Mitsubishi Electronics PUHY-HP-THMU-A User Manual

Air-Conditioners For Building Application Hyper Heating Inverter Y-Series OUTDOOR UNIT

For use with R410A

PUHY-HP-THMU-A

INST ALLA TION MANUAL

For safe and correct use, please read this installation manual thoroughly before installing the air-conditioner unit.

MANUEL D’INSTALLATION

Veuillez lire le manuel d’installation en entier avant d’installer ce climatiseur pour éviter tout accident et vous assurer d'une utilisation correcte.

Contents

1. Safety precautions ...................................................................................... 2

1.1. Before installation and electric work .......................................... 2

1.2. Precautions for devices that use R410A refrigerant .................. 2

1.3. Before installation ...................................................................... 3

1.4. Before installation (relocation) - electrical work ......................... 3

1.5. Before starting the test run ........................................................ 3

2. About the product ....................................................................................... 3

3. Combination of outdoor unit........................................................................ 4

4. Specifications.............................................................................................. 4

5. Parts included list........................................................................................ 4

6. Space required for unit installation and operation....................................... 4

7. Transporting the unit ................................................................................... 5

8. Installation of unit ........................................................................................ 6

8.1. Installation ................................................................................. 6

9. Refrigerant piping installation ..................................................................... 6

9.1. Caution ...................................................................................... 6

9.2. Refrigerant piping system.......................................................... 7

1. Safety precautions

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1.1. Before installation and electric work

s Before installing the unit, make sure you read all the “Saf ety

precautions”.

s The “Safety precautions” provide very important points re-

garding safety. Make sure you follow them.

Symbols used in the text

Warning:

Describes precautions that should be observed to prevent danger of injury or death to the user.

Caution:

Describes precautions that should be observed to prevent damage to the unit.

Warning:

Carefully read the labels attached to the outdoor unit.

Warning:

• Ask the dealer or an authorized technician to install the air conditioner.

- Improper installation by the user ma y result in w ater leakage, electric shock, or fire.

• Install the unit at a place that can withstand its weight.

-Failure to do so may cause the unit to fall down, resulting in injuries and damage to the unit.

• Use the specified cables for wiring. Make the connections securely so that the outside force of the cable is not applied to the terminals.

- Inadequate connection and fastening may generate heat and cause a fire.

• Prepare for str ong winds and earthquakes and install the unit at the specified place.

- Improper installation may cause the unit to topple and result in injury and

damage to the unit.

•Always use filters and other accessories specified by Mitsubishi Electric.

- Ask an authorized technician to install the accessories. Improper installation

by the user may result in water leakage, electric shock, or fire.

•Never attempt to repair the unit without the proper qualifications. If the air conditioner must be repaired consult the dealer, contractor or qualified Refrigeration Engineer.

- If the unit is repaired improperly, water leakage, electric shock, or fire may

result.

• Do not touch the heat exchanger fins.

- Improper handling may result in injury.

• If refrigerant gas leaks during installation work, ventilate the room.

- If the refrigerant gas comes into contact with a flame, poisonous gases will

be released.

• Install the air conditioner according to this Installation Manual.

- If the unit is installed improperly, water leakage, electric shock, or fire may

result.

•Have all electric work done by a licensed electrician according to “Electric Facility Engineering Standard” and “Interior Wire Regulations” and the instructions given in this manual and always use a dedicated power supply.

- If the power source capacity is inadequate or electric work is performed im-

properly, electric shock and fire may result.

• Securely install the outdoor unit terminal cover (panel).

- If the terminal cover (panel) is not installed properly, dust or water may enter

the outdoor unit and fire or electric shock may result.

10. Additional refrigerant charge ....................................................................... 9

10.1. Calculation of additional refrigerant charge ............................... 9

10.2. Precautions concerning piping connection and valve

operation ................................................................................. 10

10.3. Airtight test, evacuation, and refrigerant charging ................... 11

10.4. Thermal insulation of refrigerant piping................................... 12

11. Wiring (For details, refer to the installation manual of each indoor/outdoor

unit and controller.)................................................................................... 13

11.1. Caution .................................................................................... 13

11.2. Control box and connecting position of wiring ......................... 13

11.3. Wiring transmission cables ...................................................... 13

11.4. Wiring of main power supply and equipment capacity ............ 16

12. Test run/Typical unit operation .................................................................. 17

13. Rating plate information ............................................................................ 17

• When installing and moving the air conditioner to another site, do not

charge it with a refrigerant different from the refrigerant specified on the unit.

- If a diff erent refrigerant or air is mix ed with the original refrigerant, the refrigerant cycle may malfunction and the unit may be damaged.

• If the air conditioner is installed in a small room, measures must be taken to prevent the refrigerant concentration from exceeding the safety limit if the refrigerant should leak.

- Consult the dealer regarding the appropriate measures to prev ent the saf ety

limit from being exceeded. Should the refrigerant leak and cause the safety limit to be exceeded, hazards due to lack of oxygen in the room could result.

• When moving and reinstalling the air conditioner, consult the dealer or an authorized technician.

- If the air conditioner is installed improperly, water leakage, electric shock, or

fire may result.

• After completing installation work, make sure that refrigerant gas is not leaking.

- If the refrigerant gas leaks and is exposed to a fan heater, stove, oven, or

other heat source, it may generate noxious gases.

• Do not reconstruct or change the settings of the protection devices.

- If the pressure switch, thermal switch, or other protection device is shorted

or operated forcibly, or parts other than those specified by Mitsubishi Electric are used, fire or explosion may result.

•To dispose of this product, consult your dealer.

• The installer and system specialist shall secure safety against leakage according to local regulation or standards.

- Choose the appropriate wire size and the s witch capacities for the main power

supply described in this manual if local regulations are not available.

•Pay special attention to the place of installation, such as a basement, etc. where refrigeration gas can accumulate, since refrigerant is heavier than the air.

• For outdoor units that allow outside air intake to the indoor unit, the installation site must be carefully chosen to ensure only clean air can enter the room.

- Direct exposure to outdoor air may have harmful effects on people or food.

1.2. Precautions for devices that use R410A

refrigerant

Caution:

• Do not use existing refrigerant piping.

- The old refrigerant and refrigerant oil in the existing piping contains a large

amount of chlorine which may cause the refrigerant oil of the new unit to deteriorate.

- R410A is a high-pressure refrigerant and can cause the existing piping to

burst.

• Use refrigerant piping made of phosphorus deoxidized copper and copper alloy seamless pipes and tubes. In addition, be sure that the inner and outer surfaces of the pipes are clean and free of hazardous sulphur , oxides, dust/dirt, shaving particles, oils, moisture, or any other contaminant.

- Contaminants on the inside of the refrigerant piping ma y cause the refriger-

ant oil to deteriorate.

• Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing. (Store elbows and other joints in a plastic bag.)

- If dust, dirt, or water enters the refrigerant cycle, deterioration of the oil and

compressor failure may result.

• Apply onl y a small amount of ester oil, ether oil, or alkyl benzene to flare connections (for indoor unit).

- Infiltration of a large amount of mineral oil may cause the refrigerant oil to

deteriorate.

• Use liquid refrigerant to fill the system.

- If gas refrigerant is used to fill the system, the composition of the refrigerant

in the cylinder will change and performance may drop.

• Do not use a refrigerant other than R410A.

- If another refrigerant (R22, etc.) is mixed with R410A, the chlorine in the

refrigerant may cause the refrigerant oil to deteriorate.

• Use a vacuum pump with a reverse flow check valve.

- The v acuum pump oil may flo w back into the refrigerant cycle and cause the

refrigerant oil to deteriorate.

• Do not use the following tools that are used with conventional refrigerants. (Gauge manifold, charge hose, gas leak detector, reverse flow c heck valve, refrigerant charge base, refrigerant recovery equipment)

- If the conv entional refrigerant and refrigerant oil are mix ed in the R410A, the

refrigerant may deteriorate.

- If water is mixed in the R410A, the refrigerant oil may deteriorate.

- Since R410A does not contain any chlorine, gas leak detectors for conven-

tional refrigerants will not react to it.

• Do not use a charging cylinder.

- Using a charging cylinder may cause the refrigerant to deteriorate.

• Be especially careful when managing the tools.

- If dust, dirt, or water gets into the refrigerant cycle, the refrigerant may dete-

riorate.

1.3. Before installation

Caution:

• Do not install the unit where combustible gas may leak.

- If the gas leaks and accumulates around the unit, an explosion may result.

• Do not use the air conditioner where food, pets, plants, precision instruments, or artwork are kept.

- The quality of the food, etc. may deteriorate.

• Do not use the air conditioner in special environments.

- Oil, steam, sulfuric smoke, etc. can significantly reduce the performance of

the air conditioner or damage its parts.

• When installing the unit in a hospital, communication station, or similar place, provide sufficient protection against noise.

-Inverter equipment, private power generator, high-frequency medical equip-

ment, or radio communication equipment may cause the air conditioner to operate erroneously , or f ail to operate. On the other hand, the air conditioner may affect such equipment by creating noise that disturbs medical treatment or image broadcasting.

• Do not install the unit on or over things that are subject to water dama ge.

- When the room humidity exceeds 80% or when the drain pipe is clogged,

condensation may drip from the indoor unit. P erform collective drainage w ork together with the outdoor unit, as required.

1.4. Before installation (relocation) - electri-

cal work

Caution:

•Ground the unit.

- Do not connect the ground wire to gas or water pipes, lightning rods, or

telephone ground lines. Improper grounding may result in electric shock.

• Install the power cable so that tension is not applied to the cable.

-Tension may cause the cable to break and generate heat and cause a fire.

• Install a leak circuit breaker, as required.

- If a leak circuit breaker is not installed, electric shock may result.

• Use power line cables of sufficient current carrying capacity and rating.

- Cables that are too small may leak, generate heat, and cause a fire.

• Use only a circuit breaker and fuse of the specified capacity.

-A fuse or circuit breaker of a larger capacity, or the use of a substitute simple steel or copper wire may result in a general unit failure or fire.

• Do not wash the air conditioner units.

-Washing them may cause an electric shock.

• Be careful that the installation base is not damaged by long use.

- If the damage is left uncorrected, the unit ma y f all and cause personal injury or property damage.

• Install the drain piping according to this Installation Manual to ensure proper drainage. Wrap thermal insulation around the pipes to prevent condensation.

- Improper drain piping ma y cause water leakage causing damage to furniture

and other possessions.

• Be very careful about transporting the product.

- One person should not carry the product. Its weight is in excess of 20 kg

[45LBS].

- Some products use PP bands f or pac kaging. Do not use any PP bands as a

means of transportation. It is dangerous.

- Do not touch the heat exchanger fins. Doing so may cut your fingers.

- When transporting the outdoor unit, support it at the specified positions on

the unit base. Also support the outdoor unit at four points so that it cannot slip sideways.

• Safely dispose of the packing materials.

-Packing materials, such as nails and other metal or wooden parts, may cause

stabs or other injuries.

-Tear apart and throw away plastic packaging bags so that children will not

play with them. If children play with a plastic bag which has not been torn apart, they face the risk of suffocation.

1.5. Before starting the test run

Caution:

•Turn on the power at least 12 hours before starting operation.

- Starting operation immediately after turning on the main power switch can

result in irreversible damage to internal parts. Keep the power switch turned on during the operational season. Make sure of the phase order of power supply and voltage between each phase.

• Do not touch the switches with wet fingers.

-Touching a switch with wet fingers can result in an electric shock.

• Do not touch the refrigerant pipes during and immediately after operation.

- During and immediately after operation, the refrigerant pipes may be hot or

cold, depending on the condition of the refrigerant flowing through the refrigerant piping, compressor, and other refrigerant cycle parts. Your hands may suffer burns or frostbite if you touch the refrigerant pipes.

• Do not operate the air conditioner with the panels and guards removed.

- Rotating, hot, or high-voltage parts can cause injuries.

• Do not turn off the power immediately after stopping operation.

- Always wait at least 5 minutes before turning off the power. Otherwise,

drainage water leakage or mechanical failure of sensitive parts may occur.

• Do not touch the surface of the compressor during servicing.

- If the unit is connected to a supply and not running, the crank case heater

located at the base of the compressor may still be operating.

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2. About the product

• This unit uses R410A-type refrigerant

• Piping for systems using R410A may be different from that for systems using conventional refrigerant because the design pressure in systems using R410A is higher. Refer to the Data Book for more information.

• Some of the tools and equipment used for installation with systems that use other types of refrigerant cannot be used with the systems using R410A. Refer to the Data Book for more information.

• Do not use the existing piping, as it contains chlorine, which is found in conventional refrigerating machine oil and refrigerant. This chlorine will deteriorate the refrigerant machine oil in the new equipment. The existing piping must not be used as the design pressure in systems using R410A is higher than that in the systems using other types of refrigerant and the existing pipes may burst.

3. Combination of outdoor unit

Component units of PUHY-HP144 to HP192 are listed below.

Outdoor unit model PUHY-HP72THMU-A(-BS) PUHY-HP96THMU-A(-BS) PUHY-HP144TSHMU-A(-BS) PUHY-HP192TSHMU-A(-BS)

* PUHY-HP144/192TSHMU-A(-BS) require “Twinning Kit” to connect component unit modules in the field.

PUHY-HP72THMU-A(-BS) PUHY-HP96THMU-A(-BS)

Component unit models

PUHY-HP72THMU-A(-BS) PUHY-HP96THMU-A(-BS)

4. Specifications

Model Sound level (60Hz) External static pressure

Indoor units

Operation temperature

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*1: The total indoor capacity of units run simultaneously is 130% or less. *2: To enable high static pressure, set the DipSW on the main panel as follows. SW3-9: ON, SW3-10 60Pa compatible: OFF, 30Pa compatible: ON

Total capacity

Model

Quantity

Standard type

Outside air intake type

PUHY-HP72THMU-A

56dB <A>

1 ~ 13 Cooling mode: – 5°CDB ~ 43°CDB [23°FDB ~ 109°FDB] (0°CDB ~ 43°CDB [32°FDB ~ 109°FDB] with outdoor unit at lower position) Heating mode: – 25°CWB ~ 15.5°CWB [–13°FWB ~ 60°FWB] Cooling mode: 21°CDB/15.5°CWB ~ 43°CDB/35°CWB (70°FDB/60°FWB ~ 109°FDB/95°FWB) Heating mode: – 10°CDB ~ 20°CDB [14°FDB ~ 68°FDB]

PUHY-HP96THMU-A

57dB <A>

1 ~ 16

5. Parts included list

Model

P72 P96

1 Connecting pipe (flare)

1 pc.

–

2 Connecting pipe (flange)

–

1 pc.

3 Connecting pipe (flare)

6. Space required for unit installation and operation

1 In case of single installation

• Secure enough space around the unit as shown in the figure below.

[Fig. 6.0.1] (1) If the distance is 300 mm [11-13/16 in] or more between the rear side and

the wall

<A> T op view

300*

[11-13/16]

450*

[17-23/32]

15*15*

[19/32][19/32]

(Unit: mm [in])

(3) If the wall height (H) of the front, rear or side exceeds the wall height

0 Pa*

50 ~ 130%*

06 ~ 96

1 pc. 1 pc.

restriction

<B> Side view

PUHY-HP144TSHMU-A

59dB <A>

1 ~ 22

4 Adapter <Check joint>

2 pcs. 2 pcs.

500

PUHY-HP192TSHMU-A

60dB <A>

1 ~ 24

5 Packing

(Inside ø23, Outside ø30)

–

1 pc.

(Unit: mm [in])

[19-11/16]

(2) If the distance is 100 mm [3-15/16 in] or more between the rear side and

the wall

<A> T op view

100*

[3-15/16]

450*

[17-23/32]

50*50*

[1-31/32][1-31/32]

(Unit: mm [in])

• When the height of the walls on the front, back or on the sides <H> exceeds the wall height limit as defined here, add the height that exceeds the height limit <h> to the figures that are marked with an asterisk (*).

<Wall height limit> Front: Up to the unit height

(4) If there are obstacles at the upper part of the unit

<C> When there is little space up to an obstruction

45°

240

[9-15/32]

A Front B Unit height C Back D Air outlet guide (field-supplied)

Back: Up to 500mm [19-11/16 in] from the unit bottom Side: Up to the unit height

(Unit: mm [in])

1000

[39-3/8]

[1-31/32]

2 In case of collective installation and continuous installation

[Fig. 6.0.2]

(Unit: mm [in])

AAA

[1-3/16]

100

[3-15/16]

300*

450*

450* 100*

15*

100*

[19/32]

[11-13/16][17-23/32]

[3-15/16][17-23/32]

[17-23/32] [17-23/32][17-23/32][3-15/16]

450* 450 450

450 450

[17-23/32] [17-23/32]

300*300*

1000*

[39-3/8]

A Front B Must be open C Wall height (H)

[11-13/16][11-13/16]

900

[35-7/16]

300*

[11-13/16]

900

[35-7/16]

• When multiple units are installed adjacent to each other, secure enough space to allow for air circulation and walkway between groups of units as shown in the figures.

• At least two sides must be left open.

• As with the single installation, add the height that exceeds the height limit <h> to the figures that are marked with an asterisk (*).

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7. Transporting the unit

[Fig. 7.0.1]

[26]

• Use suspension ropes that will withstand the weight of the unit.

• When moving the unit, use a 4-point suspension, and a void giving impacts to the unit (Do not use 2-point suspension).

• Place protective pads on the unit where it comes in contact with the ropes to protect the unit from being scratched.

• Set the angle of roping at 40˚ or less.

• Use 2 ropes that are each longer than 8 m [26ft].

[26]

• Place protective padding at the corners of the product to protect the product from scratches or dents that might be caused by the rope.

Caution:

Be very careful when carrying/moving the product.

- When installing the outdoor unit, suspend the unit at the specified location of the

unit base. Stabilize as necessary so that it does not mov e to the side and support it at 4 points. If the unit is installed or suspended with 3-point support, the unit may become unstable and fall.

(Unit: m [ft])

8. Installation of unit

8.1. Installation

[Fig. 8.1.1]

[1-3/16]

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A Field-supplied M10 anchor bolt B Corner is not seated. C Fixing bracket for the hole-in anchor bolt (3 locations to fix with screws)

[Fig. 8.1.2]

Outlet

InletInlet

• In abnormally harsh environments such as clod and/or windy areas, sufficient countermeasures to guard against excessive wind and snow should be taken to ensure the unit's correct operation. When the unit is expected to operate in cooling mode in conditions under 10°C [50°F], in snowy areas, in environments subject to strong winds or rain, install air inlet and outlet ducting as shown in [Fig. 8.1.2].

Inlet

(Unit: mm [in])

•

Fix unit tightly with bolts so that unit will not fall down due to earthquakes or strong winds.

• Use concrete base or an angle bracket as the foundation of unit.

•

Vibration may be transmitted to the installation section and noise and vibration may be generated from the floor and walls, depending on the installation conditions. Therefore, provide ample vibrationproofing (cushion pads, cushion frame, etc.).

• Be sure that the corners are firmly seated. If the corners are not firmly seated, the installation feet may be bent.

• The projecting length of the anchor bolt should be less than 30 mm [1-3/16 in].

•Post-installed anchor bolts (i.e., bolts not firmly cemented into the base) are not compatible with this product unless fixing brackets are first mounted on the four locations.

Note:

1. Height of frame base for snow damage prev ention (H) shall be twice as high as expected snowfall. Width of frame base shall not exceed that of the unit. The frame base shall be made of angle steel, etc., and designed so that snow and wind slip through the structure. (If frame base is too wide, snow will be accumulated on it.)

Install unit so that wind will not directly lash against openings of inlet and outlet ducts.

3. Build frame base at customer referring to this figure.

Material : Galvanized steel plate 1.2T Painting : Overall painting with polyester powder Color : Munsell 5Y8/1 (same as that of unit)

4. When the unit is used in a cold region and the heating operation is continuously performed for a long time when the outside air temperature is below freezing, install a heater to the unit base or take other appropriate measures to prevent water from freezing on the base.

Warning:

•

Be sure to install unit in a place strong enough to withstand its weight. Any lack of strength may cause unit to fall down, resulting in a personal injury.

•

Have installation work in order to protect against strong winds and earthquakes. Any installation deficiency may cause unit to fall down, resulting in a per sonal injury.

When building the foundation, give full attention to the floor strength, dr ain water disposal <during operation, drain water flows out of the unit>, and piping and wiring routes.

Precautions when routing the pipes and wires below the unit (Without detachable leg)

When routing the pipes and wires below the unit, be sure that the foundation and base work do not block the base through-holes. Also make sure the foundation is at least 100 mm [3-15/16 in] high so that the piping can pass under the unit.

9. Refrigerant piping installation

The pipe is connected via a terminal-branch type connection in which refrigerant piping from the outdoor unit is branched at the terminal and is connected to each of the indoor units. The method of pipe connection is as follows: flare connection for the indoor units, gas pipes for outdoor units, flare connection for P72 and brazed connection for P96 ~ P192; liquid pipes, flare connection. Note that the branched sections are brazed.

Warning:

Always use extreme care to prevent the refrigerant gas from leaking while using fire or flame. If the refrigerant gas comes in to contact with a flame from any source, such as a gas stove, it breaks down and generates a poisonous gas which can cause gas poisoning. Never weld in an unventilated room. Alwa ys conduct an inspection f or gas leaka ge after installation of the refrigerant piping has been completed.

9.1. Caution

This unit uses refrigerant R410A. Follow the local regulations on materials and pipe thickness when selecting pipes. (Refer to the table on page 7.)

1 Use the following materials for refrigeration piping.

• Material: Use copper alloy seamless pipes made of phosphorus deoxi-

dized copper. Ensure the inner and outer surfaces of the pipes are clean and free from hazardous sulfur, oxide, dusts, shaving particles, oils, and moisture (contamination). Size: Refer to item 9.2. for detailed information on refrigerant piping system.

•

2 Always observe the restrictions on the refrigerant piping (such as rated length,

height difference, and piping diameter) to prevent equipment failure or a decline in heating/cooling performance.

3 Branching cannot be made after header branching (corresponding parts are

marked with

4 Do not install outdoor unit piping when it is raining. 5 Commercially available piping often contains dust and other materials. Alwa ys

blow it clean with a dry inert gas.

6 Use care to prevent dust, water or other contaminants from entering the piping

during installation.

7 Reduce the number of bending portions as much as possible, and make bend-

ing radius as big as possible.

8 For indoor and outdoor branching, be sure to use the following twinning pipe

sets (sold separately).

in the diagram below).

To the outdoor unit

CAP

9 Use an adapter if a specified refrigerant pipe has a different diameter from that

of a branching pipe.

0 Braze only with non-oxide brazing material for piping. Failure to do so

may damage the compressor. Be sure to perf orm the non-oxidation brazing with a nitrogen purge.

Do not use any commercially available anti-oxidizing agent since it may cause pipe corrosion and degrading of the refrigerant oil.

Please contact Mitsubishi Electric for more details.

(Refer to item 10.2. for details of the piping connection and valve operation)

A Always insulate the piping properly. Insufficient insulation will result in a de-

cline in heating/cooling performance, water drops from condensation forming and other such problems. (Ref er to item 9 f or installation of refrigerant piping.)

B When connecting the refrigerant piping, make sure the valve of the outdoor

unit is completely closed (the factory setting). Do not operate it until the refrigerant piping for the outdoor and indoor units has been connected, a refrigerant leakage test has been performed, and the evacuation process has been completed.

C Never use refrigerant to perform an air purge. Always evacuate using a

vacuum pump.

D Be sure to charge the system using liquid refrigerant. E Either a lack or an excess of refrigerant causes the unit to make an emergency

stop. Charge the system with an appropriate amount of refrigerant. When servicing, always check the notes concerning pipe length and amount of additional refrigerant at both locations, the refrigerant volume calculation table on the back of the service panel and the additional refrigerant section on the labels for the combined number of indoor units. (Refer to item 9.2. for detailed information on refrigerant piping system.)

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Indoor twinning pipe set model

Line branch

Downstream indoor unit capacity

Less than 72 in total

CMY-Y102S-G2

Downstream indoor unit capacity

More than 73 and less than

144 in total

CMY-Y102L-G2

Downstream indoor unit capacity

More than 145 and less than

288 in total

CMY-Y202-G2

Warning:

When installing and moving the unit, do not charge the system with any other refrigerant other than the refrigerant specified on the unit.

- Mixing of a different refrigerant, air, etc. may cause the refrigerant cycle to malfunction and may result in severe damage.

Caution:

• Use a vacuum pump with a reverse flow check valve.

- If the vacuum pump does not have a reverse flow check valve, the vacuum pump oil may flow back into the refrigerant cycle and cause deterioration of the refrigerant oil.

• Do not use the tools shown below used with conventional refrigerant. (Gauge manifold, charge hose, gas leak detector , chec k valve, refrigerant charge base, vacuum gauge, refrigerant recovery equipment)

- Mixing of conv entional refrigerant and refrigerator oil may cause the refriger-

ant oil to deteriorate.

9.2. Refrigerant piping system

Connection Example

[Fig. 9.2.1] [Outdoor model : P72 ~ P96]

Header branch

4 branches

CMY-Y104-G

- Mixing of water will cause the refrigerant oil to deteriorate.

- R410A refrigerant does not contain any chlorine. Theref ore , gas leak detectors for conventional refrigerants will not react to it.

• Manage the tools used for R410A more carefully than normal.

- If dust, dirt, or water gets in the refrigerant cycle, the refrigerant oil will deteriorate.

•Never use existing refrigerant piping.

- The large amount of chlorine in conv entional refrigerant and refrigerant oil in the existing piping will cause the new refrigerant to deteriorate.

• Store the piping to be used during installation indoors and keep both ends of the piping sealed until just before brazing.

- If dust, dirt, or water gets into the refrigerant cycle, the oil will deteriorate and

the compressor may fail.

• Do not use a charging cylinder.

- Using a charging cylinder may cause the refrigerant to deteriorate.

• Do not use special detergents for washing piping.

8 branches

CMY-Y108G

10 branches

CMY-Y1010-G

Outdoor Twinning Kit model

Total outdoor model

P144 ~ P192

CMY-Y100VBK2

B C D

a b c d

CCC

c d e

[Outdoor model : P144 ~ P192]

unit 1

unit 2

unit 1

unit 2

A2A1

A Outdoor unit B 1st branch C Indoor unit D Cap E Outdoor T winning Kit F Header

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* The total length of A1 and A2 is less than 10 m [32 ft].

A (Unit: mm [in])

Outdoor model

P72 P96

P144 P192

B C D

a b c d

CCC

A2A1

c d e

Unit combination A A1 A2

unit 1

P72 P96

unit 2

P72 P96

Liquid pipe

12.7 [1/2] Brazed

15.88 [5/8] Brazed

Gas pipe

ø19.05 [3/4] Brazed

ø22.2 [7/8] Brazed

28.58 [1-1/8] Brazed

Liquid pipe

9.52 [3/8] Flare

Gas pipe

ø19.05 [3/4] Brazed

ø22.2 [7/8] Brazed

Liquid pipe

ø9.52 [3/8] Flare ø9.52 [3/8] Flare

ø19.05 [3/4] Brazed

ø22.2 [7/8] Brazed

B, C, D (Unit: mm [in])

Total capacity of indoor units

~ 54

55 ~ 72

73 ~ 108 109 ~ 144 145 ~ 234

Liquid pipe ø9.52 [3/8] ø9.52 [3/8] ø9.52 [3/8] ø12.7 [1/2]

ø15.88 [5/8]

a, b, c, d, e (Unit: mm [in])

Model number

06, 08, 12, 15, 18

24, 27, 30, 36, 48, 54

72 96

Liquid pipe ø6.35 [1/4] ø9.52 [3/8] ø9.52 [3/8] ø9.52 [3/8]

Gas pipe ø15.88 [5/8] ø19.05 [3/4]

ø22.2 [7/8] ø28.58 [1-1/8] ø28.58 [1-1/8]

Gas pipe

ø12.7 [1/2] ø15.88 [5/8] ø19.05 [3/4]

ø22.2 [7/8]

Downstream unit model total

~ 72

73 ~ 144

145 ~ 234

The 1st branch of P144 ~ P234

4-Branch header

(Downstream indoor

unit model total

72)

8-Branch header

(Downstream indoor

unit model total

CMY-Y104-G

Outdoor model

P144 ~ P192

CMY-Y108-G

Joint CMY-Y102S-G2 CMY-Y102L-G2

CMY-Y202-G2

10-Branch header

144)

unit model total

(Downstream indoor

CMY-Y1010-G

Outdoor T winning Kit

CMY-Y100VBK2

Gas pipe

234)

Precautions for outdoor unit combinations

Refer to [Fig. 9.2.2] for the positioning of twinning pipes.

[Fig. 9.2.2]

<A>Make sure the pipes from the twinning pipe to the outdoor unit are sloped downwards (towards the twinning pipes).

<B>When the piping on the outdoor unit side (from the twinning pipe) exceeds 2 m [6 ft], ensure a trap (gas pipe only) within 2 m [6 ft].

Make sure the height of the trap is 200 mm [7-7/8 in] or more. If there is no trap, oil can accumulate inside the pipe, causing a shortage of oil and may damage the compressor.

2[6

]

(Unit: m [ft])

<C>Slope of twinning pipes

Make sure the slope of the twinning pipes are at an angle within ±15˚ to the ground. If the slope exceeds the specified angle, the unit may be damaged.

±15°

<D>Pipe connection example

GBDFEINLPGRRUTRCZSVSLHGPO

A Downward slope B Upward slope C 1st branch D Trap (gas pipe only) E Within 2 m [6 ft] F Twinning pipe G Slope of the twinning pipes are at an angle within ±15˚ to the ground H Pipes on site I Twinning Kit J Straight run of pipe that is 500 mm [19-11/16 in] or more

10. Additional refrigerant charge

At the time of shipping, the outdoor unit is charged with refrigerant. This charge does not include the amount needed for extended piping and additional charging of each refrigerant line will be required on site. In order that future servicing may be properly provided, always keep a record of the size and length of each refrigerant line and the amount of additional charge by writing it in the space provided on the outdoor unit.

10.1. Calculation of additional refrigerant charge

• Calculate the amount of additional charge based on the length of the piping

extension and the size of the refrigerant line.

• Use the table below as a guide for calculating the amount of additional charg-

ing and then charge the system accordingly.

• If the calculation results in a fraction of less than 0.1 kg [4 oz], round up to the

next 0.1 kg [4 oz]. For example, if the result of the calculation was 11.38 kg [402 oz], round the result up to 11.4 kg [404 oz].

Additional refrigerant charge

(kg) [oz]

Liquid pipe size Total length of ø19.05 mm [3/4"]

=++

(m) × 0.29 (kg/m) (ft)

3.1 (oz/ft)

Liquid pipe size Total length of

+++ α

ø9.52 mm [3/8"] (m) × 0.06 (kg/m) (ft)

0.65 (oz/ft)

Liquid pipe size Total length of ø15.88 mm [5/8"]

(m) × 0.2 (kg/m) (ft)

2.15 (oz/ft)

Liquid pipe size Total length of ø6.35 mm [1/4"]

(m) × 0.024 (kg/m) (ft)

0.26 (oz/ft)

Liquid pipe size Total length of ø12.7 mm [1/2"]

(m) × 0.12 (kg/m) (ft)

1.29 (oz/ft)

<Example> Indoor

1: 48 A: ø12.7 mm [1/2"] 40 m [131 ft] a: ø9.52 mm [3/8"] 10 m [32 ft] 2: 36 B: ø9.52 mm [3/8"] 10 m [32 ft] b: ø9.52 mm [3/8"] 5 m [16 ft] 3: 15 C: ø9.52 mm [3/8"] 15 m [49 ft] c: ø6.35 mm [1/4"] 10 m [32 ft] 4: 12 D: ø9.52 mm [3/8"] 10 m [32 ft] d: ø6.35 mm [1/4"] 10 m [32 ft] 5: 24 e: ø9.52 mm [3/8"] 10 m [32 ft]

The total length of each liquid line is as follows: ø12.7 mm [1/2"]: A = 40 m [131 ft] = 40 m [131 ft] ø9.52 mm [3/8"]: B + C + D + a + b + e

= 10 m [32 ft] + 15 m [49 ft] + 10 m [32 ft] + 10 m [32 ft] +

5 m [16 ft] + 10 m [32 ft] = 60 m [193 ft] ø6.35 mm [1/4"]: c + d = 10 m [32 ft] + 10 m [32 ft] = 20 m [64 ft] Therefore, <Calculation example> Additional refrigerant charge

= 40 m [131 ft] × 0.12 kg/m [1.29 oz/ft] + 60 m [193 ft] × 0.06 kg/m [0.65 oz/ft]

+ 20 m [64 ft] × 0.024 kg/m [0.26 oz/ft] + 3.5 kg [124 oz] = 12.4 kg [435 oz]

Value of α

Total capacity of connecting indoor units α

Models ~ 27 2.0 kg [71 oz] Models 28~ 54 2.5 kg [89 oz] Models 55~ 126 3.0 kg [106 oz] Models 127~ 144 3.5 kg [124 oz] Models 145~ 180 4.5 kg [160 oz] Models 181~ 234 5.0 kg [177 oz] Models 235~ 6.0 kg [212 oz]

At the conditions below:

10.2. Precautions concerning piping connection and valve operation

• Conduct piping connection and valve operation accurately.

• The gas side connecting pipe is assembled in the factory before shipment.

1 For brazing to the connecting pipe with flange, remove the connecting

pipe with flange from the valve, and braze it outside of the unit.

2 The refrigerant circuit is closed with a round, close-packed packing upon

shipment to prevent gas leak between flanges. As no operation can be done under this state, be sure to replace the packing with the hollow packing attached at the piping connection.

3 At the mounting of the hollow packing, wipe off dust attached on the flange

sheet surface and the packing. Coat refrigerating machine oil (Ester oil, ether oil or alkylbenzene [small amount]) onto both surfaces of the packing.

[Fig. 10.2.1]

A Close-packed packing B Hollow packing

GBDFEINLPGRRUTRCZSVSLHGPO

• After evacuation and refrigerant charge, ensure that the handle is fully open. If

operating with the valve closed, abnormal pressure will be imparted to the high- or low-pressure side of the refrigerant circuit, giving damage to the compressor, four-way valve, etc.

• Determine the amount of additional refrigerant charge by using the formula,

and charge refrigerant additionally through the service port after completing piping connection work.

• After completing work, tighten the service port and cap securely so as not to

generate any gas leakage.

• Flare machining dimension for systems using R410A is larger than that for

systems using other types of refrigerant in order to increase the air tightness.

• Refer to the table on the below for flare machining dimensions, and follow the

regulations set forth by the local authorities.

flare machining dimension (mm)

outer diameter

ø6.35

ø9.52

ø12.7 ø15.88 ø19.05

flare nut size (mm)

outer diameter

ø6.35

ø9.52

ø12.7 ø15.88 ø19.05

C Valve D Packing E Connecting pipe with flange

size in inches

1/4" 3/8" 1/2" 5/8" 3/4"

size in inches

1/4" 3/8" 1/2" 5/8" 3/4"

dimension A

R410A

13.2

16.6

19.7

24.0

dimension B

R410A

17.0

22.0

26.0

29.0

36.0

9.1

A Service port

For vacuuming in the refrigerant pipes on the site. (Tightening torque 12 N·m [120 kg·cm])

B Shaft

Fully closed at the factory, when connecting the piping, and when vacuuming. Open fully after these operations are completed. <When opening>

• Turn the shaft counterclockwise with a hexagonal wrench.

• Turn around the shaft until it stops. <When closing>

• Turn the shaft clockwise with a hexagonal wrench.

• Turn around the shaft until it stops.

C Flare nut

Coat the flare contact surface with refrigerating machine oil (small amount of ester oil, ether oil, or alkyl benzene) and tighten the nut with a double-ended wrench (refer to the following table for tightening torque).

D Cap

Remove the cap before operating the shaft. Be sure to return it to the original position after completing the operation.

E Packing

Coat both sides of the packing with machine refrigerating oil (small amount of ester oil, ether oil, or alkyl benzene) and tighten the flange. (Tightening torque 25 N·m [250 kg·cm])

F Connecting pipe (accessory)

Be sure to remove the connecting pipe from the valve and braze it outside the unit.

G Field piping

Braze to the connecting pipe with unoxidized brazing.

H ø9.52 mm [3/8"] (PUHY-HP72, HP96, when combining PUHY-HP72, HP96)

ø12.7 mm [1/2"] (PUHY-HP72, HP96)

I ø22.2 mm [7/8"] (PUHY-HP96) J ø19.05 mm [3/4"] (PUHY-HP72)

Appropriate tightening torque:

Outer diameter of

copper pipe (mm [in])

ø9.52 [3/8]

ø12.7 [1/2] ø15.88 [5/8] ø19.05 [3/4]

ø25.4 [1]

Cap (N·m /kg·cm)

22/220 20/200 25/250 25/250 40/400

Shaft (N·m /kg·cm)

5/50

9/90 15/150 15/150 30/300

Size of hexagonal

wrench (mm)

4 4 6 6

Appropriate tightening torque and its angle:

Outer diameter of

copper pipe (mm [in])

ø9.52 [3/8]

ø12.7 [1/2] ø15.88 [5/8] ø19.05 [3/4]

Tightening torque

(N·m/kg·cm)

35 - 42/350 - 420

50 - 57.5/500 - 575

75 - 80/750 - 800

100 - 140/1000 - 1400

Tightening angle

(°)

60 to 90 30 to 60 20 to 35

Warning:

When connecting a pipe to the service valve, be sure to use only the supplied open-end flare nut, with small holes cut into the flats.

* Using a regular flare nut (i.e., non-supplied) will result in any water that

naturally flows into the nut being unable to escape. Consequently , when the temperature becomes lo w, this water inside the nut may freeze and cause damage to the joint. This, in turn, may result in a gas leakage.

[Fig. 10.2.3]

[Fig. 10.2.2]

<A> Valve liquid side/

()

flared type

<B> Valve

gas side/

()

flanged type

<C> Valve gas side/

()

flared type

Note: If a torque wrench is not available, use the following method as a standard; When you tighten the flare nut with a wrench, you will reach a point where the tightening torque will abruptly increase. Turn the flare nut beyond this point by the angle shown in the table above.

Caution:

•Always remove the connecting pipe from the valve and braze it outside the unit.

-Brazing the connecting pipe while it is installed will heat the valve and cause

trouble or gas leakage. The piping, etc. inside the unit may also be burned.

• Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerating machine oil to coat flares and flange connections.

- The refrigerating machine oil will deg rade if it is mix ed with a large amount of

mineral oil.

•Keep the valve closed until refrigerant charging to the pipes to be added on site has been completed. Opening the valve before charging the refrigerant may result in unit damage.

• Do not use a leak detection additive. [Fig. 10.2.4]

Caution:

Make sure to seal-off and excess space around areas where the wires and refrigerant pipes enter the unit.

• Small animals and rainwater entering through the openings may cause damage to the device.

10.3. Airtight test, evacuation, and refrigerant

charging

1 Airtight test

Perform with the valve of the outdoor unit closed, and pressurize the connection piping and the indoor unit from the service port provided on the valve of the outdoor unit. (Always pressurize from both the liquid pipe and the gas pipe service ports.)

[Fig. 10.3.1]

A Example of closure materials (field supply) B Fill the gap at the site

Make sure to seal-off and excess space around areas where the wires and refrigerant pipes enter the unit to ensure that small animals and rainwater cannot enter the unit through such openings and cause damage to the unit.

1. Nitrogen gas pressurization (1) After pressurizing to the design pressure (4.15 MPa [602 psi]) using nitrogen gas, allow it to

stand for about one day. If the pressure does not drop, airtightness is good. However, if the pressure drops, since the leaking point is unknown, the following bubble test may also be performed.

(2) After the pressurization described above, spray the flare connection parts, brazed parts, flanges,

and other parts that may leak with a bubbling agent (Kyuboflex, etc.) and visually check for bubbles.

(3) After the airtight test, wipe off the bubbling agent.

2. Pressurization using refrigeration gas and nitrogen gas (1) After first pressurizing with R410A liquid refrigerant to a gas pressure of approximately 0.2

Mpa [29 psi], pressurize to the design pressure of 4.15 Mpa [602 psi] using nitrogen gas. However, do not pressurize at one time. Stop during pressurization and check that the pressure does not drop.

(2) Check for gas leaks by checking the flare connection parts, brazed parts, flanges, and other

parts which may leak using an R410A compatible electric leak detector.

(3) This test may be used together the with bubble type gas leak test.

Observe the following restrictions when conducting an air tightness test to prevent negative effects on the refrigerating machine oil. Also, with nonaz eotropic refrigerant (R410A), gas leakage causes the composition to change and affects performance. Therefore, perform the airtightness test cautiously.

Airtight test procedure

A Nitrogen gas B To indoor unit C System analyzer D Lo knob E Hi knob F Valve G Liquid pipe H Gas pipe I Outdoor unit J Service port

• If a flammable gas or air (oxygen) is used as the pressurization gas, it may catch fire or explode.

• Do not use a refrigerant other than that indicated on the unit.

• Sealing with gas from a cylinder will cause the composition of the refrigerant in the cylinder to change.

• Use a pressure gauge, charging hose, and other parts especially designed for use with R410A.

• An electric leak detector for R22 cannot detect leaks of R410A.

• Do not use a haloid torch. (Leaks cannot be detected.)

Restriction

GBDFEINLPGRRUTRCZSVSLHGPO

Caution:

Only use refrigerant R410A.

- The use of other refrigerant such as R22 or R407C, which contains chlorine, will deteriorate the refrigerating machine oil or cause the compressor to malfunction.

2 Evacuation

Evacuate with the valve of the outdoor unit closed and evacuate both the connection piping and the indoor unit from the service port provided on the valve of the outdoor unit using a vacuum pump. (Always evacuate from the service port of both liquid pipe and gas pipe.) After the vacuum reaches 650 Pa [abs] [0.0943 psi/5 Torr], continue evacuation for at least one hour or more. Then, stop the vacuum pump and leave it for 1 hour. Ensure the degree of vacuum has not increased. (If the degree of vacuum increase is larger than 130 Pa

[0.01886 psi/1.0 Torr], water might have entered. Apply pressure to dry nitrogen gas up to 0.05 MPa [7.25 psi] and vacuum again.) Finally, seal in

with the liquid refrigerant through the liquid pipe, and adjust the gas piping to obtain an appropriate amount of the refrigerant during operation. * Never perform air purging using refrigerant.

[Fig. 10.3.2]

A System analyzer B Lo knob C Hi knob D Valve E Liquid pipe F Gas pipe G Service port H Three-way joint I Valve J Valve K R410A cylinder L Scale M Vacuum pump N To indoor unit O Outdoor unit

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