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

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

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 7 9 12

AS 1-Way Air Discharge SPW-

Semi-Concealed

SPWSPW-

ASR74GXH56(A/B) ASR94GXH56(A/B) ASR124GXH56(A/B)

16 18 25 36 48

LD 1-Way Air Discharge

Semi-Concealed Slim

S

X

SPWSPW-

LDR94GXH56(A/B) LDR124GXH56(A/B)

SPWSPW-

LDR184GXH56(A/B) LDR254GXH56(A/B)

2-Way Air Discharge SPW-

Semi-Concealed SR74GXH56(A/B)

SPW-

SR94GXH56(A/B)

SPW-

SR124GXH56(A/B)

SPW-

SR164GXH56(A/B)

SPW-

SR184GXH56(A/B)

SPW-

SR254GXH56(A/B)

4-Way Air Discharge SPW-

Semi-Concealed*

SPWSPWSPWSPWSPWSPWSPW-

XDR74GXH56(A/B) XDR94GXH56(A/B) XDR124GXH56(A/B) XDR164GXH56(A/B) XDR184GXH56(A/B) XDR254GXH56(A/B) XDR364GXH56(A/B) XDR484GXH56(A/B)

K Wall-Mounted

T Ceiling-Mounted

SPWSPWSPWSPWSPWSPW-

KR74GXH56(A/B) KR94GXH56(A/B) KR124GXH56(A/B) KR164GXH56(A/B) KR184GXH56(A/B) KR254GXH56(A/B)

SPWSPWSPWSPW- SPWSPW-

TDR124GXH56(A/B) TDR164GXH56(A/B) TDR184GXH56(A/B) TDR254GXH56(A/B) TDR364GXH56(A/B) TDR484GXH56(A/B)

U Concealed-Duct

D Concealed-Duct

High Static Pressure*

SPWSPWSPWSPWSPWSPWSPWSPW-

UR74GXH56(A/B) UR94GXH56(A/B) UR124GXH56(A/B) UR164GXH56(A/B) UR184GXH56(A/B) UR254GXH56(A/B) UR364GXH56(A/B) UR484GXH56(A/B)

SPWSPWSPW-

DR254GXH56(A/B) DR364GXH56(A/B) DR484GXH56(A/B)

F Floor-Standing

FM Concealed-Floor-

Standing

SPWSPWSPWSPWSPWSPW-

FR74GXH56(A/B) FR94GXH56(A/B) FR124GXH56(A/B) FR164GXH56(A/B) FR184GXH56(A/B) FR254GXH56(A/B)

SPWSPWSPWSPWSPWSPW-

FMR74GXH56(A/B) FMR94GXH56(A/B) FMR124GXH56(A/B) FMR164GXH56(A/B) FMR184GXH56(A/B) FMR254GXH56(A/B)

* 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

Wireless Remote Controller (For X type)

Wireless Remote Controller (For S, LD type)

Wireless Remote Controller (For T type)

RCS-SH80AG

RCS-SH80AG.WL

RCS-TH80AG.WL

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

Remote Sensor

RCS-KR1AG

ART-K45AG

System Controller

Schedule Timer

SHA-KC64AG

SHA-TM64AG

C

RC

85464359780000 ©SANYO 2005

SANYO Electric Co., Ltd.

Gunma, Japan

W

WT

05-194 5/27/05 5:06 PM Page 2

IMPORTANT!

Please Read Before Starting

This air conditioning system meets strict safety and operating standards. As the installer or service person, it is an important part of your job to install or service the system so it operates safely and efficiently.

For safe installation and trouble-free operation, you must:

Carefully read this instruction booklet before beginning.

Follow each installation or repair step exactly as shown.

Observe all local, state, and national electrical codes.

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.

WARNING

This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death.

CAUTION

This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage.

If Necessary, Get Help

These instructions are all you need for most installation sites and maintenance conditions. If you require help for a special problem, contact our sales/service outlet or your certified dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for improper installation or maintenance service, including failure to follow the instructions in this document.

SPECIAL PRECAUTIONS

WARNING

When Wiring

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH.

ONLY A QUALIFIED, EXPERIENCED

ELECTRICIAN SHOULD ATTEMPT TO

WIRE THIS SYSTEM.

• 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.

• Ground the unit following local electrical codes.

• 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.

When Installing…

…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.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a solid, level foundation for the outdoor unit. This prevents water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a metal frame. Provide a suitable air baffle.

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is higher than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• 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.

• Keep all tubing runs as short as possible.

• Use the flare method for connecting tubing.

• 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.

• Check carefully for leaks before starting the test run.

When Servicing

• Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring.

• Keep your fingers and clothing away from any moving parts.

• 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.

CAUTION

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.

• 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.

2

05-194 5/27/05 5:06 PM Page 3

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.

Total amount of refrigerant (kg)

Min. volume of the indoor unit installed room (m

3

)

Density limit (kg/m

3

)

The density limit of refrigerant which is used in multi air conditioners is 0.3 kg/m

3

(ISO 5149).

NOTE

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.

For the amount of charge in this example:

Outdoor unit e.g., charged amount (10 kg) e.g., charged amount (15 kg)

Indoor unit

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.

2. The standards for minimum room volume are as follows.

(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

Outdoor unit

Very small room

Indoor unit

Small room

Medium room

Large room

Mechanical ventilation device – Gas leak detector

3. The minimum indoor floor space compared with the amount of refrigerant is roughly as follows (when the ceiling is 2.7 m high):

40 m

2

35

30

25

20

15

10

5

0

Range below the density limit of 0.3 kg/m

3

(countermeasures not needed)

Range above the density limit of 0.3 kg/m

3

(countermeasures needed)

10 20 30

Total amount of refrigerant kg

3

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

Copper tube

Material

Outer diameter

Wall thickness

6.35

0.8

9.52

0.8

O

12.7

0.8

15.88

1.0

19.05

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

New tool?

R407C tools compatible Remarks with R410A?

Manifold gauge Yes No

Charge hose Yes No

Vacuum pump Yes Yes

Types of refrigerant, refrigerating machine oil, and pressure gauge are different.

To resist higher pressure, material must be changed.

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

Flaring oil 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.

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.

Manifold gauge

Vacuum pump

Outlet

Inlet

* Using tools for R22 and R407C and new tools for R410A together can cause defects.

4

05-194 5/27/05 5:06 PM Page 5

3-2. Use R410A exclusive cylinder only.

Single-outlet valve

(with siphon tube)

Liquid refrigerant should be recharged with the cylinder standing on end as shown.

Liquid

Valve

5

05-194 5/27/05 5:06 PM Page 6

CONTENTS

Page

IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Please Read Before Starting

Check of Density Limit

Precautions for Installation Using New Refrigerant

Page

6. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . .34

Air Purging with a Vacuum Pump (for Test Run)

Preparation

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

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

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.

1-1. Tools Required for Installation (not supplied)

1.

Standard screwdriver

2.

Phillips head screwdriver

3.

Knife or wire stripper

4.

Tape measure

5.

Carpenter’s level

6.

Sabre saw or key hole saw

7.

Hacksaw

8.

Core bits

9.

Hammer

10. Drill

11.

Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

1-2. Accessories Supplied with 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.

1-4. Additional Materials Required for Installation

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire

(See your local codes.)

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

7

05-194 5/27/05 5:06 PM Page 8

Table 1-1 (Outdoor Unit)

Part name Figure

Q ty

365 Model

(4 hp)

485 Model

(5 hp)

605 Model

(6 hp)

Tube Discharge

Assy

0 0 1

Instruction manual paper

1 1 1 hp = horsepower

1-5. Tubing Size

Table 1-2 Main Tubing Size (LA) kW

System horsepower

Gas tubing

(mm)

Liquid tubing

(mm)

11.2

4

14.0

ø15.88

5

ø9.52

15.5

6

ø19.05

Unit: mm

Table 1-3 Main Tubing Size After Distribution (LB, LC...)

Total capacity after distribution

Tubing size

Below kW

Over kW

Gas tubing

(mm)

Liquid tubing (mm)

7.1

(2.5 hp)

ø12.7

ø9.52

11.2

(4 hp)

ø15.88

14.0

(5 hp)

7.1

(2.5 hp)

ø9.52

15.5

(6 hp)

ø19.05

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

,

18

2

...

n–1

)

25 36

ø15.88

48

ø9.52

60

Unit: mm

8

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

12.7

Gas tubing size (mm)

90

°

elbow

45

°

elbow

U-shape tube bend (R60 100 mm)

0.30

0.23

0.90

15.88

0.35

0.26

1.05

19.05

0.42

0.32

1.26

Trap bend

Y-branch distribution joint

Ball valve for service

2.30

2.80

3.20

Equivalent length conversion not needed.

Equivalent length conversion not needed.

Table 1-6 Required Copper Tubing Dimensions

Material

Outer diameter

Copper tubing

Wall thickness

6.35

0.8

9.52

0.8

O

12.7

0.8

Unit: mm

15.88

1.0

19.05

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

φ

6.35

φ

9.52

Amount of refrigerant charge/m (g/m)

26

56

Required amount of charge = (Amount of refrigerant charge per meter of each size of liquid tube

× its tube length) + (...) + (...)

*Always charge accurately using a scale for weighing.

Table 1-8 Refrigerant Charge Amount at Shipment (for outdoor unit)

Heat pump unit

(kg)

Cooling only unit

(kg)

SPW-CR365GXH56

3.5

SPW-CR365GX56

3.5

SPW-CR485GXH56

3.5

SPW-CR485GX56

3.5

SPW-CR605GXH56

3.5

SPW-CR605GX56

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

6

485

8

50 130%

605

9

9

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.

LA

Main tube of unit

1st branch

Unit distribution tube

L3

1

LB

2

LC

L1

L2

3

LD n

n-1

H2

H1

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

Allowable tubing length

Allowable elevation difference

Marks

L1

L (L2 – L3)

1

,

2

~ n

1

+

2

+~ n–1

+L1

H1

H2

Contents

Max. tubing length

Actual length

Equivalent length

Difference between max. length and min.

length from the No.1 distribution joint

Max. length of each distribution tube

Total max. tubing length including length of each distribution tube (only narrow tubing)

When outdoor unit is installed higher than indoor unit

When outdoor unit is installed lower than indoor unit

Max. difference between indoor units

Length (m)

>

150

>

175

>

>

>

>

>

>

40

30

200

50

40

15

L = Length, H = Height

10

05-194 5/27/05 5:06 PM Page 11

WARNING

Always check the gas density limit for the room in which the unit is installed.

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.

(Total refrigerant charged amount: kg)

(Min. indoor volume where the indoor unit is installed: m 3 )

Limit density 0.3 (kg/m

3

)

The limit density of refrigerant which is used in this unit is 0.3 kg/m

3

(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.

1-11. Installing Distribution Joint

(1) Refer to “HOW TO ATTACH DISTRIBUTION

JOINT” enclosed with the optional distribution joint kit (APR-RP160AG).

(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.

(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.)

Minimum indoor volume & floor area as against the amount of refrigerant is roughly as given in the following table.

m

2

100

95

90

85

80

75

70

65

60

55

50

45

40

35

30

25

20

15 m

3

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/m

3

(Countermeasures not needed)

Range above the density limit of

0.3 kg/m 3

(Countermeasures needed)

20 30 40 50 60 70 80 kg

Total amount of refrigerant

Tube branching methods (horizontal use)

°

15 to 30

B

B

A

Horizontal line

A

View as seen from arrow

Arrow view

Types of vertical trap specifications

(When using ball valve)

Main tubing

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

Branch tubing is directed upward.

More than

20 cm

(Each unit is connected to tubing that is either level or is directed downward.)

Indoor unit is directed downward

11

05-194 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.)

• 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.

Gas tube

210 55

HG

F F

145

F

F

G

H

F

F

GH

J I

H

Liquid tube

185 50

H

I J

135

H

I

J

Insulator

Table 1-12 Dimension for Connections of Each Part

Position A B C D

Dimension – – – –

E

Insulator

F

φ

19.05

G

φ

15.88

H

φ

12.7

I

φ

9.52

Unit: mm

J

φ

6.35

1-13. Optional Ball Valve Kit

Table 1-13

Model No.

BV-RXP160AG

BV-RXP56AG

Valve connecting tube size (mm)

Gas tube

15.88

12.7

Liquid tube

9.52

6.35

Indoor unit where used

Total capacity of indoor units after the valve

16.0 kW or less

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

Type with flare nut at each end

A

Figure

E

D

Dimensions

Size

ø6.35 (1/4")

ø9.52 (3/8")

ø12.7 (1/2")

ø15.88 (5/8")

A

72

76

89

108

B

42

42

42

51

C

54

54

58

68

D

16

16

20

22

Unit: mm

E

44

44

51

56

Insulator

(divided in 2)

30˚

Service port

Note: Install the service port so that it faces the extension side.

12

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

BV-RXP56AG

BV-RXP160AG

Size

φ

6.35 •

φ

12.7

φ

9.52 •

φ

15.88

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

φφ

7.94. The face-to-face distance between the

φφ

12.7 or

φφ

15.88 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

2. Flare nut tightening

The flare nut on the service port side is fully tightened. Recommended tightening torque is

(8~10 N·m).

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.

Indoor unit extension

Valve cap

Tightening torque (19~21 N

• m)

Fully tightened (this side only)

Service port

Plug

• 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

Spindle

Valve closed

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.

Insulator

Notch

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

Main tube

Distribution tube

Ball valve (for extension)

Main tube

Distribution tube

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 refrigerant charge (kg)

= [56

×

(a) + 26

×

(b)]

×

10

–3

(a): Liquid tubing Total length of

φ

9.52 (m) (b): Liquid tubing Total length of

φ

6.35 (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.

Tightening torque for valve stem cap: 19~21 N·m

4

Tightening torque: 34~42 N·m

3

1 Tightening torque: 68~82 N·m

2

Tightening torque for valve stem cap: 28~32 N·m

CAUTION

1. R410A additional charging absolutely must be done through liquid charging.

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

05-194 5/27/05 5:06 PM Page 16

Example:

LA

LC

L1

L2

LN

Main tube of unit

LB n

1st branch

Unit distribution tube

1

2 3 n–1 model 74 model 94 model 124 model 164

Example of each tubing length

Main tubing Distribution joint tubing

LA = 40 m Indoor side

LB = 5 m

LC = 5 m

LD = 15 m

1 = 5 m

2 = 5 m

3 = 2 m

4 = 6 m

5 = 5 m model 184

Obtain charge amount for each tubing size

Note that the charge amounts per 1 meter are different for each liquid tubing size.

φ

9.52

LA + LB + LC + LD : 65 m

×

0.056 kg/m = 3.64 kg

φ

6.35

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

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 m 2

× ceiling height 2.7 m = room volume

20.06 m 3 ), the graph at right shows that the minimum room volume should be 14.1 m 3 (floor area 5.2 m 2 ) for refrigerant of 4.238 kg. Accordingly, openings such as louvers are required for this room.

<Determination by calculation>

Overall refrigerant charge amount for the air conditioner: kg

(Minimum room volume for indoor unit: m

3

)

=

4.238 (kg) + 3.5 (kg)

20.06 (m

3

)

= 0.39 (kg/m

3

)

0.3 (kg/m

3

)

Therefore, openings such as louvers are required for this room.

m 3

108.0

94.5

81.0

67.5

54.0

40.5

27.0

13.5

0 m

2

40

35

30

25

20

15

Range below the density limit of 0.3 kg/m

3

(countermeasures not needed)

10

5

0

Range above the density limit of 0.3 kg/m

3

(countermeasures needed)

10 20 30

Total amount of refrigerant kg

16

05-194 5/27/05 5:06 PM Page 17

2. SELECTING THE INSTALLATION SITE

2-1. Indoor Unit

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.

● 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.

● locations where high-frequency emissions are generated.

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.

● 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.

NOTE

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).

Floor-Standing, Concealed Floor-Standing Type

min.

10 cm min.

10 cm min. 100 cm min. 100 cm

Wall min. 25 cm

Front view

min. 25 cm

NOTE

The rear of the indoor unit can be installed flush against the wall.

Air discharge

1m

Ceiling-Mounted Type

Ceiling min. 50 cm

Side view

Fig. 2-1

Max. 25 cm

Obstacle

Concealed-Duct Type

1m

Fig. 2-2

1-Way Semi-Concealed & Slim Type

Semi-Concealed Type Semi-Concealed Slim Type

Ceiling min. 5 cm

Wall

100 cm

Obstacle

Air discharge

Air intake min. 5 cm

Side view

Wall

20 cm

Fig. 2-3

Wall-Mounted Type

100

cm

20 cm

20 cm min.

15 cm

1m

Air intake

1m

1m min.15 cm min.

15 cm

Horizontal view

Fig. 2-4

Vertical view

Front View

Fig. 2-5

17

05-194 5/27/05 5:06 PM Page 18

2-2. Outdoor Unit

AVOID:

● heat sources, exhaust fans, etc. (Fig. 2-6)

● damp, humid or uneven locations

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.

Installation space

Distance between obstructions and the unit air inlet and outlet must be as shown below.

Hot air

Outdoor unit

Exhaust fan

Fig. 2-6

Heat source

(Obstruction above unit)

*3

Inlet side C

Air direction chamber

(field supply)

More than 1 cm

*2

More than 1 cm

*4

A

B

Outlet side

More than

100 cm

*1

Fig. 2-7

*1

Fig. 2-8

Inlet side

More than 20 cm

(Obstruction on inlet side)

(Ground)

CAUTION

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.

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)

● use lug bolts or equal to bolt down unit, reducing vibration and noise.

Anchor bolts

(4 pieces)

Fig. 2-9

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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.

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.

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.

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.

(3) The platform foundation must be firm and the unit must be secured with anchor bolts.

(4) In case of installation on a roof subject to strong wind, countermeasures must be taken to prevent the unit from being blown over.

Without snowproof ducting

(Low platform)

With snowproof ducting

(High platform)

Fig. 2-11

Outdoor

Unit

Air discharge

Fig. 2-10

In regions with significant snowfall, the outdoor unit should be provided with a platform and snow-proof duct.

Duct

19

Air

Intake

Fig. 2-12

05-194 5/27/05 5:06 PM Page 20

2-6. Dimensions of Air-Discharge Chamber

Reference diagram for air-discharge chamber (field supply)

STK-DRE140A for SPW-CR365/485/605GX(H)56

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

2

29.5

240

1

4

3

Rectangular hole

240 29.5

Rectangular hole

Rectangular hole

25

569

544 25

2-7. Dimensions of Outdoor Unit with Air-Discharge Chamber (field supply)

SPW-CR365/485/605GX(H)56 with STK-DRE140A

170 660

13

Wind direction

13

110

Wind direction

13

300

Wind direction

68 544

940

Rectangular hole

Unit: mm

Wind direction

Wind direction

Wind direction

Wind direction

Wind direction

Unit: mm

20

05-194 5/27/05 5:06 PM Page 21

Reference for air-discharge chamber (field supply)

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.

(1) Single-unit installation

CAUTION

The top and both sides must remain open.

If there are obstacles to the front and rear of the outdoor unit, the obstacle at either the front or rear must be no taller than the height of the outdoor unit.

Unit: mm

(2) Multiple-unit installation

Installation in lateral rows

More than 300

More than 200

More than 300

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

More than 400

More than 1500

Installation with intakes facing outlets

More than 2000

CAUTION

The front and both sides must remain open.

21

Unit: mm

05-194 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

3

645

444

95 500

4

1

Unit: mm

101

302

2

Fastened by screws at

3 locations (also on reverse side)

Fastened by screw at

1 location (also on reverse side)

388

41

Un it a

(7 nch or h

– ø

7 h ole ole

)

730

778

2-9. Dimensions of Outdoor Unit with Snow-Proof Vents (field supply)

SPW-CR365/485/605GX(H)56 with STK-BDR140U

764

Wind direction

179

Wind direction

16

Wind direction Wind direction

632

940

Wind direction

Unit: mm

302

Wind direction

22

46

05-194 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]

Top is open:

(1) Single-unit installation (2) Obstacles on both sides

[Obstacle to the front of unit]

Top is open:

(1) Single-unit installation

Min. B

Min. C

(2) Multiple-unit installation (2 or more units)

(3) Multiple-unit installation (2 or more units)

Min. I Min. I

Outdoor unit

SPW-CR365 / 485 / 605GX(H)56

H I J

500 300 1000

Min. E

Min. F

Min. E Min. E

Outdoor unit

SPW-CR365 / 485 / 605GX(H)56

A B

150 150

C

300

D

200

E F G

300 150 200

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:

Top is blocked by an obstacle:

Min. M

Min. L

Outdoor unit

SPW-CR365 / 485 / 605GX(H)56

K L

500 150

Outdoor unit M N

SPW-CR365 / 485 / 605GX(H)56 1000 1000

Unit: mm

23

05-194 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.

(1) Single-unit installation

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

SPW-CR365 / 485 / 605GX(H)56

O P

1000 150

(2) Obstacles on both sides

Min. 300 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.

Min. 300

0

Min. 1000 Min. 1500 Min. 2000 Min. 200

Unit: mm

Dimension Q

If a snow protection duct is attached after the unit is installed, verify that dimension

Q is 500 mm or more.

24

05-194 5/27/05 5:06 PM Page 25

3. HOW TO INSTALL THE OUTDOOR UNIT

3-1. Installing the Outdoor Unit

Use concrete or a similar material to create the base, and ensure good drainage.

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)

3-2. Drainage Work

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).

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.)

(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.

(2) If the routing direction is down, use a nipper or similar tool to cut out the lower flange from cover A.

Drain port

Drain port (2 locations)

171

219

660

150

13 13

111

13

942

13

Fig. 3-1

Inter-unit control wiring outlet

Inspection panel

Anchor bolt (M10)

Rear

Cover A

Front

Power wiring outlet

Down

Cover B

Right

Tubing outlet

Fig. 3-2

CAUTION

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.

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.

(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.

(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.

(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.

(7) Regulations on wire diameters differ from locality to locality. For field wiring rules, please refer to your LOCAL ELECTRICAL CODES before beginning.

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:

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.

4-2. Recommended Wire Length and Wire Diameter for Power Supply System

Outdoor unit

SPW-CR365GX(H)56

SPW-CR485GX(H)56

SPW-CR605GX(H)56

(A) Power supply

Wire size Max. length

4 mm

6 mm

6 mm

2

2

2

16 m

24 m

20 m

Time delay fuse or circuit capacity

25 A

35 A

35 A

Indoor unit

Type

K

AS, SL, S, X, T, U, F, FM

D

(B) Power supply

2.5 mm

2

Time delay fuse or circuit capacity

Max. 150 m

Max. 130 m

Max. 60 m

10 ~ 16A

10 ~ 16A

10 ~ 16A

Control wiring

(C) Inter-unit (between outdoor and

indoor units) control wiring

0.75 mm 2 (AWG #18)

Use shielded wiring*

Max. 1,000 m

NOTE

* With ring-type wire terminal.

(D) Remote control wiring

0.75 mm

2

(AWG #18)

Use shielded wiring

Max. 500 m

26

(E) Control wiring for group control

0.75 mm 2 (AWG #18)

Use shielded wiring

Max. 500 m (Total)

05-194 5/27/05 5:06 PM Page 27

4-3. Wiring System Diagram

Power supply

220-240V 50Hz

L

N

Remote controller

WHT

BLK

1

2

1

2

Ground

Power supply

220-240V 50Hz

L

N

Remote controller

WHT

BLK

1

2

1

2

Ground

Group control:

Power supply

220-240V 50Hz

L

N

Ground

D

D

B

E

B

Indoor unit (No. 1)

1

2

3

U1

U2

1

2

B

C

Indoor unit (No. 2)

1

2

3

U1

U2

1

2

C

Indoor unit (No. 3)

1

2

3

U1

U2

1

2

C

Ground

Ground

Ground

Ground

F

Ground

C

Power supply

220-240V 50Hz

L

N

Ground

Remote controller

WHT

BLK

1

2

1

2

D

B

Indoor unit (No. n)

1

2

3

U1

U2

1

2

Ground

Outdoor unit

INV unit

U1

U2

3

4

3

4

1

2

5

A

Inter-outdoor-unit control wiring

Outdoor unit

CS unit

3

4

3

4

1

2

5

A

L1

L2

L3

N

Ground

Power supply

380-415V-3N 50Hz

L1

L2

L3

N

Ground

Power supply

380-415V-3N 50Hz

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.

(3) Refrigerant Circuit (R.C.) address should be set before turning the power on.

(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(L) 2(N)

Power supply

U1

U2

Inter-unit control wiring

R1 R2

Remote controller

S, X, T Type

8P terminal board

1 2 U1 U2 R1 R2

1(L)2(N)

Power supply

R1 R2

Remote

U1 U2

Inter-unit controller control wiring

AS, LD, U,

D, F, FM Type

5P terminal board

1 2

1(L)2(N)

Power supply

3 4 5

4 5

Inter-unit control wiring

K Type

27

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.

NO

Indoor unit Outdoor unit

NO

Indoor unit

Indoor unit Indoor unit

Branch point

Fig. 4-2

Outdoor unit

Indoor unit

Indoor unit

Indoor unit

(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 Outdoor unit Outdoor unit

Indoor unit Indoor unit more than 1 m

Branch point

16 or fewer

Indoor unit more than 1 m

Indoor unit

Indoor unit less than 1 m

Indoor unit

Fig. 4-3

28

Indoor unit Indoor unit

Indoor unit Indoor unit

05-194 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

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.

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

(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)

(2) Using a Phillips head screwdriver, remove the terminal screw(s) on the terminal plate.

(3) Using a ring connector fastener or pliers, securely clamp each stripped wire end with a ring pressure terminal.

(4) Place the ring pressure terminal, and replace and tighten the removed terminal screw using a screwdriver. (Fig. 4-6)

Ground

Shielded wire

Ground

Fig. 4-4

Stranded wire

Fig. 4-5

Special washer

Wire

Screw

Ring pressure terminal

Terminal plate

Wire

Fig. 4-6

Ring pressure terminal

Screw and

Special washer

Ring pressure terminal

29

05-194 5/27/05 5:06 PM Page 30

5. HOW TO PROCESS TUBING

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.

(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)

NOTE

When reaming, hold the tube end downward and be sure that no copper scraps fall into the tube. (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)

(*Use “RIGID ® ” or equivalent.)

NOTE

A good flare should have the following characteristics:

● inside surface is glossy and smooth edge is smooth tapered sides are of uniform length

Before

Deburring

After

Fig. 5-1

Copper tubing

Reamer

Fig. 5-2

Flare tool

Fig. 5-3

Flare nut

Copper tubing

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.

(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)

(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)

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.

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.)

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.

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:

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.

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.

Indoor unit

Apply refrigerant lubricant here and here

Fig. 5-4

Union

Fig. 5-5

Flare nut

Torque wrench

Spanner

Outdoor unit

Fig. 5-6

31

Tube diameter

φ

6.35 (1/4")

φ

9.52 (3/8")

φ

12.7 (1/2")

φ

15.88 (5/8")

φ

19.05 (3/4")

Tightening torque, approximate

14 – 18 N

·

m

(140 – 180 kgf

·

cm)

34 – 42 N

·

m

(340 – 420 kgf

·

cm)

49 – 61 N

·

m

(490 – 610 kgf

·

cm)

68 – 82 N · m

(680 – 820 kgf

·

cm)

100 – 120 N

·

m

(1000 – 1200 kgf

·

cm)

Tube thickness

0.8 mm

0.8 mm

0.8 mm

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.

● 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

Tubing Insulation

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

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

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 material

The material used for insulation must have good insulation characteristics, be easy to use, be age resistant, and must not easily absorb moisture.

CAUTION

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.

Two tubes arranged together

Liquid tubing

Insulation

Gas tubing

Sealer (supplied)

Insulation tape (white)

(supplied)

Flare insulator (supplied)

Unit side insulator

Tube insulator

(not supplied)

Heat resistant

120

°

C or above

Flare nut

Vinyl clamps (supplied)

Fig. 5-8

Drain insulator and clamp.

Large

(supplied)

Refrigerant tubing and insulator

(not supplied)

Drain pipe and insulator

(not supplied)

Packing clamp.

Small hose band

(supplied)

Seal

Insulation tape

Vinyl

Flare insulator clamp

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.

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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.

(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.

(3) Clamp the tubing bundle to the wall, using 1 clamp approx. each meter. (Fig. 5-10)

NOTE

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.

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)

Clamp

Insulated tubes Drain hose

Fig. 5-10

Apply putty here

Tubing

Fig. 5-11

33

05-194 5/27/05 5:06 PM Page 34

6. AIR PURGING

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

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.

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.

C

Leak test

(1) Attach a manifold valve (with pressure gauges) and dry nitrogen gas cylinder to this service port with charge hoses.

CAUTION

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.

(2) Pressurize the system to no more than 36 kgf/cm

2

G with dry nitrogen gas and close the cylinder valve when the gauge reading reaches 36 kgf/cm

2

G.

Then, test for leaks with liquid soap.

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.)

Pressure gauge

Gas tube

Liquid tube

Manifold gauge

Fig. 6-1

Vacuum pump

Outlet

Inlet

Fig. 6-2

Manifold valve

Lo Hi

Cylinder valve

Open

Open

Charge hose

Close

Outdoor unit

Close

Fig. 6-3

Nitrogen gas cylinder

(In vertical standing position)

Service port ø7.94 mm

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.

(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.

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:

Required time for evacuation when 30 gal/h vacuum pump is used

If tubing length is less than 15 m

45 min. or more

If tubing length is longer than 15 m

90 min. or more

NOTE

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).

(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.

Pressure gauge

Manifold valve

Lo Hi

Gas tube

Liquid tube

Vacuum pump

Service port ø7.94 mm

Open

Close

Outdoor unit

Open

Fig. 6-4

Close

C

35

05-194 5/27/05 5:06 PM Page 36

C

CAUTION

Use a cylinder designed for use with R410A respectively.

Charging additional refrigerant

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)

Finishing the job

(1) With a hex wrench, turn the liquid tube service valve stem counter-clockwise to fully open the valve.

(2) Turn the gas tube service valve stem counterclockwise to fully open the valve.

CAUTION

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).

(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.

(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.

(5) Replace the valve caps at both gas tube and liquid tube service valves and fasten them securely.

This completes air purging with a vacuum pump. The air conditioner is now ready for a test run.

Pressure gauge

Gas tube

Gas tube

Liquid tube

Manifold valve

Lo Hi

Close

Open

Fig. 6-5

Open

Liquid

R410A

Close

Outdoor unit

Close

Valve

Open

Outdoor unit

Close

Liquid tube

Open

Fig. 6-6

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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.

(1) All loose matter is removed from the cabinet, especially steel filings, bits of wire, and clips.

(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.

(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)

(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.

ON

(Power must be turned ON at least 5 hours before attempting test run)

Power mains switch

Fig. 7-1

Liquid tube service cap

Fig. 7-2

Gas tube service cap

37

05-194 5/27/05 5:06 PM Page 38

7-2. Test Run Procedure

<Outdoor unit control PCB>

Unit No. setting switch

(S004)

Recheck the items to check before the test run.

Have the outdoor sub units been connected?

YES

Set the unit address.

Set the No. of outdoor units.

Set the No. of indoor units.

*1

NO

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.

2. Turn the outdoor service valves (2 locations) to the full-open positions.

*1

The unit with the unit

No. set to 1 is the main unit. All other units are sub units.

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.

(Check the link wiring.)

<Outdoor unit control PCB>

Unit No. setting switch

(S002 and S003)

Refer to Fig. 10-4

Are the inter-unit control wires connected to more than 1 refrigerant system?

YES

Set the system address.

NO

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.

CASE 1

NO

CASE 3B

Is it OK to start the compressors?

Is it possible to turn ON the power only for the 1 refrigerant system where the test run will be performed?

NO

Will automatic address setting be performed in Heating mode?

YES

CASE 3A

Is it OK to start the compressors?

YES

CASE 2

Turn ON the indoor and outdoor unit power for that refrigerant system only.

Make necessary corrections.

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

Check the alarm contents.

LED 1 and 2 blink alternately

(about 2 or 3 minutes).

Turn ON the indoor and outdoor unit power.

*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

Start indoor and outdoor unit cooling operation.

LED 1 and 2 blink alternately.

Turn ON the indoor and outdoor unit power.

*2

Short-circuit the automatic address pin (CN51) on the outdoor unit PCB for 1 second or longer, then release it.

*3

Start indoor and outdoor unit heating operation.

LED 1 and 2 blink alternately.

NO

NO

Make necessary corrections

Turn OFF the indoor and outdoor unit

Refer to “Table of

Self-Diagnostic Functions and

Description of Alarm Displays.”

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.

Are LEDs 1 and 2 on the outdoor unit PCB OFF?

YES

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.

Does system operate?

NO

YES

Return remote control to normal mode

End test run.

Check and make corrections according to

“Table of Self-Diagnostic Functions.”

Fig. 7-3

38

05-194 5/27/05 5:06 PM Page 39

7-3. Outdoor Unit PCB Setting

CN33

S003

S002

S004

Fig. 7-4

39

CN51

CN50

D043

(LED2)

D042

(LED1)

05-194 5/27/05 5:06 PM Page 40

Examples of the No. of indoor units settings

No. of indoor units

1 unit (factory setting)

2 units

Indoor unit setting (S004)

(Rotary switch, red)

1

Set to 1

2

Set to 2

9 units 9 Set to 9

Examples of refrigerant circuit (R.C.) address settings (required when link wiring is used)

System address No.

System 1 (factory setting)

System 11

System 21

System 30

System address (S003)

(2P DIP switch, blue)

10 20

ON

ON

Both OFF

1

2 OFF

ON

ON

1 ON

1 2

ON

OFF

ON

2 ON

1

ON

2

OFF

ON

1 & 2 ON

1

2

OFF

System address (S002)

(Rotary switch, black)

0

1

1

1

Set to 1

Set to 1

Set to 1

Set to 0

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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

System address

(system 1 setting)

(S003)

ON ON

(S002)

1

1 2

OFF

(S004)

No. of indoor units

(8 units setting)

(S004)

8

Outdoor Unit

Unit

No. 1

Inter-unit control wiring

Indoor Unit

1-1 1-2 1-3

Remote controller cross-over wiring

1-8

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.”

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05-194 5/27/05 5:06 PM Page 42

Basic wiring diagram: Example (2)

¥ If link wiring is used

* 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 .

No. 1 unit settings

System address

(system 1 setting)

(S003)

ON

ON

(S002)

1

1 2

OFF

No. of indoor units

(6 units setting)

(S004)

Outdoor unit system 1

Unit

No. 1

Leave the socket that is used to short-circuit the terminal plug.

(CN33)

Inter-unit control wiring

1-3

Remote controller communication wiring

Indoor unit

Remote controller

1-1 1-2

No. 2 unit settings

System address

(system 2 setting)

(S002)

2

(S003)

ON

ON

1 2

OFF

No. of indoor units

(7 units setting)

(S004)

7

1-6

Outdoor unit system 2

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

Remote controller

2-2

Remote controller cross-over wiring

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

Automatic address setting in Cooling mode

Case 2

Case 3

Fig. 7- 6

2-7

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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

DIP switch (S003) is set to “0.”

ON

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 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.”

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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 button at the same time. (Press and hold for 4 seconds or longer.)

Next, press either the temperature setting

(Check that the item code is “A1.”) or button.

Use either the or form automatic address setting.

Then press the button. button to set the system No. to per-

(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.

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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

LED 2

: OFF)

Display meaning

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

Simultaneous

Automatic address setting is in progress.

Automatic address setting completed.

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.

Alternating

Refer to Table of Self-Diagnostic Functions and Description of Alarm Displays.

Note: 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

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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.

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 button again and check the address of each indoor unit in sequence.

6. Press the 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.)

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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.

CAUTION

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.

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.

( : Blinking)

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.

Error in transmitting serial communication signal.

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 remote controller.

Indoor unit address setting is duplicated.

During auto. address setting, number of connected units does not correspond to number set.

When turning on the power supply, number of connected units does not correspond to number set.

(Except R.C. address is “0.”)

Remote controller address connector (RCU. ADR) is duplicated.

(Duplication of main remote controller)

Starting auto. address setting is prohibited.

This alarm message shows that the auto address connector CN100 is shorted while other RC line is executing auto address operation.

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.

Main outdoor unit is detecting error signal from sub outdoor unit.

Indoor unit communication error of group control wiring.

Error of outdoor unit address setting.

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.

Alarm message

<E01>

<E02>

<<E03>>

E04

<E06>

E08

<<E09>>

E12

E15

E16

E20

E24

E25

E26

E29

E18

Continued

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05-194 5/27/05 5:06 PM Page 49

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.

There are 2 or more indoor units controllers which have operation mode priority in 1refrigerant circuit.

Priority set remote controller

Non-priority set remote controller

Group control wiring is connected to individual control indoor unit.

Indoor unit address is not set.

Capacity code of indoor unit is not set.

Capacity code of outdoor unit is not set.

Activation of protective device

Protective device in indoor unit is activated.

Mis-matched connection of outdoor units which have different kinds of refrigerant.

4-way valve operation failure

Thermal protector in indoor unit fan motor is activated.

Improper wiring connections of ceiling panel.

Float switch is activated.

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.)

Incorrect discharge temperature. (Comp. No. 1)

High pressure switch is activated.

Negative (Defective) phase.

Incorrect discharge temperature. (Comp. No. 2)

Outdoor unit fan motor is unusual.

Thermistor fault

Indoor thermistor is either open or damaged.

Outdoor thermistor is either open or damaged.

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.

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.)

IPM trip (IPM current or temperature)

Inverter for compressor is unusual. (DC compressor does not operate.)

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)

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)

EEPROM on indoor unit PCB failure

Protective device for compressor is activated

Protective device for compressor

No. 1 is activated.

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.

Discharge gas temperature of the comp. No. 1 is not detected.

Temp. sensor is not seated at the sensor holder.

Protective device for compressor

No. 2 is activated.

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.

Low oil level.

Oil sensor fault.

(Disconnection, etc.)

Comp. No. 1 oil sensor

Comp. No. 2 oil sensor

Alarm message

L02

<L03>

L04

L05

L06

L07

L08

<<L09>>

L10

L17

L18

<<P01>>

<<P09>>

<<P10>>

P02

P03

P04

P05

P17

P22

P16

P26

H31

P29

<<F01>>

<<F02>>

<<F03>>

<<F10>>

<<F11>>

F04

F05

F06

F07

F08

F12

F16

F23

F24

F29

F31

H01

H02

H03

H05

H11

H12

H13

H15

H06

H07

H08

H27

49

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