning the power on.
8P terminal board
(4) Regarding the R.C. address setting, refer to page
40. Auto. address setting can be executed by
remote controller automatically. Refer to page
41~45.
1
2
U1
1(L)2(N)
Power
supply
U2
R1
R2
R1 R2
Remote
controller
U1 U2
Inter-unit
control wiring
AS, LD, U,
D, F, FM Type
27
5P terminal board
1
2
3
4
5
1(L)2(N) 4 5
Power
Inter-unit
supply control wiring
K Type
05-194
5/27/05
5:06 PM
Page 28
CAUTION
(1) When linking outdoor units in a network (S-net link system), disconnect the terminal extended from the
short plug (CN003, 2P Black, location: right bottom on the outdoor main control PCB) from all outdoor
units except any one of the outdoor units.
(When shipping: In shorted condition.)
Otherwise the communication of S-net link system is not performed. For a system without link (no connection wiring between outdoor units), do not remove the short plug.
(2) Do not install the inter-unit control wiring in a way that forms a loop. (Fig. 4-1)
Outdoor unit
Outdoor unit
Outdoor unit
Prohibited
Prohibited
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Fig. 4-1
(3) Do not install inter-unit control wiring such as star
branch wiring. Star branch wiring causes mis-address
setting.
Outdoor unit
NO
Outdoor unit
NO
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Indoor unit
Branch point
Fig. 4-2
(4) If branching the inter-unit control wiring, the number of branch points should be 16 or fewer.
(Branches less than 1 m are not included in the total branch number.) (Fig. 4-3)
Outdoor unit
Indoor unit
Outdoor unit
Indoor unit
Outdoor unit
Indoor unit
Indoor unit
Indoor unit
Indoor unit
more than 1 m
Branch
point
16 or fewer
Indoor unit
Indoor unit
more than 1 m
Indoor unit
less than 1 m
Indoor unit
Fig. 4-3
28
5/27/05
5:06 PM
Page 29
(5) Use shielded wires for inter-unit control wiring
(c) and ground the shield on both sides, otherwise misoperation from noise may occur.
(Fig. 4-4)
Connect wiring as shown in Section “4-3.
Wiring System Diagram.”
WARNING
Shielded wire
Ground
Loose wiring may cause
the terminal to overheat or
result in unit malfunction.
A fire hazard may also
exist. Therefore, ensure
that all wiring is tightly
connected.
Ground
Fig. 4-4
When connecting each power wire to the terminal, follow the instructions on “How to connect wiring to the
terminal” and fasten the wire securely with the fixing
screw of the terminal plate.
How to connect wiring to the terminal
■ For stranded wiring
Stranded wire
(1) Cut the wire end with cutting pliers, then strip the
insulation to expose the stranded wiring about 10
mm and tightly twist the wire ends. (Fig. 4-5)
Strip 10 mm
05-194
(2) Using a Phillips head screwdriver, remove the terminal screw(s) on the terminal plate.
Ring
pressure
terminal
(3) Using a ring connector fastener or pliers, securely
clamp each stripped wire end with a ring pressure
terminal.
Fig. 4-5
(4) Place the ring pressure terminal, and replace and
tighten the removed terminal screw using a screwdriver. (Fig. 4-6)
Special
washer
Screw
Ring pressure
terminal
Wire
Screw and
Special washer
Terminal plate
Ring
pressure
terminal
Wire
Fig. 4-6
29
05-194
5/27/05
5:06 PM
Page 30
5. HOW TO PROCESS TUBING
Deburring
After
Before
5-1. Connecting the Refrigerant Tubing
Use of the Flaring Method
Many of 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.
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. 30
– 50 cm longer than the tubing length you estimate.
Fig. 5-1
Copper
tubing
(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. 5-1)
Reamer
NOTE
When reaming, hold the tube end downward and be
sure that no copper scraps fall into the tube. (Fig. 5-2)
Fig. 5-2
(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.* (Fig. 5-3)
Flare nut
(*Use “RIGID® ” or equivalent.)
Copper
tubing
NOTE
A good flare should have the following characteristics:
●
inside surface is glossy and smooth
●
edge is smooth
●
tapered sides are of uniform length
Flare tool
Fig. 5-3
30
05-194
5/27/05
5:06 PM
Page 31
Caution Before Connecting Tubes Tightly
(1) Apply a sealing cap or water-proof tape to prevent
dust or water from entering the tubes before they
are used.
Apply refrigerant
lubricant here and here
(2) Be sure to apply refrigerant lubricant to the matching surfaces of the flare and union before connecting them together. This is effective for reducing
gas leaks. (Fig. 5-4)
Fig. 5-4
(3) 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. 5-5)
●
Union
Adjust the shape of the liquid tube using a tube
bender at the installation site and connect it to the
liquid tubing side valve using a flare.
Flare nut
Fig. 5-5
Cautions During Brazing
●
●
Replace air inside the tube with nitrogen gas to
prevent copper oxide film from forming during
the brazing process. (Oxygen, carbon dioxide
and Freon are not acceptable.)
Torque wrench
Spanner
Indoor unit
Do not allow the tubing to get too hot during
brazing. The nitrogen gas inside the tubing
may overheat, causing refrigerant system
valves to become damaged. Therefore allow
the tubing to cool when brazing.
●
Use a reducing valve for the nitrogen cylinder.
●
Do not use agents intended to prevent the formation of oxide film. These agents adversely
affect the refrigerant and refrigerant oil, and
may cause damage or malfunctions.
Outdoor unit
Fig. 5-6
Tube diameter
Tightening torque,
approximate
Tube thickness
φ6.35 (1/4")
14 – 18 N · m
(140 – 180 kgf · cm)
0.8 mm
φ9.52 (3/8")
34 – 42 N · m
(340 – 420 kgf · cm)
0.8 mm
φ12.7 (1/2")
49 – 61 N · m
(490 – 610 kgf · cm)
0.8 mm
5-2. Connecting Tubing Between Indoor and Outdoor Units
(1) Tightly connect the indoor-side refrigerant tubing
extended from the wall with the outdoor-side tubing.
(2) To fasten the flare nuts, apply specified torque as
at right:
●
●
φ15.88 (5/8")
When removing the flare nuts from the tubing connections, or when tightening them after connecting
the tubing, be sure to use 2 monkey wrenches or
spanners as shown. (Fig. 5-6)
If the flare nuts are over-tightened, the flare may be
damaged, which could result refrigerant leakage
and cause in injury or asphyxiation to room occupants.
φ19.05 (3/4")
68 – 82 N · m
(680 – 820 kgf · cm)
100 – 120 N · m
(1000 – 1200 kgf · cm)
1.0 mm
1.0 mm
Because the pressure is approximately 1.6 times
higher than conventional refrigerant pressure, the
use of ordinary flare nuts (type 1) or thin-walled
tubes may result in tube rupture, injury, or asphyxiation caused by refrigerant leakage.
For the flare nuts at tubing connections, be sure to
use the flare nuts that were supplied with the unit,
or else flare nuts for R410A (type 2). The refrigerant tubing that is used must be of the correct wall
thickness as shown in the table at right.
31
●
In order to prevent damage to the flare caused by
over-tightening of the flare nuts, use the table
above as a guide when tightening.
●
When tightening the flare nut on the liquid tube,
use a monkey wrench with a nominal handle length
of 200 mm.
05-194
5/27/05
5:06 PM
Page 32
5-3. Insulating the Refrigerant Tubing
Two tubes arranged together
Tubing Insulation
●
Liquid tubing
Thermal insulation must be applied to all unit tubing, including distribution joint (purchased separately).
* For gas tubing, the insulation material must be
heat resistant to 120°C or above. For other tubing,
it must be heat resistant to 80°C or above.
Insulation material thickness must be 10 mm or
greater.
If the conditions inside the ceiling exceed DB 30°C
and RH 70%, increase the thickness of the gas
tubing insulation material by 1 step.
CAUTION
Gas tubing
Insulation
If the exterior of the outdoor
unit valves has been finished
with a square duct covering,
make sure you allow sufficient space to use the valves
and to allow the panels to be
attached and removed.
Taping the flare nuts
Sealer (supplied)
Wind the white insulation tape around the flare nuts at
the gas tube connections. Then cover up the tubing
connections with the flare insulator, and fill the gap at
the union with the supplied black insulation tape.
Finally, fasten the insulator at both ends with the supplied vinyl clamps. (Fig. 5-8)
Insulation tape (white)
(supplied)
Flare insulator (supplied)
Tube insulator
(not supplied)
Heat resistant
120°C or above
Unit side
insulator
Flare nut
Vinyl clamps (supplied)
Insulation material
Fig. 5-8
The material used for insulation must have good insulation characteristics, be easy to use, be age resistant, and must not easily absorb moisture.
CAUTION
Refrigerant tubing and insulator
(not supplied)
After a tube has been insulated, never try to bend it
into a narrow curve
because it can cause the
tube to break or crack.
Drain insulator
and clamp.
Large
(supplied)
Drain pipe and insulator
(not supplied)
Packing
clamp.
Small
hose band
(supplied)
Seal
Insulation
tape
Vinyl
Flare clamp
insulator
The procedure used for
installing the insulator for
both gas and liquid
tubes is the same.
Fig. 5-9
Never grasp the drain or refrigerant connecting
outlets when moving the unit.
32
05-194
5/27/05
5:06 PM
Page 33
5-4. Taping the Tubes
(1) At this time, the refrigerant tubes (and electrical
wiring if local codes permit) should be taped
together with armoring tape in 1 bundle. To prevent the condensation from overflowing the drain
pan, keep the drain hose separate from the
refrigerant tubing.
Clamp
(2) Wrap the armoring tape from the bottom of the
outdoor unit to the top of the tubing where it
enters the wall. As you wrap the tubing, overlap
half of each previous tape turn.
Insulated tubes Drain hose
(3) Clamp the tubing bundle to the wall, using 1
clamp approx. each meter. (Fig. 5-10)
NOTE
Fig. 5-10
Do not wind the armoring tape too tightly since this
will decrease the heat insulation effect. Also ensure
that the condensation drain hose splits away from the
bundle and drips clear of the unit and the tubing.
Apply putty here
5-5. Finishing the Installation
After finishing insulating and taping over the tubing,
use sealing putty to seal off the hole in the wall to prevent rain and draft from entering. (Fig. 5-11)
Tubing
Fig. 5-11
33
05-194
5/27/05
5:06 PM
Page 34
6. AIR PURGING
Manifold gauge
Air and moisture in the refrigerant system may have
undesirable effects as indicated below.
●
●
●
●
●
pressure in the system rises
operating current rises
cooling (or heating) efficiency drops
moisture in the refrigerant circuit may freeze and
block capillary tubing
water may lead to corrosion of parts in the refrigerant system
Fig. 6-1
Therefore, the indoor unit and tubing between the
indoor and outdoor unit must be leak tested and
evacuated to remove any noncondensables and
moisture from the system.
Vacuum pump
Outlet
Inlet
■ Air Purging with a Vacuum Pump (for Test Run)
Preparation
Check that each tube (both liquid and gas tubes)
between the indoor and outdoor units has been properly connected and all wiring for the test run has been
completed. Remove the valve caps from both the gas
tube and liquid tube service valves on the outdoor
unit. Note that both liquid and gas tube service valves
on the outdoor unit are kept closed at this stage.
Fig. 6-2
Manifold valve
Pressure
gauge
Lo
Hi
Leak test
Charge hose
(1) Attach a manifold valve (with pressure gauges)
and dry nitrogen gas cylinder to this service port
with charge hoses.
CAUTION
Cylinder
valve
Use a manifold valve for air
purging. If it is not available,
use a stop valve for this purpose. The “Hi” knob of the
manifold valve must always
be kept closed.
Nitrogen gas cylinder
(In vertical standing
position)
Service port ø7.94 mm
(2) Pressurize the system to no more than 36 kgf/cm2G
with dry nitrogen gas and close the cylinder valve
when the gauge reading reaches 36 kgf/cm2G.
Then, test for leaks with liquid soap.
Open
Gas
tube
Close
Outdoor unit
C
CAUTION
To avoid nitrogen entering
the refrigerant system in a
liquid state, the top of the
cylinder must be higher than
the bottom when you pressurize the system. Usually,
the cylinder is used in a vertical standing position.
(Refer to the previous page.)
Open
Liquid
tube
Close
Fig. 6-3
34
05-194
5/27/05
5:06 PM
Page 35
(3) Do a leak test of all joints of the tubing (both
indoor and outdoor) and both gas tube and liquid
tube service valves. Bubbles indicate a leak. Wipe
off the soap with a clean cloth after the leak test.
Manifold valve
(4) After the system is found to be free of leaks,
relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen cylinder.
When the system pressure is reduced to normal,
disconnect the hose from the cylinder.
Pressure
gauge
Lo
Hi
Evacuation
(1) Attach the charge hose end described in the preceding steps to the vacuum pump to evacuate the
tubing and indoor unit. Confirm that the “Lo” knob
of the manifold valve is open. Then, run the vacuum pump. The operation time for evacuation
varies with the tubing length and capacity of the
pump. The following table shows the amount of
time for evacuation:
Vacuum pump
Service port ø7.94 mm
Open
Required time for evacuation
when 30 gal/h vacuum pump is used
If tubing length is
If tubing length is
less than 15 m
longer than 15 m
45 min. or more
90 min. or more
Gas
tube
Close
Outdoor unit
Open
Liquid
tube
NOTE
Close
The required time in the above table is calculated
based on the assumption that the ideal (or target)
vacuum condition is less than 667 Pa (–755 mm Hg,
5 Torr).
Fig. 6-4
(2) When the desired vacuum is reached, close the
“Lo” knob of the manifold valve and turn off the
vacuum pump. Confirm that the gauge pressure is
under 667 Pa (–755 mmHg, 5 Torr) after 4 to 5
minutes of vacuum pump operation.
C
35
05-194
5/27/05
5:06 PM
CAUTION
Page 36
Use a cylinder designed for
use with R410A respectively.
Manifold valve
Pressure
gauge
Charging additional refrigerant
●
Lo
Hi
Charging additional refrigerant (calculated from the
liquid tube length as shown in Section 1-7 “Additional Refrigerant Charge”) using the liquid tube
service valve. (Fig. 6-5)
●
Use a balance to measure the refrigerant accurately.
●
If the additional refrigerant charge amount cannot
be charged at once, charge the remaining refrigerant in liquid form by using the gas tube service
valve with the system in cooling operation mode at
the time of test run. (Fig. 6-6)
Valve
Liquid
Finishing the job
R410A
(1) With a hex wrench, turn the liquid tube service
valve stem counter-clockwise to fully open the
valve.
Close
Gas
tube
(2) Turn the gas tube service valve stem counterclockwise to fully open the valve.
CAUTION
Close
To avoid gas from leaking when
removing the charge hose,
make sure the stem of the gas
tube is turned all the way out
(“BACK SEAT” position).
Outdoor unit
Open
Liquid
tube
Close
(3) Loosen the charge hose connected to the gas
tube service port (for ø7.94 mm tube) slightly to
release the pressure, then remove the hose.
Fig. 6-5
(4) Replace the service port cap on the gas tube service port and fasten the cap securely with an monkey spanner or box wrench. This process is very
important to prevent gas from leaking from the
system.
Open
(5) Replace the valve caps at both gas tube and liquid
tube service valves and fasten them securely.
Gas
tube
Open
This completes air purging with a vacuum pump. The
air conditioner is now ready for a test run.
Outdoor unit
Close
Liquid
tube
C
Open
Fig. 6-6
36
05-194
5/27/05
5:06 PM
Page 37
7. TEST RUN
7-1. Preparing for Test Run
●
Before attempting to start the air conditioner,
check the following.
ON
(1) All loose matter is removed from the cabinet,
especially steel filings, bits of wire, and clips.
(Power must be turned ON
at least 5 hours before
attempting test run)
(2) The control wiring is correctly connected and all
electrical connections are tight.
(3) The transportation pads for the indoor fan have
been removed. If not, remove them now.
Power mains switch
(4) The power has been connected to the unit for at
least 5 hours before starting the compressor. The
bottom of the compressor should be warm to the
touch and the crankcase heater around the feet of
the compressor should be hot to the touch.
(Fig. 7-1)
Fig. 7-1
(5) Both the gas and liquid tube service valves are
open. If not, open them now. (Fig. 7-2)
(6) Request that the customer be present for the trial
run.
Explain the contents of the instruction manual, then
have the customer actually operate the system.
(7) Be sure to give the instruction manual and warranty certificate to the customer.
(8) When replacing the control PCB, be sure to make
all the same settings on the new PCB as were in
use before replacement.
The existing EEP ROM is not changed, and is
connected to the new control PCB.
Gas tube service cap
Liquid tube service cap
Fig. 7-2
37
05-194
5/27/05
5:06 PM
Page 38
7-2. Test Run Procedure
Items to Check Before the Test Run
Recheck the items to check before the test run.
1. Turn the remote power switch on at
least 5 hours before the test, in order
to energize the crank case heater.
NO
Have the outdoor sub units been connected?
YES
*1
*1
Set the unit address.
The unit with the unit
No. set to 1 is the
main unit. All other
units are sub units.
2. Turn the outdoor service valves (2
locations) to the full-open positions.
●
Set the No. of outdoor units.
<Outdoor unit control PCB>
Unit No. setting switch
(S004)
●
Set the No. of indoor units.
NO
Are the inter-unit control wires
connected to more than 1 refrigerant
system?
(Check the link wiring.)
Use caution when making the settings. If there are duplicated system
addresses, or if the settings for the
Nos. of the indoor units are not consistent, an alarm will occur and the
system will not start.
These settings are not made on the
indoor unit PCB.
CASE 1
YES
<Outdoor unit control PCB>
Unit No. setting switch
(S002 and S003)
Set the system address.
When multiple outdoor units exist, disconnect the terminals
extended from the shorted plugs (CN33) at all outdoor main unit
PCBs except for 1.
Alternatively, move the sockets to the OPEN side.
Refer to Fig. 10-4
YES
Is it possible to turn ON the power only
for the 1 refrigerant system where the
test run will be performed?
CASE 2
Turn ON the indoor and
outdoor unit power for that
refrigerant system only.
NO
Will automatic address setting be
performed in Heating mode?
NO
YES
CASE 3B
Is it OK to start the compressors?
Make necessary corrections.
Is it OK to start the compressors?
Turn ON the indoor and
outdoor unit power.
Check the alarm contents.
Turn ON the indoor and
outdoor unit power.
*2
NO
Make necessary
corrections
*2
Short-circuit the mode change pin
(CN50) on the outdoor main unit PCB.
At the same time, short-circuit the
automatic address pin (CN51) for 1
second or longer, then pull it out.
*3
Turn OFF the indoor and
CASE 3A
Short-circuit the automatic address
pin (CN51) on the outdoor unit PCB
for 1 second or longer,
then release it.
Turn OFF the indoor
and outdoor unit
Refer to “Table of
Self-Diagnostic Functions and
Description of Alarm Displays.”
LED 1 and 2 blink alternately
(about 2 or 3 minutes).
Are LEDs 1 and 2 on the
outdoor unit PCB OFF?
*3
Start indoor and outdoor unit
cooling operation.
LED 1 and 2 blink alternately.
Start indoor and outdoor unit
heating operation.
LED 1 and 2 blink alternately.
Check the alarm
contents.
*2 A minimum of 5 hours must have passed after the
power was turned ON to the outdoor unit.
*3 All indoor units operate in all refrigerant systems
where the power is ON.
NO
Are LEDs 1 and 2 on the
outdoor unit PCB OFF?
YES
Check that test run preparation is OK.
(Do not allow the short-circuited pins to remain short-circuited.)
Set the wired remote controller for test run.
Refer to the remote
controller test-run
settings.
Short-circuit the automatic address pin (CN51)
on the outdoor unit PCB for 1 second or longer,
then release it.
Does system operate?
NO
Check and make corrections according to
“Table of Self-Diagnostic Functions.”
YES
Return remote control to normal mode
End test run.
Fig. 7-3
38
YES
05-194
5/27/05
5:06 PM
Page 39
7-3. Outdoor Unit PCB Setting
CN33
S003
CN51
CN50
S002
D043
(LED2)
S004
D042
(LED1)
Fig. 7-4
39
5/27/05
5:06 PM
Page 40
Examples of the No. of indoor units settings
No. of indoor units
Indoor unit setting (S004)
(Rotary switch, red)
1
1 unit (factory setting)
9 units
2
2 units
Set to 1
Set to 2
9
05-194
Set to 9
Examples of refrigerant circuit (R.C.) address settings (required when link wiring is used)
System address No.
System address (S003)
(2P DIP switch, blue)
10 20
ON
System address (S002)
(Rotary switch, black)
1
ON
System 1 (factory setting)
System 11
Both OFF
1 2
ON
OFF
ON
2
ON
OFF
ON
1 2
ON
OFF
ON
2
OFF
1
System 21
System 30
1
1 ON
2 ON
1 & 2 ON
1
1
0
40
Set to 1
Set to 1
Set to 1
Set to 0
05-194
5/27/05
5:06 PM
Page 41
7-4. Auto Address Setting
Basic wiring diagram: Example (1)
• If link wiring is not used
(The inter-unit control wires are not connected to multiple refrigerant systems.)
Indoor unit addresses can be set without operating the compressors.
No. 1 unit settings
(S004)
System address
(system 1 setting)
(S003)
ON
1
2
No. of indoor units
(8 units setting)
(S004)
(S002)
ON
1
8
OFF
Unit
No. 1
Outdoor Unit
Inter-unit control wiring
1-1
Indoor Unit
1-2
1-3
1-8
Remote controller
cross-over wiring
Remote controller
Fig. 7-5
(1) Automatic Address Setting from the Outdoor Unit
1. On the outdoor unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the
ON
DIP switch (S003) is set to “0.” ON
(These are the settings at the time of factory shipment.)
1
2
OFF
2. To set the number of indoor units that are connected to the outdoor unit to 8, on the outdoor unit control PCB set
the No. of indoor units rotary switch (S004) to “8.”
3. Turn ON the power to the indoor and outdoor units.
4. On the outdoor unit control PCB, short-circuit the automatic address pin (CN51) for 1 second or longer, then
release it.
↓
(Communication for automatic address setting begins.)
↓
* To cancel, again short-circuit the automatic address pin (CN51) for 1 second or longer, then pull it out.
The LED that indicates that automatic address setting is in progress turns OFF and the process is
stopped.
(Automatic address setting is completed when LEDs 1 and 2 on the outdoor unit control PCB turn OFF.)
↓
5. Operation from the remote controllers is now possible.
* To perform automatic address setting from the remote controller, perform steps 1 to 3, then use the remote controller and
complete automatic address setting.
Refer to “Automatic Address Setting from the Remote Controller.”
41
5/27/05
5:06 PM
Page 42
Basic wiring diagram: Example (2)
¥ If link wiring is used
No. 1 unit settings
System address
(system 1 setting)
(S003)
No. of indoor units
(6 units setting)
(S004)
(S002)
ON
ON
* When multiple outdoor units exist, remove the socket that
is used to short-circuit the terminal plug (CN33) from all
outdoor unit PCBs except for 1.
Alternatively, move the sockets to the OPEN side .
1
6
1
2
OFF
Outdoor unit
system 1
Leave the socket
that is used to
short-circuit the
terminal plug.
(CN33)
Unit
No. 1
Inter-unit control wiring
1-1
Indoor unit
1-2
1-3
1-6
Remote controller
communication wiring
Remote
controller
No. 2 unit settings
System address
(system 2 setting)
(S002)
No. of indoor units
(7 units setting)
(S003)
ON
ON
7
(S004)
2
1
2
OFF
Outdoor unit
system 2
7
05-194
Unit
No. 1
Leave the socket
that is used to open
circuit the terminal
plug (CN33).
Inter-unit control wiring
To other system
link wiring
Indoor unit
2-1
2-2
2-7
Remote controller
cross-over wiring
Remote
controller
Make settings as appropriate for the cases listed below.
(Refer to the instructions on the following pages.)
¥ Indoor and outdoor unit power can be turned ON for each system separately.
Case 1
¥ Indoor and outdoor unit power cannot be turned ON for each system separately.
Automatic address setting in Heating mode
Case 2
Automatic address setting in Cooling mode
Case 3
Fig. 7- 6
42
05-194
5/27/05
5:06 PM
Page 43
Case 1 Automatic Address Setting (no compressor operation)
● Indoor and outdoor unit power can be turned ON for each system separately.
Indoor unit addresses can be set without operating the compressors.
Automatic Address Setting from Outdoor Unit
1. On the outdoor unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the
ON (These are the settings at the time of factory shipment.)
DIP switch (S003) is set to “0.” ON
1
2
OFF
2. To set the number of indoor units that are connected to the outdoor unit to 6, on the outdoor unit control PCB set
the No. of indoor units rotary switch (S004) to “6.”
3. At the outdoor unit where all indoor and outdoor unit power has been turned ON, short-circuit the automatic
address pin (CN51) for 1 second or longer, then pull it out.
↓
(Communication for automatic address setting begins.)
↓
* To cancel, again short-circuit the automatic address pin (CN51) for 1 second or longer, then pull it out.
The LED that indicates automatic address setting is in progress turns OFF and the process is stopped.
(Automatic address setting is completed when LEDs 1 and 2 on the outdoor unit control PCB turn OFF.)
↓
4. Next turn the power ON only for the indoor and outdoor units of the next (different) system. Repeat steps 1 – 3
in the same way to complete automatic address settings for all systems.
↓
5. Operation from the remote controllers is now possible.
* To perform automatic address setting from the remote controller, perform steps 1 and 2, then use the remote controller
complete automatic address setting.
Refer to “Automatic Address Setting from the Remote Controller.”
43
05-194
5/27/05
5:06 PM
Page 44
Case 2 Automatic Address Setting in Heating Mode
● Indoor and outdoor unit power cannot be turned ON for each system separately.
In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating.
Therefore perform this process only after completing all refrigerant tubing work.
Automatic Address Setting from Outdoor Unit
1. Perform steps 1 and 2 in the same way as for Case 1 .
2. Turn the indoor and outdoor unit power ON at all systems.
↓
3. To perform automatic address setting in Heating mode , on the outdoor unit control PCB in the refrigerant system where you wish to set the addresses, short-circuit the automatic address pin (CN51) for 1 second or longer,
then pull it out.
(Be sure to perform this process for one system at a time. Automatic address settings cannot be performed for
more than one system at the same time.)
↓
(Communication for automatic address setting begins, the compressors turn ON, and automatic address
setting in heating mode begins.)
(All indoor units operate.)
↓
* To cancel, again short-circuit the automatic address pin (CN51) for 1 second or longer, then pull it out.
The LED that indicates automatic address setting is in progress turns OFF and the process is stopped.
(Automatic address setting is completed when the compressors stop and LEDs 1 and 2 on the outdoor unit control PCB turn OFF.)
4. At the outdoor unit in the next (different) system, short-circuit the automatic address pin (CN51) for 1 second or
longer, then pull it out.
↓
(Repeat the same steps to complete automatic address setting for all units.)
↓
5.
Operation from the remote controllers is now possible.
* To perform automatic address setting from the remote controller, perform steps 1 and 2, then use the remote controller
complete automatic address setting.
Refer to “Automatic Address Setting from the Remote Controller.”
44
05-194
5/27/05
5:06 PM
Page 45
Case 3 Automatic Address Setting in Cooling Mode
● Indoor and outdoor unit power cannot be turned ON for each system separately.
In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating.
Therefore perform this process only after completing all refrigerant tubing work.
Automatic address setting can be performed during Cooling operation.
Automatic Address Setting from Outdoor Unit
1. Perform steps 1 and 2 in the same way as for Case 1 .
2. Turn the indoor and outdoor unit power ON at all systems.
↓
3. To perform automatic address setting in Cooling mode , on the outdoor unit control PCB in the refrigerant system where you wish to set the addresses, short-circuit the mode change 2P pin (CN50). At the same time,
short-circuit the automatic address pin (CN51) for 1 second or longer, then pull it out. (Be sure to perform this
process for one system at a time. Automatic address settings cannot be performed for more than one system at
the same time.)
↓
(Communication for automatic address setting begins, the compressors turn ON, and automatic address
setting in Cooling mode begins.)
(All indoor units operate.)
↓
* To cancel, again short-circuit the automatic address pin (CN51) for 1 second or longer, then pull it out.
The LED that indicates automatic address setting is in progress turns OFF and the process is stopped.
(Automatic address setting is completed when the compressors stop and LEDs 1 and 2 on the outdoor unit
control PCB turn OFF.)
4. At the outdoor unit in the next (different) system, short-circuit the automatic address pin (CN51) for 1 second or
longer, then pull it out.
↓
(Repeat the same steps to complete automatic address setting for all units.)
↓
5.
Operation from the remote controllers is now possible.
* Automatic address setting in Cooling mode cannot be done from the remote controller.
Automatic Address Setting from the Remote Controller
Selecting each refrigerant system individually for automatic address setting
---Automatic address setting for each system: Item code “A1”
●
Press the remote controller timer time
button and
the same time. (Press and hold for 4 seconds or longer.)
●
Next, press either the temperature setting
(Check that the item code is “A1.”)
●
Use either the
or
button to set the system No. to perform automatic address setting.
●
Then press the
or
button at
button.
button.
(Automatic address setting for one refrigerant system begins.)
(When automatic address setting for one system is completed, the
system returns to normal stopped status.) <Approximately 4 – 5 minutes is required.>
(During automatic address setting, “SETTING” is displayed on the
remote controller. This message disappears when automatic address
setting is completed.)
●
Repeat the same steps to perform automatic address setting for each successive system.
45
05-194
5/27/05
5:06 PM
Page 46
Display during automatic address setting
●
On outdoor unit PCB
LED 2
1
Blink alternately
* Do not short-circuit the automatic address setting pin (CN51) again while automatic
address setting is in progress. Doing so will cancel the setting operation and will cause
LEDs 1 and 2 to turn OFF.
* When automatic address setting has been successfully completed, both LEDs 1 and 2 turn OFF.
* LED 1 is D042. LED 2 is D043.
* If automatic address setting is not completed successfully, refer to the table below and correct the problem.
Then perform automatic address setting again.
●
Display details of LEDs 1 and 2 on the outdoor unit control PCB
(
: ON
LED 1
:: Blinking
: OFF)
Display meaning
LED 2
After the power is turned ON (and automatic address setting is not in progress), no communication with the indoor
units in that system is possible.
After the power is turned ON (and automatic address setting is not in progress), 1 or more indoor units are
confirmed in that system; however, the number of indoor units does not match the number that was set.
Alternating
Automatic address setting is in progress.
Automatic address setting completed.
Simultaneous
Alternating
Note:
●
At time of automatic address setting, the number of indoor units did not match the number that was set.
(when indoor units are operating) indication appears on the displa y.
Refer to Table of Self-Diagnostic Functions and Description of Alarm Displays.
indicates that the solenoid is fused or that there is a C T (current detection circuit) failure (current is detected when
the compressor is OFF).
Remote controller display during automatic setting
is blinking
46
05-194
5/27/05
5:06 PM
Page 47
Request concerning recording the indoor/outdoor unit combination Nos.
After automatic address setting has been completed, be sure to record them for future reference.
List the outdoor unit system address and the addresses of the indoor units in that system in an easily visible location
(next to the nameplate), using a permanent marking pen or similar means that cannot be erased easily.
Example: (Outdoor) 1 – (Indoor) 1-1, 1-2, 1-3…
(Outdoor) 2 – (Indoor) 2-1, 2-2, 2-3…
These numbers are necessary for later maintenance. Please be sure to indicate them.
Checking the indoor unit addresses
Use the remote controller to check the indoor unit address.
<If 1 indoor unit is connected to 1 remote controller>
1. Press and hold the
button and
button for 4 seconds or longer (simple settings mode).
2. The address is displayed for the indoor unit that is connected to the remote controller.
(Only the address of the indoor unit that is connected to the remote controller can be checked.)
3. Press the
button again to return to normal remote controller mode.
<If multiple indoor units are connected to 1 remote controller (group control)>
1. Press and hold the
button and
button for 4 seconds or longer (simple settings mode).
2. “ALL” is displayed on the remote controller.
3. Next, press the
button.
4. The address is displayed for 1 of the indoor units which is connected to the remote controller. Check that the
fan of that indoor unit starts and that air is discharged.
5. Press the
6. Press the
button again and check the address of each indoor unit in sequence.
button again to return to normal remote controller mode.
Indoor unit address
Number changes to indicate which indoor unit is currently selected.
Remote Controller Test Run Settings
1. Press the remote controller
●
●
button for 4 seconds or longer. Then press the
button.
“TEST” appears on the LCD display while the test run is in progress.
The temperature cannot be adjusted when in Test Run mode.
(This mode places a heavy load on the machines. Therefore use it only when performing the test run.)
2. The test run can be performed using the HEAT, COOL, or FAN operation modes.
Note: The outdoor units will not operate for approximately 3 minutes after the power is turned ON and after
operation is stopped.
3. If correct operation is not possible, a code is displayed on the remote controller display.
(Refer to “7-6. Meaning of Alarm Messages” and correct the problem.)
4. After the test run is completed, press the
button again. Check that “TEST” disappears from the remote controller display.
(To prevent continuous test runs, this remote controller includes a timer function that cancels the test run after
60 minutes.)
* If the test run is performed using the wired remote controller, operation is possible even if the cassette-type ceiling panel has not been installed. (“P09” display does not occur.)
47
05-194
5/27/05
5:06 PM
Page 48
7-5. Caution for Pump Down
Pump down means refrigerant gas in the system is
returned to the outdoor unit. Pump down is used
when the unit is to be moved, or before servicing the
refrigerant circuit.
●
This outdoor unit cannot collect more than the rated refrigerant amount as shown
by the nameplate on the back.
●
If the amount of refrigerant is more than that recommended, do not conduct pump
down. In this case use another refrigerant collecting system.
CAUTION
7-6. Meaning of Alarm Messages
Table of Self-Diagnostics Functions and Description of Alarm Displays
Alarm messages are indicated by the blinking of LED 1 and 2 (D72, D75) on the outdoor unit PCB. They are also displayed on
the wired remote controller.
● Viewing the LED 1 and 2 (D72 and D75) alarm displays
LED 1
LED 2
Alternating
(
Alarm contents
Alarm display
LED 1 blinks M times, then LED 2 blinks N times. The cycle then repeats.
M = 2: P alarm 3: H alarm 4: E alarm 5: F alarm 6: L alarm
N = Alarm No.
Example: LED 1 blinks 2 times, then LED 2 blinks 17 times. The cycle then repeats.
Alarm is "P17."
: Blinking)
Alarm
message
Possible cause of malfunction
Serial communication errors
Mis-setting
Remote controller is detecting
error signal from indoor unit.
Error in receiving serial communication signal.
(Signal from main indoor unit in case of group control)
Ex: Auto address is not completed.
<E01>
Error in transmitting serial communication signal.
<E02>
Indoor unit is detecting error signal from remote controller (and system controller).
Indoor unit is detecting error
signal from main outdoor unit.
Error in receiving serial communication signal.
When turning on the power supply, the number of connected
indoor units does not correspond to the number set. (Except R.C.
address is “0.”)
Error of the main outdoor unit in receiving serial communication
signal from the indoor unit.
Improper setting of indoor unit or Indoor unit address setting is duplicated.
remote controller.
Remote controller address connector (RCU. ADR) is duplicated.
(Duplication of main remote controller)
Starting auto. address setting is prohibited.
During auto. address setting,
number of connected units does This alarm message shows that the auto address connector CN100
not correspond to number set.
is shorted while other RC line is executing auto address operation.
When turning on the power
supply, number of connected
units does not correspond to
number set.
(Except R.C. address is “0.”)
Indoor unit communication error
of group control wiring.
Error in auto. address setting. (Number of connected indoor units
is less than the number set)
Error in auto. address setting. (Number of connected indoor units
is more than the number set)
No indoor unit is connected during auto. address setting.
<<E03>>
E04
<E06>
E08
<<E09>>
E12
E15
E16
E20
Main outdoor unit is detecting error signal from sub outdoor unit.
E24
Error of outdoor unit address setting.
E25
The number of connected main and sub outdoor units do not
correspond to the number set at main outdoor unit PCB.
Error of sub outdoor unit in receiving serial communication signal
from main outdoor unit.
Error of main indoor unit in receiving serial communication signal
from sub indoor units.
E26
E29
E18
Continued
48
05-194
5/27/05
5:06 PM
Page 49
Alarm
message
Possible cause of malfunction
Serial communication errors
Mis-setting
Improper setting.
This alarm message shows when the indoor unit for multiple-use
is not connected to the outdoor unit.
Duplication of main indoor unit address setting in group control.
Duplication of outdoor R.C. address setting.
Group control wiring is connected to individual control indoor unit.
L07
Capacity code of outdoor unit is not set.
L10
Mis-matched connection of outdoor units which have different
kinds of refrigerant.
L17
Thermal protector in indoor unit fan motor is activated.
Improper wiring connections of ceiling panel.
Float switch is activated.
Negative (Defective) phase.
Incorrect discharge temperature. (Comp. No. 2)
Outdoor unit fan motor is unusual.
Outdoor thermistor is either
open or damaged.
Protective device for compressor
No. 1 is activated.
Protective device for compressor
No. 2 is activated.
P02
P03
P04
P05
P17
P22
P16
Overcurrent at time of compressor runs more than 80Hz (DCCT
secondary current or ACCT primary current is detected at a time
other than when IPM has tripped.)
P26
IPM trip (IPM current or temperature)
H31
Inverter for compressor is unusual. (DC compressor does not
operate.)
P29
Indoor coil temp. sensor (E1)
Indoor coil temp. sensor (E2)
Indoor coil temp. sensor (E3)
Indoor suction air (room) temp. sensor (TA)
Indoor discharge air temp. sensor (BL)
Comp. No. 1 discharge gas temp. sensor (DISCH1)
Comp. No. 2 discharge gas temp. sensor (DISCH2)
<<F01>>
<<F02>>
<<F03>>
<<F10>>
<<F11>>
F04
F05
Outdoor No. 1 coil gas temp. sensor (EXG1)
Outdoor No. 1 coil liquid temp. sensor (EXL1)
Outdoor air temp. sensor (AIR TEMP)
Compressor intake port temperature sensor (RDT)
High pressure sensor
Outdoor No. 2 coil gas temp. sensor (EXG2)
Outdoor No. 2 coil liquid temp. sensor (EXL2)
F06
F07
F08
F12
F16
F23
F24
F29
EEP ROM on the main or sub outdoor unit PCB is a failure.
Overload current is detected.
Lock current is detected.
Current is not detected when comp. No. 1 is ON.
F31
H01
H02
H03
Discharge gas temperature of the comp. No. 1 is not detected.
Temp. sensor is not seated at the sensor holder.
H05
Overload current is detected.
Lock current is detected.
Current is not detected when comp. No. 2 is ON.
Discharge gas temperature of the comp. No. 2 is not detected.
Low pressure switch is activated.
H11
H12
H13
H15
H06
H07
H08
H27
Low oil level.
Oil sensor fault.
(Disconnection, etc.)
L18
<<P01>>
<<P09>>
<<P10>>
Compressor running failure resulting from missing phase in the
compressor wiring, etc. (Start failure not caused by IPM or no gas.)
Negative (defective) N phase.
EEPROM on indoor unit PCB failure
Protective
device for
compressor is
activated
L08
<<L09>>
Incorrect discharge temperature. (Comp. No. 1)
High pressure switch is activated.
Indoor thermistor is either open
or damaged.
L06
Capacity code of indoor unit is not set.
Compressor thermal protector is activated.
Power supply voltage is unusual. (The voltage is more than 260 V
or less than 160 V between L and N phase.)
Thermistor
fault
L04
L05
4-way valve operation failure
Protective device in indoor unit
is activated.
<L03>
There are 2 or more indoor units Priority set remote controller
controllers which have operation
mode priority in 1refrigerant circuit. Non-priority set remote controller
Indoor unit address is not set.
Activation of
protective
device
L02
Comp. No. 1 oil sensor
Comp. No. 2 oil sensor
49
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising