Sanyo XHX3652, XMHX1252, XMHX1852, AHX0752, AHX0952 Installation Instructions Manual

...

– W-3WAY ECO-i System Air Conditioner –

R410A Models

for Refrigerant R410A

This air conditioner uses the new refrigerant R410A.

INSTALLATION INSTRUCTIONS

External diameter of service port R410A: 5/16"

NOTE

85464369236000 ©SANYO 2009

Indoor Units

Class 9 12 15 18 2419 36 5448

UM Slim Concealed-Duct UMHX0762 UMHX1262UMHX0962 UMHX1562 UMHX1862

4-Way Air Discharge Mini Semi-Concealed

XMHX1252 XMHX1852

U Concealed-Duct UHX0762 UHX1262UHX0962 UHX1562 UHX1862 UHX2462 UHX3662 UHX4862 UHX5462

4-Way Air Discharge Semi-Concealed

XHX1252 XHX1852 XHX2452 XHX3652

1-Way Air Discharge Semi-Concealed

AHX0752 AHX1252AHX0952

T Ceiling-Mounted THX1252 THX1852 THX2452

Concealed-Duct High Static Pressure

DHX3652 DHX4852

FHX0762 FHX1262FHX0962 FHX1562 FHX1862 FHX2462F Floor-Standing

FMHX0762

FMHX1262

FMHX0962

FMHX1562

FMHX1862

FMHX2462

Concealed-Floor Standing

KHX0752 KHX1252KHX0952K Wall-Mounted KHX1862 KHX1962 KHX2452

Optional Controllers

Timer Wired Remote Controller RCS-TM80BG

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

Wireless Remote Controller (For XM Type) RCS-XM18AAB.WL

Wireless Remote Controller (For U, UM, D, F, FM Types) RCS-BH80AAB.WL

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

Wireless Remote Controller (For K Type) RCS-SH1AAB

Simplified Remote Controller RCS-KR1EG

System Controller SHA-KC64UG

Schedule Timer SHA-TM64AGB

Intelligent Controller SHA-KT256EA

Communication Adaptor SHA-KA128AAB

Remote Sensor ART-K45AGB

LonWorks Interface SHA-LN16UAB

SANYO North America Corporation

Commercial Solutions Division 2055 Sanyo Ave., San Diego CA 92154, U.S.A.

In Canada

SANYO Canada Inc.

201 Creditview Road, Woodbridge Ontario, L4L 9T1, Canada

Class 96

CHDZ09663

CHDZR09663

Outdoor Units

Eco-i W-3WAY

CHDZ07263

CHDZR07263

 Refrigerant R410A is used in the outdoor units.

IMPORTANT!

WARNING

CAUTION

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

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.

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 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.

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).

ASHRAE and the International Mechanical Code of the ICC as well as CSA provide guidance and define safeguards related to the use of refrigerants, all of which define a Refrigerant Concentration Level (RCL) of 25 pounds per 1,000 cubic feet for R410A refrigerant. For additional guidance and precautions related to refrigerant safety, please refer to the following documents:

International Mechanical Code 2009 (IMC-2009) (or more recently revised) ASHRAE 15 ASHRAE 34

New tool?

Precautions for Installation Using New Refrigerant

Vacuum pump

Outlet Inlet

CAUTION

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.

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.

Copper tube

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

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

Material O

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

Material 1/ 2 H, H

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)

Unit: in. (mm)

over 5/128 (1.0)

over 3/64 (1.15)

over

Unit: in. (mm)

3/64 (1.20)

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.

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.

R407C tools

Manifold gauge

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

3-2. Use R410A exclusive cylinder only.

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.

Valve

Single-outlet valve

(with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown.

Liquid

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)

R410A

CONTENTS

Page Page

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 ............................................................... 7

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. Installation Standards 1-11. Check of Limit Density 1-12. Installing Distribution Joint 1-13. Optional Distribution Joint Kits 1-14. Optional Solenoid Valve Kit 1-15. Example of Tubing Size Selection and

Refrigerant Charge Amount

2. SELECTING THE INSTALLATION SITE .............. 20

2-1. Outdoor Unit 2-2. Precautions When Installing in Heavy Snow

Areas 2-3. Dimensions of Wind Ducting 2-4. Dimensions of Snow Ducting

5.HOW TO PROCESS TUBING ................................. 32

5-1. Connecting the Refrigerant Tubing 5-2. Connecting Tubing Between Indoor and

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

6. AIR PURGING ...................................................... 36

Air Purging with a Vacuum Pump (for Test Run)

■

Preparation

7. TEST RUN............................................................. 39

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

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

3-1. Transporting 3-2. Installing the Outdoor Unit 3-3. Remove the Brackets Used for Transport 3-4. Routing the Tubing 3-5. Prepare the Tubing 3-6. Connect the Tubing

4. ELECTRICAL WIRING .......................................... 28

4-1. General Precautions on Wiring 4-2. Recommended Wire Length and Wire

Diameter for Power Supply System

4-3. Wiring System Diagram

CAUTION

1. GENERAL

This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for the outdoor unit and make sure all accessory parts listed are with the system before beginning.

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

1. Flathead screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Carpenter’s level

6. Sabre saw or key hole saw

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

1-2. Accessories Supplied

See Table 1-1.

1-3. Type of Copper Tube and Insulation Material

If you wish to purchase these materials separately from a

local source, you will need:

1. Deoxidized annealed copper tube for refrigerant tubing.

2. Foamed polyethylene insulation for copper tubes as

required to precise length of tubing. Wall thickness of the

insulation should be not less than 5/16 in.

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

with the total length of wiring.

“

Refer to

4. ELECTRICAL WIRING” for details.

Check local electrical codes and

regulations before obtaining

wire. Also, check any specified

instructions or limitations.

1-4. Additional Materials Required for Installation

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire

(See your local codes.)

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

Table 1-1 Outdoor Unit

Part name

Connection tubing

Outer diameter o1-1/8"(o28.58)

Outer diameter o7/8"(o22.22)

Outer diameter o3/4"(o19.05)

Figure

Instruction manual paper

Inner diameter o3/4"(o19.05)

Inner diameter o5/8"(o15.88)

07263 Model

(8 hp)

Q’ty

09663 Model

(10 hp)

(hp = horse power)

1-5. Tubing Length

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

Balance tubing (ø

3/8"

)

Explanation of symbols

Distribution joint (APR: purchased separately)

1. Main tubing length LM = LA + LB … b 262 ft

2. Main distribution tubes LC – LH are selected according to the capacity after the

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

4. Sizes of indoor unit connection tubing

Max. 1.3 ft

distribution joint.

tubing sizes on the indoor units.

For extension

1 – 40 are determined by the connection

T-joint tubing (header joint system)

Solenoid valve kit

Ball valve (field supply)

T-joint (field supply)

Solidly welded shut (pinch weld)

Note: Do not use commercially available T-joints for the liquid tubing

* Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor

unit connections and tubing branches.

and parts.

R410A distribution joint APR-CHRZP900BAB (for outdoor unit) APR-RZP224BAB (for indoor unit) APR-RZP680BAB (for indoor unit) APR-RZP1350BAB (for indoor unit)

Table 1-2 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights

Item Mark Contents Length (ft.)



131

984

49 13

6.6

Allowable tubing length

Allowable elevation difference

Allowable length of joint tubing

L = Length, H = Height

L1 Max. tubing length

$L (L2 – L4)

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

Actual length 492

Equivalent length 574

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

, 2...

L1+

...

A+B

+LF+LG+LH each distribution tube (only liquid tubing)

Max. length of each distribution tube 98

Total max. tubing length including length of

Distance between outdoor units

When outdoor unit is installed higher than indoor unit 164

When outdoor unit is installed lower than indoor unit 131 H2 Max. difference between indoor units H3 Max. difference between outdoor units

T-joint tubing (field-supply); Max. tubing length between

the first T-joint and solidly welded-shut end point

NOTE

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

If the longest tubing length (L1) exceeds 295 ft. (equivalent length), increase the sizes of the main tubes (LM) by 1 rank for the discharge tubes, suction tubes, and narrow tubes. (field supplied)

If the longest main tube length (LM) exceeds 164 feet, increase the main tube size at the portion before 164 ft. by 1 rank for the suction tubes and discharge tubes. (field supplied)

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

1-6. Tubing Size

ø3/4"

(ø19.05)

ø1-1/8"

(ø28.58)

ø1-3/8"

(ø34.92)

ø5/8"

(ø15.88)

ø1-1/8"

(ø28.58)

ø1/2"

(ø12.70)

ø1-1/8"

(ø28.58)

ø3/8"

(ø9.52)

ø7/8"

(ø22.22)

ø5/8"

(ø15.88)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

ø3/4"

(ø19.05)

ø7/8"

(ø22.22)

ø3/8"

(ø9.52)

ø3/8"

(ø9.52)

ø3/8"

(ø9.52)

ø1/2"

(ø12.70)

–

238.900

(25 hp)

200.600

(21 hp)

24.200

(2.5 hp)

24.200

(2.5 hp)

334.400

(35 hp)

85.300

(9 hp)

54.600

(6 hp)

54.600

(6 hp)

85.300

(9 hp)

258.000

(27 hp)

ø3/4"

(ø19.05)

ø1-1/8"

(ø28.58)

ø1-1/2"

(ø38.10)

–

334.400

(35 hp)

ø3/4"

(ø19.05)

ø1-1/8"

(ø28.58)

258.000

(27 hp)

238.900

(25 hp)

102.400

(11 hp)

ø1/2"

(ø12.70)

ø1-1/8"

(ø28.58)

ø3/4"

(ø19.05)

102.400

(11 hp)

124.200

(13 hp)

124.200

(13 hp)

Below BTU/h

Over BTU/h

143.300

(15 hp)

ø1/2"

(ø12.70)

ø1-1/8"

(ø28.58)

ø7/8"

(ø22.22)

ø7/8"

(ø22.22)

ø1-1/8"

(ø28.58)

143.300

(15 hp)

162.400

(17 hp)

ø5/8"

(ø15.88)

ø1-1/8"

(ø28.58)

162.400

(17 hp)

200.600

(21 hp)

Total capacity after distribution

Tubing size

Suction tubing

Liquid tubing

Discharge tubing

hp = horsepower

Unit: in. (mm)

Below BTU/h

Over BTU/h

Total capacity after distribution

Tubing size

ø1-3/8"

(ø34.92)

Suction tubing

Liquid tubing

Discharge tubing

Table 1-5 Outdoor Unit Tubing Connection Size ( A – D)

o3/8" (o9.52)

72,000

(21.1)

96,000

(28.1)

Flare connection

Brazing connection

o3/8" (o9.52)

Flare connection

Balance tubing

Liquid tubing

Discharge tubing

Suction tubing

BTU/h

(kW)

Unit: in. (mm)

*1 If the size of tubing (LA) is less than 16.4 feet, it is recommended that the tubing diameter be larger than

Ø7/8" (Ø22.22).

*2 If the size of tubing (LA) is less than 16.4 feet, it is recommended that the tubing diameter be larger than Ø1-1/8" (Ø28.58).

o5/8"

(o15.88)

o3/4"

(o19.05)

o3/4"

(o19.05)

o7/8"

(o22.22)

Table 1-3 Main Tubing Size (LA)

BTU/h

(kW)

Total system horsepower

72,000

(21.1)

96,000

(28.1)

144,000

(42.2)

168,000

(49.2)

192,000

(56.2)

216,000

(63.3)

240,000

(70.3)

264,000

(77.3)

Unit: in. (mm)

288,000

(84.3)

Combined outdoor units

Suction tubing

Discharge tubing

Liquid tubing

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

*2: The balance tube (outdoor unit tube) diameter is ø3/8" (ø9.52). *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

*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

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.

Table 1-4 Main Tubing Size After Distribution (LB, LC...)

(o28.58)

o7/8"

(o22.22)

o1-1/8"

10 10

o5/8"

(o15.88)

8 8 8

8 8

(o28.58)

o1-1/8"

10 10

o1-3/8"

(o34.92)

o3/4"

(o19.05)

(o22.22)

o5/8"

(o15.88)

o7/8"

o3/8"

(o9.52)

108

o3/4"

(o19.05)

8 8

o1/2"

(o12.7)

However extension is not possible if the resulting tubing size is two ranks higher.

suction, discharge, and liquid tubes. (Use field-supply reducers.) (Select from Table 1-3 and Table 1-9.)

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

*1: The outdoor unit connection tubing (LO) is

determined by the total capacity of the outdoor units connected to the tube ends. The tubing size is selected based on the table of main tube sizes after the branch.

*2: If the total capacity of the indoor units con-

nected to the tube ends is different from the total capacity of the outdoor units, then the main tube size is selected based on the total capacity of the outdoor units. (For LA, LB, and LF in particular)

10 10 10

Gas tubing size (in.(mm))

1/2"

(12.7)

5/8"

(15.88)

3/4"

(19.05)

7/8"

(22.22)1"(25.4)

1-1/8"

(28.58)

1-1/4"

(31.8)

1-1/2" (38.1)

90 o elbow

1 ft.

(0.30 m)

1.1 ft.

(0.35 m)

1.4 ft.

(0.42 m)

1.6 ft.

(0.48 m)

1.7 ft.

(0.52 m)

1.9 ft.

(0.57 m)

2.3 ft.

(0.70m)

2.6 ft.

(0.79 m)

45 o elbow

0.8 ft.

(0.23 m)

0.9 ft.

(0.26 m)

1 ft.

(0.32 m)

1.2 ft.

(0.36 m)

1.3 ft.

(0.39 m)

1.4 ft.

(0.43 m)

1.7 ft.

(0.53 m)

1.9 ft.

(0.59 m)

U-shape tube bent (R2–23/64–3–15/16 in.)

3 ft.

(0.90 m)

3.4 ft.

(1.05 m)

4.1 ft.

(1.26 m)

4.7 ft.

(1.44 m)

5.1 ft.

(1.56 m)

5.6 ft.

(1.71 m)

6.9 ft.

(2.10 m)

7.8 ft.

(2.37 m)

T r ap bend

7.5 ft.

(2.30 m)

9.2 ft.

(2.80 m)

10.5 ft.

(3.20 m)

12.5 ft.

(3.80 m)

14.1 ft.

(4.30 m)

15.4 ft.

(4.70 m)

16.4 ft.

(5.00 m)

14.0 ft.

(5.80 m)

Y -br anch distr ib ution joint Equiv alent length con v ersion not needed.

Ball v alv e f or ser vice Equiv alent length con v ersion not needed.

Table 1-6 Refrigerant Charge Amount at Shipment (for outdoor unit)

CHDZR07263 CHDZR09663

(oz)

CHDZ07263 CHDZ09663

416 416

Table 1-7 Indoor Unit Tubing Connection Size ( 1 – 40)

Indoor unit type

Total system horsepower

Distribution joint-solenoid valve kit tubing

Solenoid valve kit-Indoor unit tubing connection

Suction tubing Discharge tubing Liquid tubing

Gas tubing

Liquid tubing

7 9 12 15 18 19 24 36 48 54

0.8 1 1.3 1.7 2 2.1 3 4 5 5.5

o1/2" (o12.7)

o1/4" (o6.35)

o5/8" (o15.88)

o1/2" (o12.7)

o3/8" (o9.52)

o5/8" (o15.88)

o3/8" (o9.52)

Unit: in. (mm)

*1: For the solenoid valve kits, use type 160 with parallel specifications. Branch the tubing before and after the solenoid valve kits.

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 1-8 Straight Equivalent Length of Joints

Table 1-9 Refrigerant tubing (Existing tubing can be used.)

Material O Material 1/2H • H

ø1/4" (ø6.35) t1/32 (t0.8)

ø3/8" (ø9.52) t1/32 (t0.8) ø1-1/8" (ø28.58) t5/128 (t1.0)

ø1/2" (ø12.7) t1/32 (t0.8) ø1-1/4" (ø31.75) t3/64 (t1.1)

ø5/8" (ø15.88) t5/128 (t1.0) ø1-1/2" (ø38.10) over t3/64 (t1.15)

ø3/4" (ø19.05)

ø7/8" (ø22.22) t5/128 (t1.0)

Tubing size (in. (mm))

over t5/128 (t1.0)

ø1-5/8" (ø41.28) over t3/64 (t1.20)

1-8. Additional Refrigerant Charge

Additional refrigerant charge amount is calculated from the liquid tubing total length and a type of outdoor unit as follows.

ø3/8"

(ø9.52)

Table 1-10-1 Amount of Refrigerant Charge Per ft.,

According to Liquid Tubing Size

Liquid tubing size

Amount of refrigerant charge (oz/ft.)

ø1/4"

(ø6.35)

0.279 0.602 1.38 1.99 2.78 3.93

ø1/2"

(ø12.7)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

ø7/8"

(ø22.22)

Required amount of additional refrigerant charge =

[ (Amount of additional refrigerant charge per ft. of each size of liquid tube × its tube length) + (...) + (...)] + [(Necessary amount of additional refrigerant charge per outdoor unit + (...) + (...)]

* Always charge accurately using a scale for weighing.

* 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.

Outdoor unit Outdoor unit Indoor unit

Suction tube

Discharge tube

Liquid tube

Balance tube

Suction tube

Discharge tube

Liquid tube

Gas tube

Liquid

tube

4-tube layout 3-tube layout 2-tube layout

Solenoid

valve kit

Indoor unit

Room

Hallway

Indoor unit

Room

Indoor unit

Room

Hallway

Indoor unit

Room

Solenoid valve kit

Table 1-10-2 Necessary Amount of Refrigerant Charge Per Outdoor Unit

Further charge a certain amount listed below in addition to the amount of refrigerant charge.

CHDZ07263

CHDZR07263

42 oz/unit 42 oz/unit

CHDZ09663

CHDZR09663

1-9. System Limitations

Table 1-11 System Limitations

Max. No. allowable connected outdoor units 3

Max. capacity allowable connected outdoor units

Max. connectable indoor units 40

288,000 BTU/h (30 hp, 84.3 kw)

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

*1: In the case of 20 hp (type 191.100 BTU/h) or smaller units, the number is limited by the total capacity of the connected indoor units.

1-10. Installation Standards

Relationship between A/C units and refrigerant tubing

●

Install the solenoid valve kit 98 ft. or less from the indoor unit.

●

In quiet locations such as hospitals, libraries, and hotel rooms, the refrigerant noise may be somewhat notice-

able. It is recommended that the solenoid valve kit be installed inside the corridor ceiling, at a location outside the room.

Desirable

Undesirable

Common solenoid valve kit

●

Multiple indoor units under group control can utilize a solenoid valve kit in common.

●

Categories of connected indoor unit capacities are determined by the solenoid valve kit.

Type of solenoid valve kit Total capacity of indoor units (BTU/h)

160 19.000

56 7.500

Total capacity < 54.600

Total capacity < 19.000

●

If the capacity range is exceeded, use 2 solenoid valves connected in parallel.

WARNING

Always check the gas density

15 to 30

Tube branching methods (horizontal use)

Arrow view

Horizontal line

View as seen from arrow

Ball valve

(BV: purchased

separately)

Main tubing

Types of vertical trap specifications

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

Indoor unit (1)

(When not using ball valve)

(When using ball valve)

Branch tubing is directed upward.

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

Main tubing

Indoor unit

More than 7–7/8"

Indoor unit (more than 2 units)

Horizontal

Indoor unit is directed downward

CAUTION

limit for the room in which the unit is installed.

1-11. 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.

1-12. Installing Distribution Joint

Pay special attention to any location, such as a basement, etc., where leaking refrigerant can accumulate, since refrigerant gas is heavier than air.

(1) Refer to “HOW TO ATTACH DISTRIBUTION JOINT”

enclosed with the optional distribution joint kit (APR-CHRZP900BAB, RZP224BAB, RZP680BAB, RZP1350BAB).

(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 accumulation of refrigerant oil in stopped units, if the main tubing is horizontal then each branch tubing length should be at an angle that is greater than horizontal. If the main tubing is vertical, provide a raised starting portion for each branch.

Header joint system (Indoor)

Install at a positive angle

Outdoor

Indoor

Horizontal line

L3 6.56 ft.

Indoor

Horizontal line

Install at a positive angle (15 – 30°)

Solidly welded shut (X)

[Header joint system]

●

Be sure to solidly weld shut the T-joint end (marked

by “X” in the figure). In addition, pay attention to the insertion depth of each connected tube so that the flow of refrigerant within the T-joint is not impeded.

●

When using the header joint system, do not make fur-

ther branches in the tubing.

●

Do not use the header joint system on the outdoor

unit side.

(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 15 - 3/4" of the distribution joint.)

If a trap or ball valve is not added, do not operate the system before repairs to a malfunctioning unit are completed. (The refrigerant oil sent through the tub-

ing to the malfunctioning unit will accumulate and may damage the compressor.)

1-13. Optional Distribution Joint Kits

11-13/16 11-13/16

13-25/64

EDF

3/41-1/8 3/85/8 1/21

Size

7/81-1/4

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

Inch

InsulationInsulation

Joint

Distribution

Insulation

EFG

E F

Suction Tube

Discharge Tube

Liquid Tube

Unit: in.

*Insulators for both the Suction tube and the Discharge tube are the same. *Suction tube and Discharge tube are similar in sizes and both the tube entrances have the same diameter. So the both Distribution joints can fit into different tubes. Since the diameter of the tube ends for both Suction and Discharge tube are different, take care not to connect the distribution joint different. See the " # " marks on the above figures.

Note that the dimension marked with every alphabetical letter in the diagram shows the inner diameter.

Table 1-13 Dimensions for connections of each part

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

Table 1-12

Model name Cooling capacity after distribution Remarks

1. APR-CHRZP900BAB 307.100 BTU/h or less For outdoor unit

2. APR-RZP224BAB 76.400 BTU/h or less For indoor unit

3. APR-RZP680BAB 232.000 BTU/h or less For indoor unit

4. APR-RZP1350BAB 460.700 BTU/h or less For indoor unit

Tubing size (with thermal insulation)

■

1. APR-CHRZP900BAB For outdoor unit (Capacity after distribution joint is 307.100 BTU/h or less.)

Insulation

Note that the dimension marked with every alphabetical letter in the diagram shows the inner diameter.

EFD

GF E

EFG

E F

FED

Suction Tube

Discharge Tube

Liquid Tube

11-13/16

13-25/64

11-13/16

Table 1-14 Dimensions for connections of each part

Unit: in.

Position A B C D E F G H I J

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

2. APR-RZP224BAB Use: For indoor unit (Capacity after distribution joint is 76.400 BTU/h or less.)

Example: (F below indicates inner diameter. below indicates outer diameter.)

Liquid tubing

9–1/4

I H

HIIH

2–23/32

2–11/64

Suction tubing

8–17/64

5–45/64

Discharge tubing

7–21/64

G H

3–5/8 15/32

2–11/64

1–37/64

5–23/64

3–1/32 9/32

Thermal insulation

Unit: in.

3. APR-RZP680BAB Use: For indoor unit (Capacity after distribution joint is greater than 76.400 BTU/h and no more than 232.000 BTU/h.)

4. APR-RZP1350BAB Use: For indoor unit (Capacity after distribution joint is greater than 232.000 BTU/h and no more than 460.700 BTU/h.)

Example: (B below indicates inner diameter. below indicates outer diameter.)

Suction tubing • Discharge tubing

H G

2–11/64

Thermal insulation

3–35/64

F E D C

C A

BBC

4–9/64 4–13/32

1–49/64

Liquid tubing

ECDAFFADCE

13–25/64

Thermal insulation

5–1/8

1–31/32

Unit: in.

Part

Number

Cover of relay kit

Relay kit

Cover of control box

Earth (M5 with washer)

Terminal for communication line

Terminal for power line

Base of control box

Service panel

Discharge tube: ID1/2"

Suction tube: ID5/8"

Liquid tube : ID3/8"

Suspension hook

Liquid tube : ID1/4"

Types and specifications of tubing connections

ATK-RZP56BAWB

Gas tube: ID1/2"

Specifications

1314

5-25/32

9-13/32

5-55/64

53/64 2-63/64

9-29/64

63/64

2-31/64

3-15/16

6-29/64

8-15/32

2-31/64

3-15/16

5-55/64

7/16

1-7/64

43/64

4-21/64 4-21/64

5-3/64 4-1/4 3-25/32

2-3/64

5-9/32

4-49/64

5-55/64

1-21/32

4-7/32

1-21/32

3-21/32

Unit: in.

ATK-RZP56BAWB

Compatibility Power source Power input Net weight

Accessories

7.500 Total capacity of indoor units (BTU/h) < 19.000 Single-phase AC 208–230V 60Hz (supplied by indoor unit) 33 W max.

151.7 oz.

Washer x 2 Hanging hook M4 screw x 4 Tapping screw x 4 Wire holder 3-WAY connect wire ACC-3WAY-AAB (Solenoid Valve Relay Kit)

1-14. Optional Solenoid Valve Kit

Precautions on Installation of Solenoid Valve Kit

(1) Clean base metals thoroughly.

(2) Use proper ventilation to carry fumes away from the work area.

(3) Use a high quality silver based solder of at least 15 % silver.

(4) Heat the base materials broadly and uniformly.

(5) Take precautions not to overheat the device which could damage sensitive internal components.

(6) Insure compliance with all local codes!

Part

Number

Cover of relay kit

Relay kit

Cover of control box

Earth (M5 with washer)

Terminal for communication line

Terminal for power line

Base of control box

Service panel

Discharge tube: ID1/2"

Suction tube: ID5/8"

Liquid tube : ID3/8"

Suspension hook

Liquid tube : ID3/8"

Types and specifications of tubing connections

ATK-RZP160BAWB

Compatibility Power source Power input Net weight

Accessories

ATK-RZP160BAWB

19.000 Total capacity of indoor units (BTU/h) < 54.600 Single-phase AC 208–230V 60Hz (supplied by indoor unit) 40 W max.

165.8 oz.

Gas tube: ID5/8"

Specifications

1314

5-25/32

5-55/64 5-55/64

43/64

4-49/64

5-9/32

2-3/64

5-3/64

3-25/32

4-1/4

1-7/64

7/16

5-55/64

9-29/64

4-21/64 4-21/64

1-21/32

63/64

2-31/64

3-15/16

2-31/64

3-15/16

6-29/64

8-15/32

3-21/32

4-7/32

1-21/32

3-21/32

9-13/32

53/64 2-63/64

Unit: in.

Washer x 2 Hanging hook M4 screw x 4 Tapping screw x 4 Wire holder 3-WAY connect wire ACC-3WAY-AAB (Solenoid Valve Relay Kit)

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

Nut (field supplied) (3/8" or M10)

Washer

M4 screws (12 pcs.)

Suspension hook

Installation of Solenoid Valve Kit

1. Install the relay kit into the indoor unit. Refer to the Installation Manual for the solenoid valve kit.

2. Connect the solenoid valve kit and the relay kit in the field.

Gas tube

Liquid tube

Connect with conduit for power supply

Suspension hook

Top surface

Discharge tube

Relay kit

Front

Liquid tube

Suction tube

Cover of control box

NOTE

Notes on Installation

• Be sure to secure the valve body by using its structure with the suspension bolt, etc.

• Install the valve body within a distance of 98 ft. from the indoor unit. Some refrigerant noise will be produced. Therefore in hospitals, libraries, hotel guest rooms, and other quiet locations, it is recommended that the solenoid valve kit be installed on the ceiling reverse side of a hallway or another location separated from the room.

• When installing the valve body, install with the top surface facing up. Secure 7-7/8" or more of space to the front so that the front service panel can be removed.

• If the supplied suspension hook will not be used, and other fastening devices will be attached in the field, use the 4 screw holes on the top surface. DO NOT use any long screws other than the supplied screws. Use of other screws may puncture the internal tubing, resulting in refrigerant leakage.

• Do not block the air holes.

Front

Service space

7-7/8" or more

+ 37 hidden pages

Sanyo XHX3652, XMHX1252, XMHX1852, AHX0752, AHX0952 Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual