Sanyo R410A User Manual

Outdoor Units

85464359982001 ©SANYO 2006 SANYO Electric Co., Ltd.

Gunma, Japan

– W-2WAY System Air Conditioner –

 R410A Models Indoor Units

Class 7 9 12 18 24 36 48

X 4-Way Air Discharge Semi-Concealed Type XHX1252 XHX1852 XHX2452 XHX3652

A 1-Way Air Discharge Semi-Concealed Type AHX0752 AHX0952 AHX1252

U Concealed Duct Type UHX0752 UHX1252 UHX1852 UHX2452 UHX3652

Concealed Duct

DHX3652 DHX4852

High-Static Pressure Type

T Ceiling-Mounted Type THX1252 THX1852 THX2452

K Wall-Mounted Type KHX0752 KHX0952 KHX1252 KHX1852 KHX2452

for Refrigerant R410A

* Refrigerant R410A is used in the outdoor units.

INSTALLATION INSTRUCTIONS

Class 90 140

C ECO-i W-2WAY

CHDX09053 CHDX14053

Optional Controllers

Timer Wired Remote Controller RCS-TM80BG

Wireless Remote Controller (For U, D Type) RCS-BH80AAB.WL

Wireless Remote Controller (For X Type) RCS-SH80AAB.WL

Wireless Remote Controller (For A, T Type) RCS-TRP80AAB.WL

RC Wireless Remote Controller (For K Type) RCS-SH1AAB

Simplified Remote Controller RCS-KR1AGB

System Controller SHA-KC64UG

Intelligent Controller SHA-KT256BA

Communication Adaptor SHA-KA128AAB

Remote Sensor ART-K45AGB

LonWorks Interface SHA-LN16UAB

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page a

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.



Pay close attention to all warning and caution notices given in this manual.

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

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

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.

• 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.

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WARNING

CAUTION

WARNING

CAUTION

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).

(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.

3. The minimum indoor floor space compared with the amount of refrigerant is roughly as follows: (When the ceiling is 8.8 ft. high)

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 (lbs)

Min. volume of the indoor unit installed room (ft.3)

Density limit (oz/ft.3)

The density limit of refrigerant which is used in multi air conditioners is 0.3 oz/ft.

(ISO 5149).

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:

The possible amount of leaked refrigerant gas in rooms A, B and C is 353 oz. The possible amount of leaked refrigerant gas in rooms D, E and F is 529 oz.

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NOTE

Outdoor unit

Refrigerant tubing

Indoor unit

Refrigerant tubing

Outdoor unit

Very small room

Small room

Mechanical ventilation device – Gas leak detector

Medium room

Large room

Indoor unit

e.g., charged amount (353 oz)

Indoor unit

Outdoor unit

e.g., charged amount (529 oz)

Room A Room B Room C Room D Room E Room F

ft.

4000

3500

3000

Min. indoor volume

2500

2000

1500

1000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

400200 600 800 1000 1200

Total amount of refrigerant

454

398

341

284

227

170

114

ft.

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A refriger-

ant 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

in the unit.

2-2. Since refrigerant composition changes and performance decreases when gas leaks, collect the remaining refriger-

ant 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.

Material O

Copper tube

Outer diameter 1/4 (6.35) 3/8 (9.52) 1/2 (12.7) 5/8 (15.88) 3/4 (19.05)

Wall thickness 1/32 (0.8) 1/32 (0.8) 1/32 (0.8) 5/128 (1.0)

over 5/128 (1.0)

Material 1/ 2 H, H

Copper tube

Outer diameter 7/8 (22.22) 1 (25.4) 1-1/8 (28.58) 1-1/4 (31.75) 1-1/2 (38.1) 1-5/8 (41.28)

Wall thickness 5/128 (1.0) 5/128 (1.0) 5/128 (1.0) 3/64 (1.1)

over 3/64 (1.15)

over

3/64 (1.20)

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.” For tubes of ø7/8" (ø22.22 mm) or larger, use C1220 T-1/2H material or H material, and do not bend the 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.

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

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.

R407C tools

Item compatible Remarks

with R410A?

Manifold gauge Yes No Types of refrigerant, refrigerating machine

oil, and pressure gauge are different.

Charge hose Yes No To resist higher pressure, material must be changed.

Vacuum pump Yes Yes Use a conventional vacuum pump if it is equipped

with a check valve. If it has no check valve, purchase and attach a vacuum pump adapter.

Leak detector Yes No Leak detectors for CFC and HCFC that

react to chlorine do not function because R410A contains no chlorine. Leak detector for HFC134a can be used for R410A.

Flaring oil Yes No For systems that use R22, apply mineral oil (Suniso oil)

to the flare nuts on the tubing to prevent refrigerant leakage. For machines that use R407C or R410A, apply synthetic oil (ether oil) to the flare nuts.

Unit: in. (mm)

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CAUTION

New tool?

Manifold gauge

Vacuum pump

Outlet Inlet

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.

New refrigerant R410A cannot be used for earlier models

1. Compressor specifications are different.

If recharging a R22 or R407C compressor with R410A, durability will significantly decrease since some of the materials used for compressor parts are different.

2. Existing tubing cannot be used (especially R22).

Completely cleaning out residual refrigerating

machine oil is impossible, even by flushing.

3. Refrigerating machine oil differs (R22).

Since R22 refrigerating machine oil is mineral oil, it does not dissolve in R410A. Therefore, refrigerating machine oil discharged from the compressor can cause compressor damage.

R22 refrigerating machine oil Mineral oil (Suniso oil)

R407C refrigerating machine oil Synthetic fluid (ether oil)

R410A refrigerating machine oil Synthetic fluid (ether oil)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 5

Valve

Liquid

R410A

IMPORTANT! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Please Read Before Starting Check of Density Limit Precautions for Installation Using New Refrigerant New refrigerant R410A cannot be used for earlier models

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

1-1. Tools Required for Installation (not supplied) 1-2. Accessories Supplied 1-3. Type of Copper Tube and Insulation Material 1-4. Additional Materials Required for Installation 1-5. Tubing Length 1-6. Tubing Size 1-7. Straight Equivalent Length of Joints 1-8. Additional Refrigerant Charge 1-9. System Limitations 1-10. Check of Limit Density 1-11. Installing Distribution Joint 1-12. Optional Distribution Joint Kits 1-13. Example of Tubing Size Selection and

Refrigerant Charge Amount

2. SELECTING THE INSTALLATION SITE . . . . . 19

2-1. Indoor Unit 2-2. Outdoor Unit 2-3. Shield for Horizontal Exhaust Discharge 2-4. Installing the Outdoor Unit in Heavy Snow Areas 2-5. Precautions When Installing in Heavy Snow

Areas 2-6. Dimensions of Wind Ducting 2-7. Dimensions of Snow Ducting

3. HOW TO INSTALL THE INDOOR UNIT . . . . . 24

 4-Way Air Discharge Semi-Concealed Type

(X Type)

3-1. Preparation for Suspending 3-2. Suspending the Indoor Unit 3-3. Placing the Unit Inside the Ceiling 3-4. Installing the Drain Piping 3-5. Checking the Drainage 3-6. How to Install the Ceiling Panel 3-7. Special Remarks

 1-Way Air Discharge Semi-Concealed Type

(A Type)

3-8. Suspending the Indoor Unit 3-9. Placing the Unit Inside the Ceiling 3-10. Installing the Drain Piping 3-11. Checking the Drainage 3-12. Electrical Power Wiring 3-13. How to Install the Ceiling Panel

 Concealed Duct Type (U Type)

3-14. Required Minimum Space for Installation and

Service 3-15. Suspending the Indoor Unit 3-16. Installing the Drain Piping 3-17. Checking the Drainage 3-18. Increasing the Fan Speed

 Concealed Duct High-Static Pressure Type

(D Type)

3-19. Required Minimum Space for Installation and

Service 3-20. Suspending the Indoor Unit 3-21. Installing the Drain Piping 3-22. Caution for Ducting Work 3-23. Indoor Fan Performance

 Ceiling-Mounted Type (T Type)

3-24. Required Minimum Space for Installation and

Service 3-25. Suspending the Indoor Unit 3-26. Duct for Fresh Air 3-27. Shaping the Tubing 3-28. Installing the Drain Piping

 Wall-Mounted Type (K Type)

3-29. Removing the Rear Panel from the Unit 3-30. Selecting and Making a Hole 3-31. Installing the Rear Panel onto the Wall 3-32. Removing the Grille to Install the Indoor Unit 3-33. Preparing the Tubing 3-34. Shaping the Tubing 3-35. Installing the Drain Hose 3-36. When Using Wireless Remote Controller

Instead of Wired Remote Controller

4. HOW TO INSTALL THE OUTDOOR UNIT . . . 55

4-1. Transporting 4-2. Installing the Outdoor Unit 4-3. Routing the Tubing 4-4. Prepare the Tubing 4-5. Connect the Tubing

5. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 59

5-1. General Precautions on Wiring 5-2. Recommended Wire Length and Wire

Diameter for Power Supply System 5-3. Wiring System Diagram

CONTENTS

Page Page

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 6

6. HOW TO PROCESS TUBING . . . . . . . . . . . . 63

6-1. Connecting the Refrigerant Tubing 6-2. Connecting Tubing Between Indoor and

Outdoor Units 6-3. Insulating the Refrigerant Tubing 6-4. Taping the Tubes 6-5. Finishing the Installation

7. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . . 67

 Air Purging with a Vacuum Pump (for Test Run)

Preparation

8. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

8-1. Preparing for Test Run 8-2. Test Run Procedure 8-3. Main Outdoor Unit PCB Setting 8-4. Auto Address Setting 8-5. Remote Controller Test Run Settings 8-6. Caution for Pump Down 8-7. Meaning of Alarm Messages

9. APPENDIX . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

9-1. 4-Way Air Discharge Semi-Concealed Type

(X Type) 9-2. 1-Way Air Discharge Semi-Concealed Type

(A Type) 9-3. Concealed Duct (High-Static Pressure) Type

(U, D Type) 9-4. Ceiling-Mounted Type (T Type) 9-5. Wall-Mounted Type (K Type)

Page

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 7

Table 1-1 Outdoor Unit

1-2. Accessories Supplied

See Tables 1-1 – 1-7.

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)

1-3. 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 5/16 in.

3. Use insulated copper wire for field wiring. Wire size varies

with the total length of wiring.

Refer to

“

5. ELECTRICAL WIRING” for details.

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

Check local electrical codes and

regulations before obtaining

wire. Also, check any specified

instructions or limitations.

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.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 8

CAUTION

Part name

Connection tubing

Instruction manual paper

Outer diameter ø1-1/8"

Outer diameter ø7/8"

Figure

Inner diameter ø1"

Inner diameter ø3/4"

09053 Model

(10 hp)

Q’ty

14053 Model

(16 hp)

(hp = horse power)

Table 1-2 (4-Way Air Discharge Semi-Concealed)

Table 1-3 (1-Way Air Discharge Semi-Concealed)

Table 1-4 (Concealed Duct)

 Use 3/8" for suspending bolts.  Field supply for suspending bolts and nuts.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 9

Part Name Figure

Full-scale installation diagram

Drain hose

Hose band

Drain insulator

Flare insulator

Insulating tape

Packing

Wiring cover

Screw

Washer

Screw

Part Name Figure

Full-scale installation diagram

Drain hose

White (heat-resisting)

Q’ty

Printed on container box

For securing drain hose

For drain joint

For liquid tube

For gas tube

For gas tube joint

For drain joint

For covering erectrical wiring

For full-scale installation diagram

For suspending indoor unit from ceiling

For fixing the wiring cover

Q’ty

Printed on container box

For securing drain hose

Remarks

Hose band

Drain insulator

Flare insulator

Insulating tape

Packing

Washer

Screw

Bushing

Part Name Figure

Drain hose

Hose band 1

Packing 1

Drain insulator 1

Flare insulator 1

Insulating tape

Flare insulator 1

White (heat-resisting)

For securing drain hose

For drain joint

For liquid tube

For gas tube

For gas tube joint

For drain joint

For suspending indoor unit from ceiling

For full-scale installation diagram

For electrical junction box

Q’ty

For securing drain hose

For drain joint

For liquid tube

For gas and liquid tubes flare nuts

For gas tube

Remarks

Washer

Sealing putty 1

Vinyl clamp 8

For suspending indoor unit from ceiling

For sealing recessed portion of power supply

For flare and drain insulators

Table 1-5 (Concealed Duct High-Static Pressure)

Table 1-6 (Ceiling-Mounted)

Table 1-7 (Wall-Mounted)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 10

Part Name Figure

Washer

Nut

Flare insulator

Drain socket

Part Name Figure

Full-scale installation diagram 1

Washer 4

Insulating tape 2

Vinyl clamp 8

Drain hose1

Hose band2

Drain insulator 1

T1/8"

T3/16"

White (heat-resisting)

L5-1/2"

Q’ty

For suspending indoor unit from ceiling

Remarks

1 For gas tube

For liquid tube

For drain pipe connection

Q’ty

Remarks

Printed on container box

For temporarily suspending indoor unit from ceiling

For gas and liquid tube jointsFlare insulator

For gas and liquid tubes flare nuts

For flare and drain insulators

For main unit and PVC pipe joints

For drain hose connection

For drain hose joint

Gum eyelet 1

Part Name Figure

Tapping screw

Plastic cover

Insulator

5/32" × 1"

For power supply inlet

Q’ty

For fixing the rear panel

For improved tubing appearance

For insulating flare nut (2452 type only)

Remarks

1-5. Tubing Length

Table 1-8 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights

Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown in the figure below.

1: The outdoor connection main tubing ( B portion) is determined by the total capacity of the outdoor units that are connected to

the tube ends.

2: If the longest tubing length (L1) exceeds 295 ft. (equivalent length), increase the sizes of the main tubes (LM) by 1 rank for gas

tubes and liquid tubes. (Use a field supply reducer.) (Select the tube size from the table of main tube sizes (Table 1-9) on the following page (LA table), and from the table of refrigerant tubing sizes (Table 1-14) on the second following page.)

3: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the

gas tubes. (Use a field supply reducer.) (For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table on the following page.)

4: If the size of the existing tubing is already larger than the standard tubing size, it is not necessary to further increase the size.

* If the existing tubing is used, and the amount of on-site additional refrigerant charge exceeds the value listed below, then

change the size of the tubing to reduce the amount of refrigerant.

Max. additional charge for 1 outdoor unit: 62 lbs Max. additional charge for 2 outdoor units: 111lbs

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 11

2. The outdoor connection main tubing ( B portion) is determined by the total capacity of the outdoor units that are connected to the tube ends.

Balance tubing (ø1/4

Explanation of symbols

Distribution joint (APR: purchased separately)

Ball valve (field supply)

T- j o i nt (field supply)

Solidly welded shut (pinch weld)

Main tu

bing length LM = LA + LB … ≤ 262 ft

Main distribution tubes LC – LG are selected according to the capacity after the distribution joint.

Sizes of indoor unit connection tubing 1 – 40 are determined by the connection tubing sizes on the indoor units.

LB LC

Max. 1.3 ft

For extension

LD L3

For extension

R410A distribution joint APR-CHP680BA (for outdoor unit)

APR-CHP1350BA (for outdoor unit) APR-P160BA (for indoor unit)

APR-P680BA (for indoor unit) APR-P1350BA (for indoor unit)

Note: Do not use commercially available T-joints for the liquid tubing and parts. * Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor unit connections and tubing branches.

Item Mark Contents Length (ft.)

L1 Max. tubing length

∆L (L2 – L4)

Allowable tubing length

LM Max. length of main tubing (at max. diameter) 262

, 2...

112

L1+

...

+LE+LF+LG

Allowable elevation difference

Difference between max. length and min. length from the No.1 distribution joint

Max. length of each distribution tube 98

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

Distance between outdoor units

When outdoor unit is installed higher than indoor unit 164 When outdoor unit is installed lower than indoor unit 131 Max. difference between indoor

Actual length 492

Equivalent length 574

units 49

H3 Max. difference between outdoor units

Allowable length of joint tubing

L = Length, H = Height

T-joint tubing (field-supply); Max. tubing length between the first T-joint and solidly welded-shut end point

NOTE

131

984

6.6

1-6. Tubing Size

Table 1-9 Main Tubing Size (LA)

*1: If future extension is planned, select the tubing diameter based on the total horsepower after extension.

However extension is not possible if the resulting tubing size is two ranks higher. *2: The balance tube (outdoor unit tube) diameter is ø1/4". *3: Type 1 tubing should be used for the refrigerant tubes. *4: If the length of the longest tube (L1) exceeds 295 ft. (equivalent length), increase the main tube (LM) size by 1 rank for the gas

and liquid tubes. (Use field-supply reducers.) (Select from Table 1-9 and Table 1-14.) *5: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the

gas tubes.

(For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table above.)

 Size of tubing (LO) between outdoor units

Select the size of tubing between outdoor units based on the main tubing size (LA) as given in the table above.

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. (Especially the main tubing segments of LA, LB and LF.)

Table 1-11 Outdoor Unit Tubing Connection Size

Table 1-12 Indoor Unit Tubing Connection Size

Note: Use C1220T-1/2H material for tubing over ø3/4" (ø22.22).

Table 1-10 Main Tubing Size After Distribution (LB, LC...)

Unit: in. (mm)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 12

BTU/h

(kW)

Total system horsepower

Combined outdoor units

Gas tubing

Liquid tubing

95,500

(28.0)

ø7/8"

(ø22.22)

ø3/8"

(ø9.52)

153,600

(45.0)

1610

ø1-1/8"

(ø28.58)

ø1/2"

(ø12.7)

191,100

(56.0)

10 10

ø5/8"

(ø15.88)

249,100

(73.0)

16 10

(ø31.75)

(ø19.05)

307,100

(90.0)

16 16

ø1-1/4"

ø3/4"

Total capacity after distribution

Below BTU/h

Over BTU/h

24,200

(2.5 hp)

–

Gas tubing

Tubing size

Liquid tubing

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

54,600

(6 hp)

24,200

(2.5 hp)

ø5/8"

(ø15.88)

ø3/8"

(ø9.52)

76,800

(8.1 hp)

54,600

(6 hp)

ø3/4"

(ø19.05)

ø3/8"

(ø9.52)

102,400

(11 hp)

76,800

(8.1 hp)

ø7/8"

(ø22.22)

ø3/8"

(ø9.52)

143,300

(15 hp)

102,400

(11 hp)

ø1"

(ø25.4)

ø1/2"

(ø12.7)

178,800

(19 hp)

143,300

(15 hp)

ø1-1/8"

(ø28.58)

ø1/2"

(ø12.7)

238,900

(25 hp)

178,800

(19 hp)

ø1-1/8"

(ø28.58)

ø5/8"

(ø15.88)

hp = horsepower

334,400

(35 hp)

238,900

(25 hp)

ø1-1/4"

(ø31.75)

ø3/4"

(ø19.05)

–

334,400

(35 hp)

ø1-1/2" (ø38.1)

ø3/4"

(ø19.05)

( A – C)

BTU/h

(kW)

Gas tubing

Liquid tubing

Balance tubing

Indoor unit type7 9 12 18 24 3648

Gas tubing

Liquid tubing

95,500

(28.0)

ø7/8"

(ø22.22)

Brazing connection

ø3/8" (ø9.52)

Flare connection

ø1/4" (ø6.35)

Flare connection

ø1/2" (ø12.7)

153,600

(45.0)

ø1-1/8"

(ø28.58)

ø1/2" (ø12.7)

Balance tube

Liquid tube

ø5/8" (ø15.88)

ø3/8" (ø9.52)ø1/4" (ø6.35)

Gas tube

Table 1-16 Refrigerant Charge Amount at Shipment (for outdoor unit)

CHDX09053 CHDX14053

(oz)

423 458

1-9. System Limitations

Table 1-17 System Limitations

Max. No. allowable connected outdoor units 2 *1

Max. capacity allowable connected outdoor units 307,100 BTU/h (32 hp, 90 kW)

Max. connectable indoor units 40

Max. allowable indoor/outdoor capacity ratio 50 – 130 %

*1: Up to 2 units can be connected if the system has been extended.

1-7. Straight Equivalent Length of Joints

Design the tubing system by referring to the following table for the straight equivalent length of joints.

Table 1-13 Straight Equivalent Length of Joints

Table 1-14 Refrigerant tubing (Existing tubing can be used.)

Tubing size (in. (mm))

Material O Material 1/2H • H

ø1/4" (ø6.35) t1/32" (0.8) ø7/8" (ø22.22) t5/128" (1.0)

ø3/8" (ø9.52) t1/32" (0.8) ø1" (ø25.40) t5/128" (1.0)

ø1/2" (ø12.7) t1/32" (0.8) ø1-1/8" (ø28.58) t5/128" (1.0)

ø5/8" (ø15.88) t5/128" (1.0) ø1-1/4" (ø31.75) t3/64" (1.1)

ø3/4" (ø19.05) over t5/128" (1.0) ø1-1/2" (ø38.10) over t3/64" (1.15)

ø1-5/8" (ø41.28) over t3/64" (1.20)

* When bending the tubes, use a bending

radius that is at least 4 times the outer

diameter of the tubes.

In addition, take sufficient care to avoid

crushing or damaging the tubes when

bending them.

1-8. Additional Refrigerant Charge

Additional refrigerant charge amount is calculated from the liquid tubing total length as follows.

Table 1-15 Amount of Refrigerant Charge Per Meter, According to Liquid Tubing Size

Liquid tubing size Amount of refrigerant

(in. (mm)) charge (oz/ft.)

ø1/4" (ø6.35) 0.279

ø3/8" (ø9.52) 0.602

ø1/2" (ø12.7) 1.38

ø5/8" (ø15.88) 1.99

ø3/4" (ø19.05) 2.78

ø7/8" (ø22.22) 3.93

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.

* If the existing tubing is used, and the amount of on-site additional

refrigerant charge exceeds the value listed below, then change the

size of the tubing to reduce the amount of refrigerant.

Max. additional charge for 1 outdoor unit : 62 lbs

Max. additional charge for 2 outdoor units :111 lbs

Max. additional charge for 3 outdoor units :133 lbs

Unit: ft.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 13

Gas tubing size (in. (mm))

90° elbow

45° elbow 0.8 0.9 1 1.2 1.3 1.4 1.7 1.9

1/2"

(12.7)

5/8"

(15.88)

1 1.1 1.4 1.6 1.7 1.9 2.3 2.6

3/4"

(19.05)

7/8"

(22.22)1"(25.4)

U-shape tube bent (R2-3/8" – 4" (60 – 100)) 33.4 4.1 4.7 5.1 5.6 6.9 7.8

Tra p b end

Y-branch distribution jointEquivalent length conversion not n

Ball valve for service Equivalent length conversion not needed.

7.5 9.2 10.5 12.5 14.1 15.4 16.4 14.0

1-1/8"

(28.58)

eeded.

1-1/4" (31.8)

1-1/2"

(38.1)

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 a leak detector.

(Total refrigerant charged amount: oz)

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

< Limit density 0.3 (oz/ft.

)

The limit density of refrigerant R410A which is used in this unit is

0.3 oz/ft.

(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.)

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

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-CHP680BA, APR-CHP1350BA, APR-P160BA,

APR-P680BA, APR-P1350BA).

(2) When creating a branch using a commercially available

T-joint (header joint system), orient the main tubing so that it is

either horizontal (level) or vertical. In order to prevent accumu-

lation 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 verti-

cal, 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 1.3 ft. of the distribution joint.)

If a trap or ball valve is not added, do not operate the sys-

tem 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.)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 14

WARNING

CAUTION

ft.

10000

9500 9000

8500 8000

7500 7000

Min. indoor volume

6500 6000 5500 5000 4500 4000

3500 3000

2500 2000 1500 1000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

1000500 1500 2000 2500 3000

Total amount of refrigerant

Tube branching methods (horizontal use)

15 to 30°

Horizontal

Ty pe s of vertical trap specifications

(When using ball valve)

Main tubing

line

Arrow view

View as seen from arrow

ft.

1136 1079 1022 966 909 852 795 738 682 625 568 511 454

398 341

284 227 170 114 57

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

Ball valve

(BV: purchased

separately)

Indoor unit (1)

(When not using ball valve)

Main tubing

Indoor unit is directed downward

Indoor unit (more than 2 units)

Branch tubing is directed upward.

More than 8 inch

(If only 1 unit is connected, a ball valve is also needed on this side.)

Horizontal

Indoor unit

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

1-12. Optional Distribution Joint Kits

See the installation instructions packaged with the distribution joint kit for the installation procedure.

Table 1-18

1. APR-CHP680BA For outdoor unit (Capacity after distribution joint is 232,000 BTU/h (68.0 kW) or less.)

Table 1-19 Size of connection point on each part (Shown are inside diameters of tubing)

2. APR-CHP1350BA For outdoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than

Table 1-20 Size of connection point on each part (Shown are inside diameters of tubing)

Model name Cooling capacity after distribution Remarks

1. APR-CHP680BA 232,000 BTU/h (68.0 kW) or less For outdoor unit

2. APR-CHP1350BA 460,700 BTU/h (135.0 kW) or less For outdoor unit

3. APR-P160BA 76,400 BTU/h (22.4 kW) or less For indoor unit

4. APR-P680BA 232,000 BTU/h (68.0 kW) or less For indoor unit

5. APR-P1350BA 460,700 BTU/h (135.0 kW) or less For indoor unit

 Tubing size (with thermal insulation)

Unit: in.

Example:

Unit: in.

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" (ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52)

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8"

(ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52)

460,700 BTU/h (135.0 kW).)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 15

Distribution Joint

Reducing Joints

Gas tubing Liquid tubing

6-59/64

5-5/16

CDEF

Insulation

4-31/64

Distribution Joint

Insulation

4-21/64

3-13/16

HFI

Reducing Joints

2-53/64

Gas tubing Liquid tubing

Insulation

6-57/64

5-5/16

Distribution Joint

C D

Reducing Joints

4-31/64

Distribution Joint

Insulation

4-21/64

3-13/16

HFI

2-53/64

Reducing Joints

3. APR-P160BA

Use: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.)

Table 1-21 Size of connection point on each part (Shown are inside diameters of tubing)

4. APR-P680BA

Use: For indoor unit (Capacity after distribution joint is greater than 76,400 BTU/h (22.4 kW) and no more than

Table 1-22 Size of connection point on each part (Shown are inside diameters of tubing)

5. APR-P1350BA

Use: For indoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than

Table 1-23 Size of connection point on each part (Shown are inside diameters of tubing)

Example:

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I Part J

in. (mm)

ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" ø1/4" (ø38.1) (ø31.75) (ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Size Part A Part B Part C Part D Part E Part F Part G Part H

in. (mm)

ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" ø1/4"

(ø28.58) (ø25.4) (ø22.22) (ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Size Part A Part B Part C Part D Part E

in. (mm)

ø3/4" ø5/8" ø1/2" ø3/8" ø1/4"

(ø19.05) (ø15.88) (ø12.7) (ø9.52) (ø6.35)

Unit: in.

232,000 BTU/h (68.0 kW).)

460,700 BTU/h (135.0 kW).)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 16

Gas tubing Liquid tubing

4-21/64

Insulation

3-13/16

Distribution Joint

2-53/64

Insulation

4-21/64

3-13/16

Distribution Joint

D E

2-53/64

DCB

Distribution Joint

Insulation

Distribution

Joint

Insulation

Gas tubing Liquid tubing

6-57/64

5-5/16

Gas tubing Liquid tubing

6-57/64

5-5/16

B C

E F

C D

E F

G H

BCD

Reducing Joints

4-31/64

Distribution Joint

Insulation

Distribution Joint

Insulation

4-21/64

3-13/16

F G H

4-21/64

3-13/16

FGH

Reducing Joints

2-53/64

1-13. Example of Tubing Size Selection and Refrigerant Charge Amount

Additional refrigerant charging

Based on the values in Tables 1-9, 10, 11, 12 and 15, use the liquid tubing size and length, and calculate the amount of additional

refrigerant charge using the formula below.

= 3.93 × (a) + 2.78 × (b) + 1.99 × (c) + 1.38 × (d) + 0.602 × (e) + 0.279 × (f)

(a) : Liquid tubing Total length of ø7/8" (ft.) (d) : Liquid tubing Total length of ø1/2" (ft.)

(b) : Liquid tubing Total length of ø3/4" (ft.) (e) : Liquid tubing Total length of ø3/8" (ft.)

 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.

However if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valves fully closed.)

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.

Required additional refrigerant charge (oz)

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.

Example:

 Example of each tubing length

Main tubing Distribution joint tubing

LA = 131 ft. Outdoor side Indoor side LB = 16 ft. A = 7 ft. 1 = 98 ft. LC = 16 ft. B = 7 ft. 2 = 16 ft.

3 = 16 ft. 4 = 65 ft.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 17

CAUTION

Balance tube

Use a flathead screwdriver and open by turning the part with the screw groove to the right, from “–” to “|”.

Outdoor unit

09053 model

1 2 3 4

Liquid tube

Use a hex wrench (width 5/32 inch) and turn to the left to open.

Gas tube Use a flathead screwdriver and

open by turning the part with the screw groove to the right, from “–” to “|”.

48 model 48 model 48 model

36 model

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 161 ft.

× ceiling

height 8.8 ft. = room volume 1417 ft.

), the graph at right

shows that the minimum room volume should be 2455 ft.

(floor area 279 ft.2) for refrigerant of 418 oz.

Overall refrigerant charge amount for the air conditioner: oz

(Minimum room volume for indoor unit: ft.3)

418 (oz)

= 0.29 (oz/ft.

) < 0.3 (oz/ft.3)

1417 (ft.

)

Therefore, openings such as louvers are not required for this

room.

 Obtain liquid tubing size from Tables 1-9, 10, 11, 12 and 15.

Main tubing

LA = ø5/8 (ft.) (Total capacity of indoor unit is 179,400 BTU/h) The longest tubing length in this example

LB = ø1/2 (ft.) (Total capacity of indoor unit is 131,600 BTU/h) (LA = 131 ft.)

LC = ø3/8 (ft.) (Total capacity of indoor unit is 83,800 BTU/h)

Distribution joint tubing

Outdoor side A: ø3/8 (ft.) B: ø3/8 (ft.) (from outdoor unit connection tubing)

Indoor side 1: ø3/8 (ft.) 2: ø3/8 (ft.) 3: ø3/8 (ft.) 4: ø3/8 (ft.) (from indoor unit connection tubing)

 Obtain charge amount for each tubing size

Note that the charge amounts per 1 meter are different for each liquid tubing size. ø5/8 (ft.) → LA : 131 ft. × 1.99 oz/ft. = 261 oz ø1/2 (ft.) → LB : 16 ft. × 1.38 oz/ft. = 22 oz ø3/8 (ft.) → LC + A – B + 1 – 4 : 225 ft. × 0.602 oz/ft. = 135 oz

Total 418 oz

Additional refrigerant charge amount is 418 oz.

Be sure to check the limit density for

the room in which the indoor unit is

installed.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 18

CAUTION

ft.

4000

Range below the density limit of

0.3 oz/ft. (countermeasures not needed)

500

Range above the density limit of

0.3 oz/ft. (countermeasures needed)

400200 600 800 1000 1200

Total amount of refrigerant

Min. indoor volume

3500

3000

2500

2000

1500

1000

454

398

341

284

227

170

114

ft.

Min. indoor floor area

(when the ceiling is 8.8 ft. high)

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 1-8.

 allow room for mounting the remote controller about 3 ft.

off the floor, in an area that is not in direct sunlight nor in

the flow of cool air from the indoor unit.

Air delivery will be degraded if the distance from the floor to

the ceiling is greater than 10 ft.

Fig. 2-1

Fig. 2-2

Fig. 2-3

Fig. 2-4

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 19

Ceiling-Mounted Type

Ceiling

Wall

min. 10 in.

Front view

min. 10 in.

NOTE

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

Air discharge

min. 2 ft.

Side view

Air intake

Max. 10 in.

Obstacle

Concealed Duct (High-Static Pressure) Type 4-Way Air Discharge Semi-Concealed Type

3 ft.

NOTE

1-Way Air Discharge Semi-Concealed Type

Ceiling

min. 2 in.

Air discharge

min. 3 ft.

Obstacle

Air intake

min. 2 in.

Wall

Side view

Wall-Mounted Type

min. 6 in.

min.6 in.

min. 6 in.

Front View

Fig. 2-5

Fig. 2-6

Fig. 2-7

2-2. Outdoor Unit

AVOID:

 heat sources, exhaust fans, etc.

 damp, humid or uneven locations

 indoors (no-ventilation location)

DO:

 choose a place as cool as possible.

 choose a place that is well ventilated.

 allow enough room around the unit for air intake/

exhaust and possible maintenance.

Installation Space

Install the outdoor unit where there is enough space for ven-

tilation. Otherwise the unit may not operate properly. Fig. 2-6

shows the minimum space requirement around the outdoor

units when 3 sides are open and only 1 side is shuttered,

with open space above the unit. The mounting base should

be concrete or a similar material that allows for adequate

drainage. Make provisions for anchor bolts, platform height,

and other site-specific installation requirements.

 Leave space open above the

unit.

 Construct louvers or other

openings in the wall, if necessary, to ensure adequate ventilation.

 Do not do any wiring or tubing within 1 ft. of the front

panel, because this space is needed as a servicing

space for the compressor.

 Ensure a base height of 4 in. or more to ensure that

drainage water does not accumulate and freeze

around the bottom of the unit.

 If installing a drain pan, install the drain pan prior to

installing the outdoor unit.

* Make sure there is at least 6 in. between the outdoor

unit and the ground.

Also, the direction of the tubing and electrical wiring

should be from the front of the outdoor unit.

Unit: in.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 20

Exhaust fan

Hot air

Heat

Outdoor unit

source

Example of installation of 2 units

(When wall height is below 6 ft.)

* More than 4 in.

CAUTION

NOTE

More than 2 in.

* More than 4 in.

* However, be sure to ensure a space of 1 ft. or more at

either the right side or the rear of the unit.

74-1/64 (Ceiling panel dimensions)

35-3/64 (Ceiling panel dimensions) 35-3/64 (Ceiling panel dimensions)

3-15/16

31-7/64 (Installation hole pitch) 31-7/64 (Installation hole pitch)

70-5/64 (Installation hole pitch)

7-7/8

Top view

More than

1.7 ft.

35-3/64 (Ceiling panel dimensions)

36-7/32 (Installation hole pitch)

37-13/32 (Maximum dimensions)

2-3. Shield for Horizontal Exhaust Discharge

It is necessary to install an air-discharge chamber (field

supply) to direct exhaust from the fan horizontally if it is diffi-

cult to provide a minimum space of 7 ft. between the air-dis-

charge outlet and a nearby obstacle. (Fig. 2-8)

In regions with heavy snowfall,

the outdoor unit should be

provided with a solid, raised plat-

form and snow-proof ducting

(field supply). (Fig. 2-9)

2-4. Installing the Outdoor Unit in Heavy Snow

Areas

In locations where wind-blown snow can be a problem,

snow-proof ducting (field supply) should be fitted to the unit

and direct exposure to the wind should be avoided as much

as possible. (Fig. 2-10) The following problems may occur if

proper countermeasures are not taken:

 The fan in the outdoor unit may stop running, causing the

unit to be damaged.

 There may be no air flow.

 The tubing may freeze and burst.

 The condenser pressure may drop because of strong

wind, and the indoor unit may freeze.

2-5. Precautions When Installing in Heavy Snow

Areas

a) The platform should be higher than the maximum snow

depth. (Fig. 2-9)

b) 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 the outdoor unit.

c) The platform foundation must be solid and the unit must

be secured with anchor bolts.

d) When installing on a roof subject to strong wind, coun-

termeasures must be taken to prevent the unit from

being overturned.

Fig. 2-8

Fig. 2-9

Fig. 2-10

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 21

CAUTION

AVOID

Without snowproof ducting

(Without platform)

With snowproof ducting

(High platform)

Fall en snow

2-6. Dimensions of Wind Ducting

Reference diagram for air-discharge chamber (field supply)

2-unit installation

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 22

unit: in.

Ceiling panel

33-3/16 35-3/64

(Ceiling panel dimensions)

35-15/64

(Maximum bracket dimensions)

Air direction: Front direction Air direction: Right direction

35-3/64

2-11/64 15/16

97-29/32

(Ceiling panel dimensions)

65-53/64 (32-5/64)

35-3/64

(Ceiling panel dimensions)

2-11/6415/16

33-3/16

35-3/64

97-29/32

65-53/64 (32-5/64)

35-15/64

(Ceiling panel dimensions)

Ceiling panel

(Maximum bracket dimensions)

Front view Front viewRight side view Right side view

Note: Can be installed so that the air direction is to the front, right, left or rear direction.

74-7/32

(2-unit installation: maximum dimensions)

5-25/32

33-3/16

31-7/64

33-3/16

31-7/64

(Installation hole pitch)

Top view

unit: in.

36-7/32

7-7/8

(Installation hole pitch)

2-11/64 15/16

97-29/32

35-3/64

(Ceiling panel dimensions)

65-53/64 (32-5/64)

Front view Right side view

2-7. Dimensions of Snow Ducting

Reference diagram for snow-proof ducting (field supply)

2-unit installation

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 23

31-17/32

Air direction: Front direction

Ceiling panel

53-55/64

31-17/32

31-17/32 (Air intake duct)

9-13/32

45-5/16

(Ceiling panel dimensions)

36-7/64

35-3/64

53-55/64

33-3/16 (Air outlet duct)

9-13/32

1 pc.

4 pc.

9-13/32

(Ceiling panel dimensions)

(32-5/64)

97-29/32

65-53/64

31-17/32 53-55/64

45-5/16

9-13/32

(Ceiling panel dimensions)

35-3/64

32-7/832-7/8

9-13/32

15/16 15/16

36-7/64

9-13/32

Air direction: Right direction

Ceiling panel

35-3/64

53-55/64

9-13/32 9-13/32

unit: in.

33-3/16 (Air outlet duct)

31-17/32 (Air intake duct)

Front view

Note: Can be installed so that the air direction is to the front, right, left or rear direction.

Installation hole pitch

31-17/32

74-1/64 (Ceiling panel dimensions)

35-3/64

31-7/64

7-7/8

223

Right side view

35-3/64

3-15/16

31-7/64

70-5/64

Ceiling panel dimensions

Top (Before installation of snowfall protection duct)

36-7/32

35-3/64

37-13/32

Installation hole pitchInstallation hole pitch

31-17/32

Ceiling panel

Front view

35-3/64

9-29/64 9-29/64

(Ceiling panel dimensions)

7/82-11/64

Right side view

unit: in.

45-5/16

36-7/64

92-53/64

Front view

97-29/32

65-53/64

ht side view

36-7/64

45-5/16

36-7/64

45-5/16

3. HOW TO INSTALL THE INDOOR UNIT

 4-Way Air Discharge Semi-Concealed Type (X Type)

3-1. Preparation for Suspending

This unit uses a drain pump. Use a carpenter’s level to check that the unit is level.

3-2. Suspending the Indoor Unit

(1) Fix the suspension bolts securely in the ceiling using the method

shown in the diagrams (Figs. 3-1 and 3-2), by attaching them to the ceiling support structure, or by any other method that ensures that the unit will be securely and safely suspended.

(2) Follow Fig. 3-2 and Table 3-1 to make the holes in the ceiling.

Table 3-1

Unit: in. (mm)

(3) Determine the pitch of the suspension bolts using the supplied

full-scale installation diagram. The diagram and table (Fig. 3-3 and Table 3-2) show the relationship between the positions of the suspension fitting, unit, and panel.

Table 3-2

Fig. 3-1

Fig. 3-2

Note: For DC Fan Tap Change Procedure

for 4-Way Cassette, see page 30.

Fig. 3-4

3-3. Placing the Unit Inside the Ceiling

(1) When placing the unit inside the ceiling, determine

the pitch of the suspension bolts using the supplied full-scale installation diagram. (Fig. 3-4) Tubing and wiring must be laid inside the ceiling when suspending the unit. If the ceiling is already constructed, lay the tubing and wiring into position for connection to the unit before placing the unit inside the ceiling.

Unit: in. (mm)

Fig. 3-3

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 24

-in-anchor

-in-plug

Concrete Insert

Type

Length

12, 18, 24, 36

ABCD

31-1/32

(788)

28-15/32

(723)

34-27/32

(885)

34-27/32

(885)

Type

Length

12, 18, 24

ABCD

4-29/64

(113)

4-29/64

(113)

6-13/16

(173)

6-13/16

(173)

10-5/64

(256)

12-9/16

(319)

8-17/64

(210)

8-17/64

(210)

3-15/32

(88)

3-15/32

(88)

Drain outlet(other side)

(VP25)

Refregerant tubing joint(liquid side) Refregerant tubing joint(gas side)

Suspension bolt (M10 or 3/8") (field supply)

A (suspension bolt pitch)

C (ceiling opening dimension)

B (suspension bolt pitch)

Suspension lug

Over 19/32 (15)

Supplied bolt

Powe r supply outlet

Inter-unit control wiring

Full-scale installation diagram (printed on top of container box)

1-3/8 (35)

15/32 – 43/64

(12 – 17)

Fig. 3-5

(2) The length of suspension bolts must be appropriate

for a distance between the bottom of the bolt and the bottom of the unit of more than 19/32 in. as shown in Fig. 3-5.

(3) Thread the 3 hexagonal nuts and 2 washers (field

supply) onto each of the 4 suspension bolts as shown in Fig. 3-5. Use 1 nut and 1 washer for the upper side, and 2 nuts and 1 washer for the lower side, so that the unit will not fall off the suspension lugs.

(4) Adjust so that the distance between the unit and the

ceiling bottom is 15/32 to 43/64 in. Tighten the nuts on the upper side and lower side of the suspension lug.

(5) Remove the protective polyethylene used to protect

the fan parts during transport.

3-4. Installing the Drain Piping

(1) Prepare a standard hard PVC pipe (O.D. 1-1/4 in.) for

the drain and use the supplied drain hose and hose band to prevent water leaks. The PVC pipe must be purchased separately. The unit’s transparent drain port allows you to check drainage. (Fig. 3-6)

 Insert the drain pipe until it contacts the socket, as

shown in Fig. 3-6, then secure it tightly with the hose band.

 Do not use adhesive when connecting the supplied

hose.

Reasons: 1. It may cause water to leak from the

connection. Since the connection is slippery just after the adhesive has been applied, the pipe easily slips off.

2. The pipe cannot be removed when maintenance is needed.

 Do not bend the supplied drain hose 90° or more.

The hose may slip off.

 Align the hose bands with the end of the hose.

Tighten the hose band firmly. Please make sure that the bead is not covered by the hose band. (Fig. 3-6)

(2) After checking the drainage, wrap the supplied packing

and drain pipe insulator around the pipe. (Fig. 3-7)

Make sure the drain pipe has a downward gradient (1/100 or more) and that there are no water traps.

Tighten the hose clamps so their locking nuts face upward. (Fig. 3-6)

 Do not install an air bleeder

as this may cause water to spray from the drain pipe outlet. (Fig. 3-8)

Fig. 3-6

Fig. 3-7

Fig. 3-8

Unit: in. (mm)

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 25

Suspension bolt

Nuts and washers (use for upper and lower)

Double nut

Connection pipe

(drain port)

Hose band

Align the hose band with the end of the pipe

Suspension lug

15/32 – 43/64 (12 – 17)

Hard PVC

socket

Supplied

drain hose

VP-25

(Field supply)

Packing

(supplied)

Notch

Hard PVC pipe VP-25

(Field supply)

PVC adhesive

CAUTION

NOTE

Bead

Drain insulator (supplied)

Air bleeder prohibited

CAUTION

Fig. 3-9

Fig. 3-10

Fig. 3-11

Fig. 3-12

 In cases where it is necessary to raise the height

of the drain piping, the drain piping can be raised to a maximum height of 33-15/32" above the bottom surface of the ceiling. Under no conditions attempt to raise it higher than 33-15/32" above the bottom surface of the ceiling. Doing so will result in water leakage. (Fig. 3-9)

 Do not install the pipe with an upward gradient

from the connection port. This will cause the drain water to flow backward and leak when the unit is not operating. (Fig. 3-10)

 Do not apply force to the piping on the unit side

when connecting the drain pipe. The pipe should not be allowed to hang unsupported from its connection to the unit. Fasten the pipe to a wall, frame, or other support as close to the unit as possible. (Fig. 3-11)

 Provide insulation for any pipes that are run

indoors.

3-5. Checking the Drainage

After wiring and drain piping are completed, use the following procedure to check that the water will drain smoothly. For this, prepare a bucket and wiping cloth to catch and wipe up spilled water.

(1) Connect power to the power terminal board (R, S

terminals) inside the electrical component box.

(2) Slowly pour about 0.3 gal of water into the drain pan

to check drainage. (Fig. 3-12)

(3) Short the check pin (CHK) on the indoor control

board and operate the drain pump. Check the water flow through the transparent drain pipe and see if there is any leakage.

(4) When the check of drainage is complete, open the

check pin (CHK) and remount the tube cover.

Be careful since the fan will start when you short the pin on the indoor control board.

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 26

CAUTION

11-3/16 in. or less (as short as possible)

33-15/32 in. or less

0 – 45°

* Length of supplied drain hose = 9-27/32 in.

Upward gradient prohibited

Support pieces

Drainage check

CAUTION

Over 3-15/16 in.

Water (Approx. 0.3 gal)

Plastic container

for water intake

Drain pan outlet

3-6. How to Install the Ceiling Panel

3-6-1. Before Installing the Ceiling Panel

Checking the unit position

(1) Check that the ceiling hole is within this range:

33-55/64 × 33-55/64 to 35-53/64 × 35-53/64 in.

(2) Use the full-scale installation diagram (from the

packaging) that was supplied with the unit to determine the positioning of the unit on the ceiling surface. If the positions of the ceiling surface and unit do not match, air leakage, water leakage, flap operation failure, or other problems may result.

 Never place the panel face-down. Either hang

it vertically or place it on top of a projecting object. Placing it face-down will damage the surface.

 Do not touch the flap or apply force to it.

(This may cause flap malfunction.)

must be within the range of 15/32 – 43/64 in.

If not within this range, malfunction or other trouble may result.

Fig. 3-13

Fig. 3-14

Fig. 3-15

Remove the air-intake grille and air filter from the ceiling panel. (Figs. 3-16, 3-17 and 3-18)

a) Remove the 2 screws on the latch of the air-intake

grille. (Fig. 3-16)

b) Slide the air-intake grille catches in the direction

shown by the arrows to open the grille. (Fig. 3-17)

c) With the air-intake grille opened, remove the grille

hinge from the ceiling panel by sliding it in the direction shown by the arrow . (Fig. 3-18)

Removing the corner cover

a) Slide the corner cover to the direction shown

by the arrow to remove the corner cover. (Fig. 3-18).

Fig. 3-17

Fig. 3-18

Fig. 3-16

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 27

Main unit

CAUTION

Ceiling side

Ceiling opening dimension

Flap

Latch

Screw

Corner cover

Air-intake grille hinge

Push

Air-intake grille

Corner cover

Ceiling panel

Strap

3-6-2. Installing the Ceiling Panel

After completing the wiring process, install the supplied wiring cover before installing the panel. It is not possible to install the wiring cover after installing the panel. The power must be turned ON in order to change the flap angle. (Do not attempt to move the flap by hand. Doing so may damage the flap.)

(1) Insert the temporary fasteners (stainless steel) on

the inside of the ceiling panel into the square holes on the unit to temporarily fasten the ceiling panel in place. (Fig. 3-20-1)

 The ceiling panel must be installed in the correct

direction relative to the unit. Align the REF. PIPE and DRAIN marks on the ceiling panel corner with the correct positions on the unit.

 To remove the ceiling panel, support the ceiling

panel while pressing the temporary fasteners toward the outside. (Fig. 3-20-1)

(2) Align the panel installation holes and the unit screw

holes.

(3) Tighten the supplied washer head screws at the

4 panel installation locations so that the panel is attached tightly to the unit. (Fig. 3-20-2)

(4) Check that the panel is attached tightly to the

ceiling.

 At this time, make sure that there are no gaps

between the unit and the ceiling panel, or between the ceiling panel and the ceiling surface. (Fig. 3-21)

 If there is a gap between the panel and the ceiling,

leave the ceiling panel attached and make fine adjustments to the installation height of the unit to eliminate the gap with the ceiling. (Fig. 3-21)

Fig. 3-20-1

Fig. 3-20-2

Fig. 3-21

Fig. 3-22

 If the screws are not sufficiently tight-

ened, trouble such as that shown in the figure below may occur. Be sure to tighten the screws securely.

 If a gap remains between the ceiling

surface and the ceiling panel even after the screws are tightened, adjust the height of the unit again.

The height of the unit can be adjusted from the ceiling panel corner hole, with the ceiling panel attached, to an extent that does not affect the unit levelness, the drain hose, or other elements.

Fig. 3-23

Fig. 3-19-1

Fig. 3-19-2

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 28

Inter-unit control wiring

Screw (supplied)

M4-8 or 5/32" – 5/16"

Push when you remove

Celling panel

Wiring cover (supplied) Power supply outlet

Square hole in unit

Temporary fastener

Drain tubing corner

Refrigerant tubing corner

After completing the wiring process, install the supplied wiring cover before installing the panel. It is not possible to install the wiring cover after installing the panel.

DRAIN mark

CAUTION

Air leakage

Air leakage from ceiling surface

Staining

Condensation, water leakage

Ceilin

surface

Adjust so that there are no gaps.

Washer head screws

Main unit

Do not allow

Ceiling panel

gaps

REF,PIPE mark

Panel installation hole (4 locations)

Insert a wrench or other tool into the corner cover installation hole and make fine adjustments to the unit nut.

3-6-3. Wiring the Ceiling Panel

(1) Open the cover of the electrical component box.

(2) Connect the 7P wiring connector (red) from the

ceiling panel to the connector in the unit electrical component box.

 If the connectors are not connected, the Auto flap will

not operate. Be sure to connect them securely.

 Check that the wiring connector is not caught

between the electrical component box and the cover.

 Check that the wiring connector is not caught

between the unit and the ceiling panel.

3-6-4. How to Attach the Corner & Air-Intake Grille

Attaching the corner cover and air-intake grille

A. Attaching the corner cover

(1) Check that the safety cord from the corner cover is

fastened to the ceiling panel pin, as shown in the figure.

(2) Use the supplied screws to attach the corner cover

to the ceiling panel.

B. Attaching the air-intake grille

 To install the air-intake grille, follow the steps for

Removing the grille in the reverse order. By rotating the air-intake grille, it is possible to attach the grille onto the ceiling panel from any of 4 directions. Coordinate the directions of the air-intake grilles when installing multiple units, and change the directions according to customer requests.

 When attaching the air-intake grille, be careful

that the flap lead wire does not become caught.

 Be sure to attach the safety cord that prevents

the air-intake grille from dropping off to the ceiling panel unit as shown in the figure at right.

 With this ceiling panel, the directions of the air-intake

grille lattices when installing multiple units, and the position of the label showing the company name on the corner panel, can be changed according to customer requests, as shown in the figure below. However, the optional wireless receiver kit can only be installed at the refrigerant-tubing corner of the ceiling unit.

Fig. 3-24

Fig. 3-25

Fig. 3-26

Fig. 3-27

07-007 W-2WAY_II_NA 1/23/07 6:09 PM Page 29

(Direction that the unit faces has been changed to facilitate explanation.)

Electrical component box cover

Screws (3 locations)

Ceiling panel side

Ceiling panel wiring connector

Locations of the air-intake grille catches at the time the product is shipped. * The grille can be installed with these

catches facing in any of 4 directions.

Unit drain hose side

Unit electrical component box

Mains side

Clamp

* Pass the wiring connector through the clamp to fasten it in place, as shown in the fi

Hole for ceiling panel hook

ure.

Place the corner cover so that the 3 tabs fit into the holes in the ceiling panel. Then fasten it in place with the supplied screws.

Hook that prevents the grille from dropping

Unit refrigerant tube side

Optional wireless receiver kit * Can only be installed in this position.

Can be installed rotated 90˚

+ 67 hidden pages

Sanyo R410A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual