Daikin RXYN10AY1 Installation manuals

INSTALLATION MANUAL

System air conditioner

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RXYN10AY1

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DAIKIN.TCF.024C19/07-2008

TÜV Rheinland EPS B.V.

0510260101

Umeda Center Bldg., 2-4-12, Nakazaki-Nishi,

Kita-ku, Osaka, 530-8323 Japan

Low Voltage 2006/95/EC

Machinery Safety 98/37/EC

Electromagnetic Compatibility 2004/108/EC

Noboru Murata

Manager Quality Control Department

1st of October 2008

DAIKIN INDUSTRIES, LTD.

RXYN10AY1

FXSN20AV1, FXSN25AV1, FXSN32AV1, FXSN40AV1, FXSN50AV1, FXSN63AV1, FXSN100AV1

BEVN32AV1, BEVN50AV1, BEVN125AV1

EN60335-2-40,

2P229632-1

RXYN10AY1

VRV System air conditioner

Installation manual

CONTENTS

1. FIRST OF ALL ......................................................................... 1

1-1 Safety precautions ............................................................ 1

2. BEFORE INSTALLATION........................................................2

2-1 About this product ............................................................. 2

2-2 Standard supplied accessories ......................................... 2

2-3 Combination ...................................................................... 2

2-4 Option accessory ..............................................................2

3. SELECTION OF LOCATION ...................................................3

4. HANDING THE UNIT ............................................................... 4

5. PLACING THE UNIT................................................................4

6. REFRIGERANT PIPING .......................................................... 4

6-1 Selection of piping material and

Refrigerant branching kit ................................................... 4

6-2 Installation tools ................................................................ 6

6-3 Protection against contamination when

installing pipes .................................................................. 6

6-4 Pipe connection ................................................................ 6

6-5 Connecting the refrigerant piping ...................................... 6

7. FIELD WIRING ........................................................................ 8

7-1 Wiring Connection Example for Whole System ................8

7-2 Leading wire Procedure .................................................... 8

7-3 Transmission Wiring Connection Procedure.....................9

7-4 Power Wiring Connection Procedure ................................ 9

7-5 Procedure for Wiring Inside Units ................................... 10

8. INSPECTION AND PIPE INSULATION................................. 11

8-1 Testing Instruments ........................................................ 11

8-2 Operation method of shutoff valve .................................. 11

8-3 Operation method of service port.................................... 11

8-4 Air tight test and vacuum drying method......................... 12

8-5 Pipe insulation................................................................. 12

8-6 Checking of device and installation conditions ............... 13

9. PROCEDURE OF ADDING REFRIGERANT CHARGING

AND CHECK OPERATION....................................................13

9-1 Procedure of adding refrigerant charging ....................... 13

9-2 Check operation.............................................................. 14

10. TEST RUN ............................................................................. 14

1. FIRST OF ALL

• This document is an installation manual for the Daikin RXYN10AY1 Series VRV Inverter. Before installing the unit, read this manual thoroughly, and following the instructions contained in it. After installation, do a test run to make sure the unit runs properly, and then explain how to operate and take care of the unit to the customer, using the operation manual.

• Lastly, make sure the customer keeps this manual, along with the operation manual, in a safe place.

•

This manual does not describe how to install the indoor unit. Refer to the installation manual included with the indoor unit for that.

1-1 Safety precautions

Please read these “Safety precautions” carefully before installing air conditioning unit and be sure to install it correctly. After completing installation, conduct a trial operation to check for faults and explain to the customer how to operate the air conditioner and take care of it with the aid of the operation manual. Ask the customer to store the installation manual along with the operation manual for future reference. Meaning of WARNING and CAUTION notices

WAR NING .....Failure to follow these instructions properly may

result in personal injury or loss of life.

CAUTION......Failure to observe these instructions properly

may result in property damage or personal injury, which may be serious depending on the circumstances.

WARNING

• Ask your dealer or qualified personnel to carry out installation work. Do not attempt to install the air conditioner yourself. Improper installation may result in water leakage, electric shocks or fire.

• Install the air conditioner in accordance with the instructions in this installation manual. Improper installation may result in water leakage, electric shocks or fire.

• When installing the unit in a small room, take measures against to keep refrigerant concentration from exceeding allowable safety limits in the event of refrigerant leakage. Contact the place of purchase for more information. Excessive refrigerant in a closed ambient can lead to oxygen deficiency.

• Be sure to use only the specified accessories and parts for installation work. Failure to use the specified parts may result in the unit falling, water leakage, electric shocks or fire.

• Install the air conditioner on a foundation strong enough to withstand the weight of the unit. A foundation of insufficient strength may result in the equipment falling and causing injury.

• Carry out the specified installation work after taking into account strong winds, typhoons or earthquakes. Failure to do so during installation work may result in the unit falling and causing accidents.

• Make sure that a separate power supply circuit is provided for this unit and that all electrical work is carried out by qualified personnel according to local laws and regulations and this installation manual. An insufficient power supply capacity or improper electrical construction may lead to electric shocks or fire.

• Make sure that all wiring is secured, the specified wires are used, and that there is no strain on the terminal connections or wires. Improper connections or securing of wires may result in abnormal heat build-up or fire.

• When wiring the power supply and connecting the remote controller wiring and transmission wiring, position the wires so that the EL.COMPO.BOX 1 lid can be securely fastened. Improper positioning of the EL.COMPO.BOX 1 lid may result in electric shocks, fire or the terminals overheating.

• If refrigerant gas leaks during installation, ventilate the area immediately. Toxic gas may be produced if the refrigerant comes into contact with fire.

• After completing installation, check for refrigerant gas leakage. Toxic gas may be produced if the refrigerant gas leaks into the room and comes into contact with a source of fire, such as a fan heater, stove or cooker.

• Do not directly touch refrigerant that has leaked from refrigerant pipes or other areas, as there is a danger of frostbite.

• Be sure to switch off the unit before touching any electrical parts.

• Do not allow children to climb on the outdoor unit and avoid placing objects on the unit. Injury may result if the unit becomes loose and falls.

• Be sure to earth the air conditioner. Do not earth the unit to a utility pipe, lightning conductor or telephone earth lead. Imperfect earthing may result in electric shocks or fire. A high surge current from lightning or other sources may cause damage to the air conditioner.

• Be sure to install an earth leakage breaker. Failure to install an earth leakage breaker may result in electric shocks or fire.

English 1

CAUTION

• While following the instructions in this installation manual, install drain piping to ensure proper drainage and insulate piping to prevent condensation. Improper drain piping may result in indoor water leakage and property damage.

• Install the indoor and outdoor units, power cord and connecting wires at least 1 meter away from televisions or radios to prevent picture interference and noise. (Depending on the incoming signal strength, a distance of 1 meter may not be sufficient to eliminate noise.)

•

Remote controller (wireless kit) transmitting distance can be shorter than expected in rooms with electronic fluorescent lamps (inverter or rapid start types). Install the indoor unit as far away from fluorescent lamps as possible.

• Make sure to provide for adequate measures in order to prevent that the outdoor unit be used as a shelter by small animals. Small animals making contact with electrical parts can cause malfunctions, smoke or fire. Please instruct the customer to keep the area around the unit clean.

• Do not install the air conditioner in the following locations:

1. Where there is a high concentration of mineral oil spray or

vapour (e.g. a kitchen). Plastic parts will deteriorate, parts may fall off and water leakage could result.

2. Where corrosive gas, such as sulphurous acid gas, is pro-

duced. Corroding of copper pipes or soldered parts may result in refrigerant leakage.

3. Near machinery emitting electromagnetic radiation.

Electromagnetic radiation may disturb the operation of the control system and result in a malfunction of the unit.

4. Where flammable gas may leak, where there is carbon fibre or

ignitable dust suspensions in the air, or where volatile flammables such as paint thinner or gasoline are handled. Operating the unit in such conditions may result in fire.

CAUTION

• When installing the indoor unit, refer to the installation manual provided for the indoor unit.

• Optional accessories are required for the installation of the product. Refer to the information on optional accessory.

2-2 Standard supplied accessories

The following accessories are included. The storage location of the accessories is shown in the figure.

Note

Do not throw away any of the accessories until installation is complete.

Gas side

accessory

pipe (2)

Name Clamp (1) Clamp (2) Clamp (3)

Quantity

Shape

Name

Quantity

Shape

8 pcs. 2 pcs. 1 pc. 1 pc. 1 pc.

Small Large Thick

Liquid side

accessory

pipe (1)

1 pc. 1 pc. 1 pc.

Liquid side

accessory

pipe (2)

Thin

Gas side

accessory

pipe (1)

Muffler

2. BEFORE INSTALLATION

2-1 About this product

This product uses R744 (CO2) refrigerant. The utmost attention is required to handle R744 refrigerant, and strict measures must be taken to keep impurities (including mineral oil and other types of oil as well as moisture) out of the system. Be sure to follow the instructions in “6. REFRIGERANT

PIPING”.

The design pressure is 12.3 MPa (4.0 MPa for R410A). Therefore, the following conventional par ts cannot be used.

• Connection pipes Thick-walled pipes are required. Refer to “6. REFRIGERANT PIPING” for the specifications of the pipes.

• Flare nut connections Unavailable. Perform brazing connections.

• Pipe brazing joints

Pipes with a maximum diameter of 12.7mm .....Make brazing

connections with sleeve flare processing.

Pipes with a diameter of 15.9mm ...................... Use sockets

sold as optional accessories.

•Elbows Use products sold as optional accessories.

• Installation instruments that must withstand high pressures, such as charge hoses and pressure gauges Use pressure-resistant instruments that withstand a minimum pressure of 12.3 MPa.

The indoor unit is an R744-dedicated unit. The following indoor unit models are connectable. (Do not connect other indoor unit models, or otherwise an inner piping rupture will result.)

Name Thermal insulation tube Others

Quantity

Shape

1 pc. 1 pc. about each item

• Operation manual

• Installation manual

• Electric wiring diagram booklet

• Declaration of conformity

• “REQUEST FOR THE INDICATION” label (Installation records)

Operation manual Installation manual Clamps

Accessory pipes

2-3 Combination

The indoor units can be installed in the following range.

Indoor unit

Total capacity of indoor units Total quantity of indoor units

125 - 325 16 units

2-4 Option accessory

• The following refrigerant branching kit as an optional accessory is required for piping. Refer to “6. REFRIGERANT PIPING” to select the refrigerant branching kit.

REFNET joint BHRN26A33T

2 English

• The sleeve flare processing of pipes with a diameter of 15.9 mm is difficult. Use the following socket as an optional accessory to connect pipes.

Socket BHFN5A10S Connection with 15.9 dia. in size

Note

Be sure to use piping materials withstanding a pressure of

12.3 MPa.

• Use a different elbow sold as an optional accessory if the bending radius needs to be reduced. This is particularly important for the bending portions of pipes with a diameter of 15.9 mm.

BHFN2A10L Connection with 6.4 dia. in size

Elbow

BHFN3A10L Connection with 9.5 dia. in size

BHFN4A10L Connection with 12.7 dia. in size

BHFN5A10L Connection with 15.9 dia. in size

3. SELECTION OF LOCATION

Select a location for installation that meets the following conditions. Get the customer’s permission.

There is no danger of fire due to leakage of inflammable gas.

Select the location of the unit in such a way that neither the discharged air nor the sound generated by the unit disturb anyone.

The foundation is strong enough to support the weight of the unit and the floor is flat to prevent vibration and noise generation.

The piping length between the outdoor unit and the indoor unit may not exceed the allowable piping length. (Refer to

“6. REFRIGERANT PIPING”)

Locations where the unit’s suction vent and outlet vent do not generally face the wind. Wind blowing directly into the suction or outlet vents will interfere with the unit’s operation. If necessary, install some kind of obstruction to block the wind.

The space around the unit is adequate for servicing and the minimum space for air inlet and air outlet is available. (See the “Installation Space Examples” for the minimum space requirements.)

Installation Space Examples

• The installation space requirement shown in the following figure is a reference for cooling operation when the outdoor temperature is 35°C. If the design outdoor temperature exceeds 35°C or the heat load exceeds maximum capacity in all the outdoor unit, take an even large space on the intake shown in the following figure.

• During installation, install the units using the most appropriate of the patterns shown in the following figure for the location in question, taking into consideration human traffic and wind.

• If the number of units installed is more than that shown in the pattern in the following figure, install the units so there are no short circuits.

• As regards space in front of the unit, consider the space needed for the local refrigerant piping when installing the units.

• If the work conditions in the following figure do not apply, contact your dealer or Daikin directly.

If installed as a single unit

(Pattern 1) NOTE)

≥10 ≥10

Front

side

(Pattern 2) NOTE) (Pattern 2) NOTE)

≥50 ≥50

Front

side

(Pattern 3) (Pattern 3)

No limit to

≥300

wall height

≥200

Front side

When installed in serial

(Pattern 1) NOTE)

≥300

Service space

of suction side

≥10 ≥20

≥500≥100≥500

Service space

of front side

Service space

of suction side

≥50 ≥100

Service space

of front side

≥200 ≥400 ≥400

Front side

≥300

Front side

≥10 ≥20

≥50 ≥100

No limit to wall height

NOTE) For Patterns 1 and 2

• Wall height for front side no higher than 1500 mm.

• Wall height on the suction side no higher than 500 mm.

• Wall height for sides – no limit.

• If the height is exceeded the above, calculate h1 and h2 shown in the figure below, and add h1/2 to the service space of front side and h2/2 to the service space of suction side.

1500

Front side

Suction side

500 h2

Service space

h1 = A (Actual height) – 1500 h2 = B (Actual height) – 500

CAUTION

Remote controller

Indoor unit

Branch switch, overcurrent

COOL/

Branch switch,

≥1500

overcurrent breaker

Personal computer

≥1000

HEAT selector

≥1500

or radio

An inverter air conditioner may cause electronic noise generated

breaker

(mm)

from AM broadcasting. Examine where to install the main air conditioner and electric wires, keeping proper distances away from stereo equipment, personal computers, etc. Particularly for locations with weak reception, ensure there is a distance of at least 3 meters for indoor remote controllers, place power wiring and transmission wiring in conduits, and ground the conduits.

If condensate may drip on downstairs (or walkway) depending on the floor condition, take a measure such as the installation of central drain pan kit (sold separately).

≥300≥500

Service space

of suction side

Service space

of front side

Service space

≥100≥500

Service space

of suction side

of front side

English 3

The refrigerant R744 itself is nontoxic, nonflammable and is safe. If the refrigerant should leak however, its concentration may exceed the allowable limit depending on room size. Due to this it could be necessary to take measures against leakage. See “Engineering Data” for details.

When installing in a locations where there is heavy snowfall, implement the following snow measures.

• Ensure the base is high enough that intakes are not clogged by snow.

• Remove the rear intake grille to prevent snow from accumulating on the fins.

The product cannot be supported with four corners.

≥100

Center of the product

Base form

≥100

4. HANDING THE UNIT

Decide on the transportation route.

If a forklift is to be used, pass the forklift arms through the large openings on the bottom of the unit.

Hole (large)

Transportation

Fork

Fixed screws of transportation clasp

If hanging the unit, use a cloth sling to prevent damaging the unit. Keeping the following points in mind, hang the unit following the procedure shown in the following figure.

• Use a sling sufficiently strong to hold the mass of the unit.

• Use 2 belts of at least 8m long.

• Place extra cloth or boards in the locations where the casing comes in contact with the sling to prevent damage.

•

Hoist the unit making sure it is being lifted at its center of gravity.

Belt sling

clasp (yellow)

Board

Foundation bolt point

930 792

729

765

(Depth of product)

Base width and base bolt positions

Note

• When installing on a roof, make sure the roof floor is strong enough and be sure to water-proof all work.

• Make sure the area around the machine drains properly by setting up drainage grooves around the foundation. Drain water is sometimes discharged from the outdoor unit when it is running.

(φ15 dia. : 4 positions)

631

of the base)

(Inner dimension

of the base)

(Outer dimension

6. REFRIGERANT PIPING

To Piping Work Contractors

Do not use flux at the time of brazing and connecting refrigerant pipes. Use phosphorous copper brazing filler metal (BCuP-2), which does not require flux. Chlorine-based flux causes piping corrosion. Furthermore, if fluoride is contained, the flux will have adverse influences on the refrigerant piping line, such as the deterioration of refrigerating machine oil.

6-1 Selection of piping material and Refrigerant

Hole (small) (Hole 40×30)

After installation, remove the transportation clasp attached to the large openings.

Note

Apply a filler cloth on a fork to prevent coating of the bottom frame from coming off and rust from occurring when bringing in the unit with anti-corrosion treatment type using a forklift.

5. PLACING THE UNIT

• Make sure the unit is installed level on a sufficiently strong base to prevent vibration and noise.

• The base should be bigger around than the width of the unit’s legs (66 mm), and should support the unit. If protective rubber is to be attached, attach it to the whole face of the base.

• The height of the base should be at least 150mm from the floor.

•

Secure the unit to its base using foundation bolts. (Use four commercially available M12-type foundation bolts, nuts, and washers.)

• The foundation bolts should be inserted 20 mm.

4 English

branching kit

• Refer to the following table for pipe size section.

• The following types of refrigerant pipes are available. Material: Phosphorus deoxidized seamless copper pipe (C1220T-

Pipe wall thickness: Product withstanding 12.3 MPa

〈Pipe wall thickness examples〉 (length: mm)

• Use only pipes which are clean inside and outside and which do not accumulate harmful sulfur, oxidants, dirt, cutting oils, moisture, or other contamination. (Foreign materials inside pipes including oils for fabrication must be 30mg/10m or less.)

• For piping work, follow the maximum tolerated length, difference in height, and length after a branch indicated.

• The refrigerant branching kit sold as an optional accessory is required for the branching of piping. Select the kit according to the following “Refrigerant branch kit selection”.

1/2H or C1220T-H)

Pipe size

(Outer diameter)

φ6.4 1/2H 0.8

φ9.5 1/2H 1.0

φ12.7 1/2H 1.3

φ15.9 1/2H 1.8

Material Smallest thickness

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