Toshiba MMU-AP0071YH, MMY-MAP0802FT8, MMY-MAP1002FT8 INSTALLATION MANUAL

INSTALLATION MANUAL

Heat Recovery Type (2 Series)

FILE NO. A05-018

R410A

Indoor Unit

<4-way Air Discharge Cassette Type>

MMU-AP0091H, AP0121H, AP0151H, MMU-AP0181H, AP0241H, AP0271H, MMU-AP0301H, AP0361H, AP0481H MMU-AP0561H

<2-way Air Discharge Cassette Type>

MMU-AP0071WH, AP0091WH, AP0121WH, MMU-AP0151WH, AP0181WH, AP0241WH, MMU-AP0271WH, AP0301WH, AP0481WH*

* CHINA market only

<1-way Air Discharge Cassette Type>

MMU-AP0071YH, AP0091YH, AP0121YH, MMU-AP0151SH, AP0181SH, AP0241SH

MMD-AP0071BH, AP0091BH, AP0121BH, MMD-AP0151BH, AP0181BH, AP0241BH, MMD-AP0271BH, AP0301BH, AP0361BH, MMD-AP0481BH, AP0561BH

MMD-AP0181H, AP0241H, AP0271H, MMD-AP0361H, AP0481H, AP0721H, MMD-AP0961H

MMC-AP0151H, AP0181H, AP0241H, MMC-AP0271H, AP0361H, AP0481H

MMK-AP0071H, AP0091H, AP0121H, MMK-AP0151H, AP0181H, AP0241H, MMK-AP0072H*, AP0092H*, AP0122H*

* European market only

MML-AP0071H, AP0091H, AP0121H, MML-AP0151H, AP0181H, AP0241H

MML-AP0071BH, AP0091BH, AP0121BH, MML-AP0151BH, AP0181BH, AP0241BH

MMF-AP0151H, AP0181H, AP0241H MMF-AP0271H, AP0361H, AP0481H MMF-AP0561H

Outdoor Unit

MMY-MAP0802FT8 MMY-MAP1002FT8 MMY-MAP1202FT8

FS unit

RBM-Y1122FE RBM-Y1802FE RBM-Y2802FE

PRINTED IN JAPAN, 2005

WARNINGS ON REFRIGERANT LEAKAGE

Check of Concentration 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 concentration 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 to be imposed which protect the ozone layer. However, since it contains more than air, it poses the risk of suffocation if its concentration should rise excessively. Suffocation from leakage of R410A is almost non-existent. With the recent increase in the number of high concentration 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 with conventional individual air conditioners. If a single unit of the multi 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 concentration 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 concentration may exceed the limit, create an opening with adjacent rooms, or install mechanical ventilation combined with a gas leak detection device. The concentration is as given below.

Total amount of refrigerant (kg)

Min. volume of the indoor unit installed room (m³)

≤ Concentration limit (kg/m³)

The concentration limit of R410A which is used in multi air conditioners is 0.3kg/m³. (For details, refer and comply with local regulations.)

NOTE 1 :

If there are 2 or more refrigerating systems in a single refrigerating device, the amounts of refrigerant should be as charged in each independent device.

e.g., charged amount (10kg)

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

For the amount of charge in this example:

The possible amount of leaked refrigerant gas in rooms A, B and C is 10kg. The possible amount of leaked refrigerant gas in rooms D, E and F is 15kg.

Outdoor unit

e.g., charged amount (15kg)

Indoor unit

Important

NOTE 2 :

The standards for minimum room volume are as follows.

(1) No partition (shaded portion)

(2) When there is an effective opening with the

adjacent room for ventilation of leaking refrigerant gas (opening without a door, or an opening 0.15% or larger than the respective floor spaces at the top or bottom of the door).

Outdoor unit

Refrigerant piping

Indoor unit

(3) If an indoor unit is installed in each partitioned room

and the refrigerant piping is interconnected, the smallest room of course becomes the object. But when a mechanical ventilation is installed interlocked with a gas leakage detector in the smallest room where the density limit is exceeded, the volume of the next smallest room becomes the object.

Refrigerant piping

Outdoor unit

Ver y small room

Small room

Mechanical ventilation device - Gas leak detector

Medium room

Large room

NOTE 3 :

The minimum indoor floor area compared with the amount of refrigerant is roughly as follows: (When the ceiling is 2.7m high)

Range below the

m²

density limit of 0.3 kg/m³

(countermeasures not needed)

Min. indoor floor area

10 20 30

Total amount of refrigerant

Range above the density limit of 0.3 kg/m³ (countermeasures needed)

Indoor unit

NOTE

A direct current motor is adopted for indoor fan motor in the Concealed Duct Standard Type air conditioner. Caused from its characteristics, a current limit works on the direct current motor. When replacing the highperformance filter or when opening the service board, be sure to stop the fan. If an above action is executed during the fan operation, the protective control works to stop the unit operation, and the check code “P12” may be issued. However it is not a trouble. When the desired operation has finished, be sure to reset the system to clear “P12” error code using the leak breaker of the indoor unit. Then push the operation stop button of the remote controller to return to the usual operation.

CONTENTS

1. SELECTING A LOCATION FOR INSTALLATION ................................. 4

2. SAFETY NOTES ...................................................................................... 8

3. CHECK POINTS ...................................................................................... 9

4. KEY POINTS OF AIR CONDITIONER INSTALLATION ...................... 10

5. REFRIGERANT PIPE INSTALLATION ................................................. 11

6. INDOOR UNIT INSTALLATION............................................................. 43

7. FLOW SELECTOR UNIT INSTALLATION ........................................... 82

8. OUTDOOR UNIT INSTALLATION ........................................................ 88

9. ELECTRIC WIRING................................................................................ 95

10. INDOOR UNIT TERMINAL BOARD PLACEMENT AND WIRING..... 111

11. DRAIN PIPE INSTALLATION .............................................................. 117

12. ADJUSTMENT OF AIR DIRECTION .................................................. 126

13. APPLIED CONTROL ........................................................................... 131

14. ADDRESS SETUP ............................................................................... 135

15. TEST OPERATION .............................................................................. 148

16. SUPPORT FUNCTION IN TEST OPERATION ................................... 157

17. TROUBLESHOOTING ......................................................................... 180

18. AIR SPEED CHARACTERISTICS ...................................................... 185

19. FAN CHARACTERISTICS .................................................................. 190

CAUTION New Refrigerant Air Conditioner Installation

• THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.

The characteristics of R410A refrigerant are ; easy to absorb water, oxidizing membrane or oil, and its pressure is approx. 1.6 times higher than that of refrigerant R22. Accompanied with the new refrigerant, refrigerating oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigerating oil does not enter the refrigerating cycle.

To prevent charging an incorrect refrigerant and refrigerating oil, the sizes of connecting sections of charging port of the main unit and installation tools are charged from those for the conventional refrigerant.

Accordingly the exclusive tools are required for the new refrigerant (R410A). For connecting pipes, use new and clean piping designed for R410A, and please care so that water or dust

does not enter. Moreover, do not use the existing piping because there are problems with pressure-resistance force and impurity in it.

1. SELECTING A LOCATION FOR INSTALLATION

WARNING

Install the air conditioner certainly at a location to sufficiently withstand the weight.

If the strength is insufficient, the unit may fall down resulting in human injury.

Perform a specified installation work to guard against a great wind such as typhoon or an earth quake.

An incomplete installation can cause accidents by the units failing and dropping.

The following models must be installed at height 2.5m or more from the floor. (Concealed type duct type and cassette type air conditioners)

If you insert your hands or others directly into the unit while the air conditioner operates, it is dangerous

because you may contact with revolving fan or active electricity.

Installation Location Selection for Outdoor unit

Obtain permission from the customer to install the unit in a location that satisfies the following requirements :

• A location that permits level installation of the unit.

• A location that provides enough space to service the unit safety

• A location where water draining from the unit will not pose a problem

Avoid installing in the following places.

• Place exposed to air with high salt content (seaside area), or place exposed to large quantities of sulfide gas (hot spring). (Should the unit be used in these places, special protective measures are needed.)

• Place exposed to oil, vapor, oil smoke or corrosive gas.

• Place where organic solvent is used nearby.

• Place close to a machine generating high frequency.

• Place where the discharged air blows directly into the window of the neighboring house. (For outdoor unit)

• Place where noise of the outdoor unit is easily transmitted. (When installing the air conditioner on the boundary with the neighbor, pay due attention to the level of noise.)

• Place with poor ventilation. (Especially in Concealed duct type indoor unit, before air ducting work, check whether value of air volume, static pressure and duct resistance are correct.)

Equipments

1. Outdoor units

Inverter unit

Corresponding HP

8 HP 10 HP 12 HP

Model name

MMY- MAP0802FT8 MAP1002FT8 MAP1202FT8

Cooling capacity (kW) 22.4 28.0 33.5

Heating capacity (kW) 25.0 31.5 35.5

2. Outdoor units (Combination of outdoor units)

Corresponding HP

Combined model

Cooling capacity (kW) Heating capacity (kW)

Combined outdoor units

No. of connectable indoor units

Corresponding HP

Combined model

Cooling capacity (kW) Heating capacity (kW)

Combined outdoor units

No. of connectable indoor units

MMY- MAP0802FT8

MMY- AP2002FT8

8HP

22.4 25

8HP

20HP

56 63

10HP 10HP

10HP

MAP1002FT8

31.5

10HP

24HP

AP2402FT8

76.5 8HP 8HP 8HP

12HP

MAP1202FT8

33.5

35.5

12HP

26HP

AP2602FT8

81.5

10HP

8HP 8HP

16HP

AP1602FT8

50 8HP 8HP

28HP

AP2802FT8

78.5

10HP 10HP

8HP

Appearance

18HP

AP1802FT8

50.4

56.5

10HP

8HP

30HP

AP3002FT8

95 10HP 10HP 10HP

Allocation standard of model name

MMY– M AP T 8

Power supply specifications, 3Ø 380–415 V, 50Hz ....... 8

T : Capacity variable unit

F : Heat recovery

Development series No.

Capacity rank HP x 10

New refrigerant R410A

M : Single module unit, No mark : Combined Model name

Modular Multi

3. FS units (Flow selector units)

Model name Inverter unit Appearance

RBM-Y1122FE

RBM-Y1802FE Total capacity for indoor unit : 11.2 to below 18.0kW

Total capacity for indoor unit : below 11.2kW

RBM-Y2802FE Total capacity for indoor unit : 18.0 to 28.0kW or less

∗ Accessory part : Connection cable kit (RBC-CBK15FE), up to 15m.

3. Indoor units

Type Appearance Model name Capacity rank Capacity code

MMU-AP0091H 009 type 1 2.8 3.2

4-way Air Discharge Cassette Type

2-way Air Discharge Cassette Type

1-way Air Discharge Cassette Type

Concealed Duct Standard Type

Concealed Duct High Static Pressure Type

Under Ceiling Type

High Wall Type (1 Series)

High Wall Type (2 Series)

Floor Standing Cabinet Type

Floor Standing Concealed Type

Floor Standing Type

MMU-AP0121H MMU-AP0151H MMU-AP0181H MMU-AP0241H MMU-AP0271H MMU-AP0301H MMU-AP0361H MMU-AP0481H MMU-AP0561H 056 type 6 16.0 MMU-AP0071WH MMU-AP0091WH MMU-AP0121WH MMU-AP0151WH MMU-AP0181WH MMU-AP0241WH MMU-AP0271WH MMU-AP0301WH MMU-AP0481WH* MMU-AP0071YH MMU-AP0091YH MMU-AP0121YH MMU-AP0151SH MMU-AP0181SH MMU-AP0241SH MMD-AP0071BH MMD-AP0091BH MMD-AP0121BH MMD-AP0151BH MMD-AP0181BH MMD-AP0241BH MMD-AP0271BH MMD-AP0301BH MMD-AP0361BH MMD-AP0481BH MMD-AP0561BH MMD-AP0181H MMD-AP0241H MMD-AP0271H MMD-AP0361H MMD-AP0481H MMD-AP0721H MMD-AP0961H MMC-AP0151H MMC-AP0181H MMC-AP0241H MMC-AP0271H MMC-AP0361H MMC-AP0481H MMK-AP0071H MMK-AP0091H MMK-AP0121H MMK-AP0151H 015 type 1.7 4.5 5.0 MMK-AP0181H MMK-AP0241H MMK-AP0072H MMK-AP0092H MMK-AP0122H MML-AP0071H MML-AP0091H MML-AP0121H MML-AP0151H MML-AP0181H MML-AP0241H MML-AP0071BH MML-AP0091BH MML-AP0121BH MML-AP0151BH MML-AP0181BH MML-AP0241BH MMF-AP0151H 015 type 1.7 4.5 5.0 MMF-AP0181H MMF-AP0241H MMF-AP0271H MMF-AP0361H MMF-AP0481H MMF-AP0561H

012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 030 type 3.2 9.0 036 type 4 11.2 048 type 5 14.0

007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 030 type 3.2 9.0

048 type 5 14.0 16.0 007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 030 type 3.2 9.0 036 type 4 11.2 048 type 5 14.0 056 type 6 16.0 018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 036 type 4 11.2 048 type 5 14.0 072 type 8 22.4 096 type 10 28.0 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 036 type 4 11.2 048 type 5 14.0 007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6

018 type 2 5.6 024 type 2.5 7.1 007 type 0.8 2.2 009 type 1.0 2.8 012 type 1.25 3.6 007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1 007 type 0.8 2.2 009 type 1 2.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 2 5.6 024 type 2.5 7.1

018 type 2 5.6 024 type 2.5 7.1 027 type 3 8.0 036 type 4 11.2 048 type 5 14.0 056 type 6 16.0

Cooling

capacity (kW)

*1) China market only *2) European market only

Heating

capacity (kW)

4.0

5.0

6.3

8.0

9.0

10.0

12.5

16.0

18.0

2.5

3.2

4.0

5.0

6.3

8.0

9.0

10.0

2.5

3.2

4.0

5.0

6.3

8.0

2.5

3.2

4.0

5.0

6.3

8.0

9.0

10.0

12.5

16.0

18.0

6.3

8.0

9.0

12.5

16.0

25.0

31.5

5.0

6.3

8.0

9.0

12.5

16.0

2.5

3.2

4.0

6.3

8.0

2.5

3.2

4.0

2.5

3.2

4.0

5.0

6.3

8.0

2.5

3.2

4.0

5.0

6.3

8.0

6.3

8.0

9.0

12.5

16.0

18.0

Tools

Required Tools

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

(1) Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22)) (2) Tools exclusive for R410A, but can be also used for conventional refrigerant (R22) (3) Tools commonly used for R410A and for conventional refrigerant (R22) The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

Conventional air

conditioner installation

Whether new equipment can be used with conventional refrigerant

{

*(Note 1)

{

No.

g h i

j k l

Used tool

Flare tool

Copper pipe gauge for adjusting projection margin

Torque wrench

Gauge manifold

Charge hose

Vacuum pump adapter

Electronic balance for refrigerant charging

Refrigerant cylinder

Leakage detector

Charging cylinder

Usage

Pipe flaring

Flaring by conventional flare tool

Connection of flare nut

Evacuating, refrigerant charge, run check, etc.

Vacuum evacuating

Refrigerant charge

Gas leakage check

Refrigerant charge

air conditioner installation

Existence of new equipment for R410A

Yes

(Note 2)

R410A

Whether conventional equipment can be used

*(Note 1)

Yes

× × ×

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection

margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

(1) Vacuum pump

Use vacuum pump by

attaching vacuum pump adapter. (2) Torque wrench (3) Pipe cutter

(4) Reamer (5) Pipe bender (6) Level vial (7) Screwdriver (+, –) (8) Spanner or Monkey wrench

(9) Hole core drill (10) Hexagon wrench

(Opposite side 4mm) (11) Tape measure (12) Metal saw

Also prepare the following equipments for other installation method and run check. (1) Clamp meter (2) Thermometer

(3) Insulation resistance tester (4) Electroscope

2. SAFETY NOTES

• Ensure that all Local, National and International regulations are satisfied.

• Read this “SAFETY NOTES” carefully before Installation.

• The precautions described below include the important items regarding safety. Observe them without fail.

• After the installation work, perform a trial operation to check for any problem. Follow the Owner’s Manual to explain how to use and maintain the unit to the customer.

• Turn off the main power supply switch (or breaker) before the unit maintenance.

• Ask the customer to keep the Installation Manual together with the Owner’s Manual.

WARNING

• Ask an authorized dealer or qualified installation professional to install/maintain the air conditioner.

Inappropriate installation may result in water leakage, electric shock or fire.

• Turn off the main power supply switch or breaker before attempting any electrical work.

Make sure all power switches are off. Failure to do so may cause electric shock.

• Connect the connecting wire correctly.

If the connecting wire is connected in a wrong way, electric parts may be damaged.

• When moving the air conditioner for the installation into another place, be very careful not to enter

any gaseous matter other than the specified refrigerant into the refrigeration cycle.

If air or any other gas is mixed in the refrigerant, the gas pressure in the refrigeration cycle becomes abnormally high and it as a result causes pipe burst and injuries on persons.

• Do not modify this unit by removing any of the safety guards or by by-passing any of the safety

interlock switches.

• Exposure of unit to water or other moisture before installation may cause a short-circuit of electrical

parts.

Do not store it in a wet basement or expose to rain or water.

• After unpacking the unit, examine it carefully if there are possible damage.

• Do not install in a place that might increase the vibration of the unit.

• To avoid personal injury (with sharp edges), be careful when handling parts.

• Perform installation work properly according to the Installation Manual.

Inappropriate installation may result in water leakage, electric shock or fire.

• When the air conditioner is installed in a small room, provide appropriate measures to ensure that

the concentration of refrigerant leakage occur in the room does not exceed the critical level.

• Install the air conditioner securely in a location where the base can sustain the weight adequately.

• Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

• If refrigerant gas has leaked during the installation work, ventilate the room immediately.

If the leaked refrigerant gas comes in contact with fire, noxious gas may generate.

• After the installation work, confirm that refrigerant gas does not leak.

If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas might generate.

• Electrical work must be performed by a qualified electrician in accordance with the Installation

Manual. Make sure the air conditioner uses an exclusive power supply.

An insufficient power supply capacity or inappropriate installation may cause fire.

• Use the specified wires for wiring connect the terminals securely fix. To prevent external forces

applied to the terminals from affecting the terminals.

• Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

• Do not install the air conditioner in a location subject to a risk of exposure to a combustible gas.

If a combustible gas leaks, and stays around the unit, a fire may occur.

3. CHECK POINTS

Check before operation

• Turn on the main power switch 12 hours or more before starting the operation.

• Check whether earth wire is disconnected or out of place.

• Check that air filter is installed to the indoor unit.

Heating capacity

• For heating operation, a heat pump type which absorbs the outdoor heat and deliver the heat in the room is adopted. If the outdoor temperature lowers, the heating capacity decreases.

• When the outdoor temperature is low, common use with other heating devices is recommended.

Defrost operation in heating operation

• If frost is found on the outdoor unit during heating operation, the defrost operation starts automatically (for approx. 2 to 10 minutes) so as to increase the heating effect.

• During defrost operation, the fans of both indoor and outdoor units stop.

Protection for 3 minutes

• The outdoor unit does not operate for approx. 3 minutes after air conditioner has been immediately restarted after stop, or power switch has been turned on. This is to protect the system.

Main power failure

• If a power failure occurs during operation, all operations stop.

• When the power is turned on after power failure, the operation lamp of the remote controller flashes to notify.

• When restarting the operation, push ON/OFF button again.

Fan rotation of stopped unit

• While other indoor units operate, the fan on indoor units on “stand-by” rotates to protect the machine once per approx. 1 hour for several minutes.

Protective device (High pressure switch)

The high pressure switch operate the air conditioner automatically stops when excessive load is applied to the air conditioner. If the protective device works, the operation lamp keeps lit but the operation stops. When the protective device works, “CHECK” characters in the remote controller display section flash. The protective device may work in the following cases.

Cooling

• When air inlet or outlet of the outdoor unit is closed.

• When strong wind blows continuously against air outlet of the outdoor unit.

Heating

• When much dust or dirt is excessively adhered to air filter of the indoor unit.

• When air outlet of the indoor unit is blocked.

NOTE

If the protective device works, turn off the main power switch, remove the cause, and then restart the operation.

Cooling/ heating operation of Multi system air conditioner

• When COOL or HEAT mode is fixed by the manager of the air conditioner, other operation than the set mode is unavailable. If other operation than the set mode has been performed, [ operation part goes on and the operation stops.

Operating temperature of Super HRM

• When outdoor temperature goes out of specified range, “ or ” mark is indicated on the remote controller display and required operation will stop. “

[Notice]

• This indication is not failure.

• When outdoor temperature goes back to specified range, “

• Operation stops because concurrent operation can not be kept in the condition of out of specification for Super HRM.

(Outdoor temp. (DB) < –10°C : Cooling, > 21°C : Heating)

• Do not use “Super HRM” for other than personal usage where the ambient temperature may go down below –10°C. (For example, OA equipment/Electric device/Food/Animals and plants/Art object)

& ” : When heating operation. “ ” : When cooling operation.

or ” disappear and start normal operation.

Characteristics of heating operation

• Air does not blow out immediately after start of the operation. When the indoor heat exchanger has been heated after 3 to 5 minutes passed (differs according to temperature of indoor/outdoor temperature), hot air starts blowing.

• During operation, the outdoor unit may stop when outdoor temperature becomes high.

• When other indoor unit performs heating operation during fan operation, fan operation may be stopped temporarily to prevent discharge of hot air.

PRE-HEAT] or [ Operation ready] on the

KEY POINTS OF AIR CONDITIONER INSTALLATION

In order to prevent problems before they arise, carefully read (1) the Installation Manual provided with the equipment, and (2) the Owner’s Manual before installing the air conditioner.

4-1. Flow of Air Conditioner Installation Work

[Step] [Key Points]

(Prior to Installation)

Determination of extent of installation work

Drafting of diagrams

(Installation)

Sleeve/insert installation Pay careful attention to the downward slope of the drain pipe.

Indoor unit and flow selector unit installation

Refrigerant pipe installation

(to outdoor outlet)

Drain pipe installation Pipes should have downward slope (of at least 1/100).

Duct installation

Insulation work

Electrical work

(control wires and power wires)

Various switch settings

Outdoor unit base installation Make sure that the base is level.

Outdoor unit installation

Outside circulation, refrigerant pipe

installation

Gas-leak test

Vacuum suction

Addition of refrigerant

Ceiling panel installation

Test operation and adjustment

Owner’s Manual transfer

Clearly determine the extent of the installation work.

Draft :

• Control wiring system diagram

• Refrigerant line system diagram

• Power wiring system diagram

Be sure to check the name of the model in order to avoid any installation mistakes. If the model has an installation pattern, attach the pattern to the ceiling to mark the position of the ceiling openings and to keep dust away.

Make sure that the pipe system is dry, clean, and airtight. When brazing pipes, blow out the system with nitrogen gas.

Do not forget the system indications.

Make sure the duct is large enough to carry the desired volume of air. Be careful not to make any errors in the external static pressure calculations.

Be especially careful to close off all gaps where connections are made to the indoor unit, and at joints in the branching kit. Do not forget the drain pipes.

Use two-core shielded wires for the control wires, and use separate power supplies for the indoor and outdoor units. For connecting the flow selector unit, be sure to use the attached cable or connection cable kit sold separately.

Set the switches correctly, as indicated in the control wiring system diagram.

Provide for adequate air flow and service space around the outdoor unit. Indicate the system names clearly.

From outside outlet to outdoor unit.

In the final test, the system must be pressurized at 3.73MPa (38kg/cm²G) for 24 hours with no decrease in pressure.

Use a vacuum pump with reverse flaw prevention adaptor with a large output volume and that can achieve a high level of vacuum.

Record the amount of refrigerant that was added to the system on both the outdoor unit and on the pre-test operation checklist.

Make sure that the ceiling panel is attached to the ceiling material tightly, with no gaps.

Operate the indoor units one by one, making sure that all wiring and pipes are connected correctly, and fill out the checklist.

Explain how to operate the system clearly and concisely.

The procedure described above presents only the general sequence of steps; the sequence of steps may have to be altered according to the circumstances of any specific installation job.

5. REFRIGERANT PIPE INSTALLATION

5-1. Work Procedure

Indoor unit

installation

Sizing

the pipes

Preliminary

installation

Nitrogen gas blow

Flaring

Flushing

Brazing

Leak test

5-2. Three Principles of Refrigerant Pipes

Causes of Problems Preventing Problems

• Moisture (in the form of

Dry

Clean

rainwater or water used during installation, for example) getting inside of the pipes

• Moisture from condensation forming or seeping into the pipes

• Oxidation inside pipes during brazing

• Dirt, dust, or foreign matter getting inside pipes

Careful

handling

of pipes

Nitrogen gas blow

Careful handling of pipes

Flushing

Vacuum

suction

Vacuum

suction

Flushing

Use of suitable materials

(copper pipes, solder, etc.)

Air-

tight

• Poor brazing

• Poor flaring

Perform basic work

of brazing carefully

Perform basic work

of flaring carefully

Dry

Make sure there is no moisture

inside of the pipes

Moisture

Make sure there is no dirt

Clean Airtight

Make sure the refrigerant

inside of the pipes

Dirt

does not leak

NOT GOOD NOT GOOD NOT GOOD

Leak test

Leak

5-3. Selecting the Refrigerant Line Material

• Refrigerant pipes

• Material: Phosphoric deoxidized seam-less pipe

• Capacity code of outdoor unit / indoor unit

• For each indoor unit, the capacity code is determined for every capacity rank.

• For each outdoor unit, the capacity code is determined for every capacity rank. The Max. number of the connectable indoor units and the total capacity code value of the indoor units are also determined.

Against the capacity code of the outdoor unit, the total capacity codes of the connectable indoor units differ

 

according to the height difference between indoor units.

   

• When the height difference between indoor units is 15m or less : Up to 135%* of capacity code of outdoor unit

 

(* For 12HP system, up to 120%.)

 

• When the height difference between indoor units is above 15m : Up to 105% of capacity code of outdoor unit

 

Table 1 Table 2

Indoor unit

capacity rank

007 type 0.8 2.2 009 type 12.8 012 type 1.25 3.6 015 type 1.7 4.5 018 type 25.6 024 type 2.5 7.1 027 type 38 030 type 3.2 9 036 type 4 11.2 048 type 514 056 type 616 072 type 8 22.4 096 type 10 28.0

Capacity code

Equivalent toHPEquivalent to

capacity

Outdoor unit

model name

MMY-MAP0802FT8 8 22.4 13 5.6 10.8 MMY-MAP1002FT8 10 28.0 16 7.0 13.5 MMY-MAP1202FT8 12 33.5 16 8.4 14.4

MMY-AP1602FT8 16 45.0 27 11.2 21.6 MMY-AP1802FT8 18 50.4 30 12.6 24.3 MMY-AP2002FT8 20 56.0 33 14.0 27.0 MMY-AP2402FT8 24 68.0 40 16.8 32.4 MMY-AP2602FT8 26 73.0 43 18.2 35.1 MMY-AP2802FT8 28 78.5 47 19.6 37.8 MMY-AP3002FT8 30 84.0 48 21.0 40.5

Capacity code

Equivalent toHPEquivalent to

capacity

No. of

indoor units

Total capacity code of connectable indoor units

Min Max.

Equivalent to HP Equivalent to HP

Table 3

No. Piping parts Name Selection of pipe size

Outdoor unit

↓

T-shape branching joint

Between T-shape branching joints

T-shape joint of header unit

↓

1st branching section

Branching section

↓

Branching section

Connecting pipe of outdoor unit

Main connecting piping between of outdoor units

Balance pipe

Main pipe

Branching pipe

1) Connecting pipe outdoor unit

Model name Suction gas side Discharge gas side Liquid side

MMY-MAP0802FT8 Ø22.2 Ø19.1 Ø12.7 MMY-MAP1002 FT8 Ø22.2 Ø19.1 Ø12.7 MMY-MAP1202 FT8 Ø28.6 Ø19.1 Ø12.7

2) Pipe size for connecting piping between outdoor units

Total capacity codes of outdoor units

at downstream side

Equivalent to

capacity

Below 61.5 Below 22 Ø28.6 Ø22.2 Ø15.9 Ø9.5

Equivalent

to HP

Suction gas

side

3) Size of main pipe

Total capacity codes of all outdoor units

Equivalent to

capacity

Below 33.5 Below 12 Ø22.2 Ø19.1 Ø12.7

33.5 12 Ø28.6 Ø 19.1 Ø12.7

45.0 to below 61.5 16 to below 22 Ø28.6 Ø22.2 Ø19.1

61.5 to below 73.0 22 to below 26 Ø34.9 Ø28.6 Ø19.1

73.0 or more 26 or more Ø34.9 Ø28.6 Ø22.2

Equivalent

to HP

Suction gas

side

4) Pipe size between branching sections

Total capacity codes of indoor units

at downstream side

Equivalent to

capacity

Below 18.0 Below 6.4 Ø15.9 Ø12.7 Ø9.5

18.0 to below 34.0 6.4 to below 12.2 Ø22.2 Ø19.1 Ø12.7

34.0 to below 56.5 12.2 to below 20.2 Ø28.6 Ø22.2 Ø15.9

56.5 to below 70.5 20.2 to below 25.2 Ø34.9 Ø28.6 Ø15.9

70.5 or more 25.2 or more Ø34.9 Ø28.6 Ø19.1

∗

If exceeding the main pipe size, decide the size same to main pipe size.

∗

When two pipes are used for the circuits exclusive to cooling, use pipes at liquid and suction

gas sides.

∗

2 pipes from FS unit to branching section shall be used with liquid pipe and suction gas pipe.

Equivalent

to HP

Suction gas side

Discharge

gas side

Discharge gas

Liquid side

side

Balance

pipe

Liquid side

No. Piping parts Name Selection of pipe size

End branching section

↓

Flow selector unit

Connecting pipe of flow selector unit

5) Pipe size between end branching section and flow selector unit

Total capacity codes of indoor units

Equivalent to capacity Equivalent to HP

at downstream side

Below 18.0 Below 6.4 Ø15.9 Ø12.7 Ø9.5

18.0 or more 6.4 or more Ø22.2 Ø19.1 Ø12.7

Suction

gas side

Discharge

gas side

Liquid side

Branching section or flow selector

Connecting pipe of indoor unit

unit

↓

Indoor unit

Branching section

Piping of cooling only indoor unit (Between branching and indoor unit)

Branching section Branching

header Y-shape branching joint T shape branching joint

Branching Flow selector unit

6) Connecting pipe size of indoor unit

Capacity rank Gas side Liquid side

007 to 012 type Ø9.5 015 to 018 type Ø12.7 024 to 056 type Ø15.9 Ø9.5 072 to 096 type Ø22.2 Ø12.7

Ø6.4

7) Connecting pipe size of cooling only indoor unit

Gas side Liquid side Capacity rank of indoor unit

Ø9.5 Ø6.4 15m or less Ø12.7 Ø9.5 above 15m Ø12.7 Ø6.4 15m or less Ø15.9 Ø9.5 above 15m Ø15.9 Ø9.5 024 to 056 Type Ø22.2 Ø12.7 072, 096 Type

∗

2 pipes for cooling only indoor unit shall be used with liquid pipe and suction gas pipe.

007 to 012 Type

015 to 018 Type

8, 9) Selection of branching joint/header

Total capacity codes of indoor units Model name

Equivalent to

capacity

Below 18.0 Below 6.4

Y-Shape branching

joint *1 *2

Branching

Header

*1, *2, *3

T-Shape branching

joint (For connecting outdoor unit)

∗

1 Branching pipe on the 1st branch should be selected according to the capacity code for

outdoor unit.

∗

2 In case total capacity code for indoor units shall be exceeded to capacity code for outdoor

unit, the pipe size should be selected with capacity code for outdoor unit.

∗

3 For 1 line after header branching, indoor units with a maximum of 6.0 capacity code in total

can be connected.

For 4

Branching

For 8

Branching

18.0 to below 40.0 6.4 to below 14.2

40.0 to below 70.5 14.2 to below 25.2

70.5 or more 25.2 or more Below 40.0 Below 14.2

40.0 to below 70.5 14.2 to below 25.2 Below 40.0 Below 14.2

40.0 to below 70.5 14.2 to below 25.2

1 set of 4 types of T-shape joint pipes as described below : The rewired quantity is arranged and combined at the site.

- Balance pipe (Ø 9.52) X 1

- Piping at liquid side (Ø 12.7 to Ø 22.2) X 1

Piping at discharge gas side (Ø 19.1 to Ø 28.6) X 1

Piping at suction gas side (Ø 22.2 to Ø 38.1) X 1

Equivalent to HP For 3 piping For 2 piping

RBM-BY53FE RBM-BY53E RBM-BY103FE RBM-BY103E RBM-BY203FE RBM-BY203E RBM-BY303FE RBM-BY303E

RBM-HY1043FE RBM-HY1043E RBM-HY2043FE RBM-HY2043E RBM-HY1083FE RBM-HY1083E RBM-HY2083FE RBM-HY2083E

RBM-BT13FE

10) Selection of flow selector unit

Model name Total capacity rank of connectable

RBM-Y1122FE below 11.2 kW 5 RBM-Y1802FE 11.2 to below 18.0kW 8 RBM-Y2802FE 18.0 below 28.0kW or less 8

∗

Confirm also Installation Manual of flow selector unit.

indoor unit

Max. No. of connected

indoor units

Outdoor unit

connecting piping

Follower UnitCFollower UnitBHeader Unit

Main connecting piping between outdoor units

T-shape branching joint

Balance pipe

Main piping

1st branching section

Discharge gas pipe

Suction gas pipe

Discharge gas pipe

Suction gas pipe

Liquid pipe

5 5 5

FS unit

Indoor unit

Y-Shape branching joint

6 6

5 5

6 6 6 6 6

Y-Shape branching joint8

7 7

< Cooling only >

Group control

5-4. Allowable Length/Height Difference of Refrigerant Piping

Height difference between outdoor units

H3 5m

Height difference between outdoor and indoor units

H1 50m

Outdoor Unit

T-shape branching

Main piping

1st branching section

Follower Unit

Header Unit

Connecting piping of indoor unit

Equivalent length corresponded to farthest piping after 1st branching Li 50m

FS unit

Follower Unit

Branching piping

ghi j

Indoor unit

Equivalent length corresponded to farthest piping L 150m

L4 L5 L6 L7LhL8

def

lmn

Indoor unit

La Lb Lc

Main connecting piping between outdoor units

Length corresponded to farthest piping between outdoor units LO 25m

Branching

header

FS unit

< Cooling only >

FS unit

(Header)

Note: In case of connecting method <Ex.2>, a large amount of refrigerant and refrigerant oil may return to the head unit. Therefore, set the T-shape joint so that oil does not enter directly.

<Ex.1>

Header UnitAFollower UnitBFollower Unit

<Ex.2>

Header UnitAFollower UnitBFollower Unit

< Cooling only >

(q)

Height difference between indoor units

H2 35m

(Upper outdoor unit)

Height difference

between indoor units

in group control by

one FS unit

H4 0.5 m

* Allowable length and height difference of refrigerant piping

Allowable value Piping section

Total extension of pipe (Liquid pipe, real length) 300 m

Farthest piping length L (*1)

Real length 125 m

Equivalent length 150 m

Max. equivalent length of main piping 85 m L1

Equivalent length of farthest piping from 1st branching Li (*1) 50 m L3+L4+L5+L6+L7+L8+q

Pipe

Length

Max. real length of indoor unit connecting piping 30 m a+g, b+h, c+i, d+l, e+m, f+n, j, k

Max. real length between FS unit and indoor unit (*2) 15 m g, h, i, l, m, n, L7+o, L7+L8+p, L7+L8+q

Max. Equivalent length of outdoor unit connecting piping LO (*1) 25 m LA+Lc (LA+Lb)

Max. real length of outdoor unit connecting piping 10 m La, Lb, Lc

30 m

15 m

50 m

Height

Difference

Max. equivalent length between FS unit and indoor unit Lj

Max. real length between FS unit and header indoor unit Lh (

Height between indoor and outdoor units H1

Height between indoor units H2

Upper outdoor unit

Lower outdoor unit 30 m ——

Upper outdoor unit 35 m ——

Lower outdoor unit 15 m ——

Height between outdoor units H3 5 m ——

Height difference between indoor units in group control by one FS unit H4

1 : The farthest outdoor unit from 1st branch to be named C, and farthest indoor unit from 1st branch to be named (q).

2 : Attached connection cable can be used up to 5 m in pipe length between indoor and FS unit. When the pipe length

between indoor and FS unit exceeds 5 m, be sure to use the connection cable kit (RBC-CBK15FE).

* System restrictions

Max. No. of combined outdoor units Max. capacity of combined outdoor units Max. No. of connected indoor units

Max. capacity of combined indoor units

1 : MMY-MAP1201HT8 : UP to 120 %

3 units

84.0 kW

48 units H2 15m H2

15m

135% (*1) 105%

Note 1) Combination of outdoor units : Header unit (1 unit) +

Note 2) Install the outdoor units in order of capacity.

Note 3) Refer to outdoor unit combination table in page.6. Note 4) Piping to indoor units shall be perpendicular to piping to

0.5 m ——

Follower unit (0 to 2 units). Header unit is outdoor unit nearest to the connected indoor units

(Header unit Follower unit 1 Follower unit 2)

the head outdoor unit as <Ex.1>. Do not connect piping to indoor units in the same direction of head outdoor unit as <Ex.2>.

LA+La+Lb+Lc+L1+L2+L3+L4+L5+L6+L7+L8+9 +a+b+c+d+e+f+g+h+i+j+k+l+m+n+o+p+q

LA+Lc+L1+L3+L4+L5+L6+L7+L8+q

L7+L8+q, L7+L8+p

L7+o

——

• Brazed couplings and special branches

• Use suitable parts for typical elbow couplings and socket couplings. (Consider the size, material, thickness, etc.)

• Special branches

Use deoxidized parts sold separately.

Branching at

outdoor unit side

T-shape branching

joint

RBM-BT13FE

Branching joint

RBM-BY53E RBM-BY103E RBM-BY203E RBM-BY303E RBM-BY53FE

RBM-BY103FE RBM-BY203FE RBM-BY303FE

Branching at indoor unit side

Branch header

4 branching 8 branching

RBM-HY1043E RBM-HY1083E

RBM-HY2043E RBM-HY2083E RBM-HY1043FE RBM-HY1083FE RBM-HY2043FE RBM-HY2083FE

• Solder

Because only “copper-to-copper” connections are made in the multi type air conditioning system, use the hard solder “phosphor copper solder.”

5-5. Careful Handling

Careful handling is the most important step in preventing moisture, dirt, and dust from getting inside of the pipes. Moisture in pipes has caused major problems in numerous instances in the past. Therefore, it is important to be as careful as possible in order to prevent problems before they occur.

Pipe delivery and storage

When pipes are delivered, care should be taken to prevent it from becoming bent or deformed, and the ends of the pipes should be capped in order to prevent dirt, mud, rain, etc., from getting inside. Build a wooden frame to hold the pipes securely, and store the pipes in the specified location.

Delivery of copper pipes without caps to a work site is not acceptable.

Cap

Frame for careful handling

and to prevent rolling

Careful handling on a pallet

Pipe caps

The ends of all pipes must be sealed. The most reliable method is the “pinch method,” but the taping method can be selected in some circumstances.

Location

Outdoors

Indoors



 Pinch method



Pinch the end of the copper pipe closed, and braze any opening closed.



 Taping method



Cover the end of the copper pipe with vinyl tape.

Time for installation

One month or more

Less than one month

Does not matter

Careful handling method

Pinch method

Pinch or taping method

Copper pipe

Solder

Braze here

[Taping method]

Opening

Copper pipe

Vinyl tape

Flatten

Fold over

Tape again

CAUTIONS

1) Do not allow dirt or moisture inside of the pipes.

• Keep the open ends of all pipes

capped until all pipes have been connected.

• Pipe openings should face

horizontally or downwards if at all possible.

GOOD NOT GOOD

Dirt and moisture get inside

Cap

Pipe

2) When passing a pipe through an

opening in a wall, always keep the end of the pipe capped.

3) Do not place pipes directly on the ground. Do not scrape pipes on the ground.

4) When deflashing (removing burrs from) a pipe, point the opening downwards so that no scraps fall inside of the pipe.

5) When installing pipes on a rainy day, always keep the ends of the pipes capped.

Cap or

Wall

plastic bag

Rubber band

Rubber

Cap or

band

plastic bag

Do not allow pipe to touch ground

Ground Ground

Pipe

Burrs

Deflasher

Cap or plastic bag

Rubber band

Rain

Wall

Dirt gets inside of pipe

Scraps get inside of pipe

Rain

Particles of the wall get inside the pipe

Rain gets inside of pipe

socket

projection

Diameter of the

connecting pipe

1pc

Ø31.8

1pc

RBM-HY2083E

Ø15.9

Ø9.5

Ø15.9

1pc each

Ø 9.5 x (Ø15.9) 7pcs

Ø12.7 x (Ø15.9) 7pcs

No.

Ø28.6 x (Ø31.8) 1pc

Ø34.9 x (Ø31.8) 1pc

No.

(Ø 9.5) 3pcs

(Ø15.9) 3pcs

(Ø15.9) 1pc

Ø 6.4 x (Ø 9.5) 7pcs

1pc

Ø19.1

Ø38.1

RBM-BY303E

Ø22.2

Ø38.1

Ø19.1

1pc

1pc each

Ø 9.5 x (Ø38.1) 1pc

Ø12.7 x (Ø38.1) 1pc

77767574737161

No.

Ø15.9 x (Ø38.1) 1pc

Ø19.1 x (Ø38.1) 1pc

Ø22.2 x (Ø38.1) 1pc

Ø 6.4 x (Ø19.1) 1pc

Ø28.6 x (Ø38.1) 2pcs

Ø34.9 x (Ø38.1) 1pc

Ø41.3 x (Ø38.1) 1pc

0407101352

Ø15.9 x (Ø22.2) 1pc

Ø 9.5 x (Ø19.1) 1pc

Ø12.7 x (Ø19.1) 1ps

Ø15.9 x (Ø19.1) 2pcs

Ø22.2 x (Ø19.1) 1pc

Ø19.1 x (Ø22.2) 1pc

1pc

Ø31.8

RBM-HY2043E

Ø15.9

indicates diameter of the indicated position, and others indicate

diameter of the connecting pipe.

( 51 , 52 , 54 , 58 , 59 , 61 , 62 , 70 , 89 : without projection)

Ø9.5

1pc

Ø15.9

1pc each

Ø 9.5 x (Ø15.9) 2pcs

Ø12.7 x (Ø15.9) 2pcs

No.

Ø28.6 x (Ø31.8) 1pc

Ø34.9 x (Ø31.8) 1pc

No.

Ø 6.4 x (Ø 9.5) 4pcs

2. Please connect pipe to the side with a projection of the socket.

1pc

NOTE : 1. All dimensions are in millimeters. In the following tables, ( )

Ø22.2

RBM-HY1083ERBM-HY1043E

Ø15.9

Ø9.5

1pc

Ø15.9

1pc each

Ø 9.5 x (Ø15.9) 8pcs

Ø12.7 x (Ø15.9) 8pcs

No.

Ø15.9 x (Ø22.2) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø28.6 x (Ø22.2) 1pc

141870

No.

Ø 6.4 x (Ø 9.5) 8pcs

Ø 9.5 x (Ø15.9) 1ps

(Ø 9.5) 1pc

(Ø15.9) 1pc

(Ø 9.5) 3pcs

(Ø15.9) 3pcs

(Ø15.9) 1pc

Ø12.7 x (Ø15.9) 1ps

1pc

Ø15.9

Ø28.6

RBM-BY203E

Ø19.1

RBM-BY103E

Ø28.6

Ø15.9

Ø31.8

1pc

Ø12.7

Ø19.1

Ø22.2

Ø15.9

Ø12.7

1pc

1pc each

Ø 9.5 x (Ø28.6) 1pc

Ø12.7 x (Ø28.6) 1pc

4849162043

No.

Ø28.6 x (Ø31.8) 1pc

Ø34.9 x (Ø31.8) 1pc

No.

1pc each

Ø 9.5 x (Ø19.1) 1pc

Ø12.7 x (Ø19.1) 1pc

0710135289

No.

Ø19.1 x (Ø22.2) 1pc

Ø28.6 x (Ø22.2) 1pc

No.

Ø 6.4 x (Ø15.9) 1pc

Ø15.9 x (Ø28.6) 1pc

Ø19.1 x (Ø28.6) 1pc

Ø22.2 x (Ø28.6) 2pcs

Ø15.9 x (Ø19.1) 2pcs

Ø22.2 x (Ø19.1) 2pcs

Ø28.6 x (Ø19.1) 1pc

Ø 9.5 x (Ø15.9) 1pc

Ø34.9 x (Ø28.6) 1pc

030609

Ø 6.4 x (Ø12.7) 1pc

Ø 9.5 x (Ø12.7) 2pcs

020554

Ø 9.5 x (Ø15.9) 1pc

Ø12.7 x (Ø15.9) 1pc

Ø12.7 x (Ø15.9) 2pcs

Ø15.9 x (Ø12.7) 1pc

1pc

Ø22.2

Ø15.9

Ø9.5

1pc

Ø15.9

1pc each

Ø 9.5 x (Ø15.9) 4pcs

Ø12.7 x (Ø15.9) 4pcs

No.

Ø15.9 x (Ø22.2) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø28.6 x (Ø22.2) 1pc

141870

No.

Ø 6.4 x (Ø 9.5) 4pcs

Ø 9.5 x (Ø15.9) 1pc

Ø12.7 x (Ø15.9) 1pc

( )

MODEL

diameter of the

connected pipe

external diameter

of socket

side

side Gas

NAME

Branching header

5-6. Parts of Branching Header/Joint

Branching Header : RBM-HY1043E / HY1083E / HY2043E / HY2083E

Branching Joint : RBM-BY53E / BY103E / BY203E / BY303E

• Check the following parts in the package.

• For piping material and size of the refrigerant pipes, refer to the Installation Manual of the Air Conditioner.

gas side

Branching header

liquid side

Heat insulator

(gas side/liquid side)

Socket

Branching Header

(Ø 9.5) 1pc

(Ø15.9) 1pc

MODEL

Liquid

Outlet sealed pipe at gas side

Header sealed pipe at liquid side

Outlet sealed pipe at liquid side

1pc

Ø12.7

RBM-BY53E

NAME

Ø15.9

Branching joint

gas side

1pc

Ø9.5

Ø12.7

Branching joint

liquid side

1pc each

Ø 9.5 x (Ø12.7) 2pcs

Ø15.9 x (Ø12.7) 2pcs

No.

Ø12.7 x (Ø15.9) 1pc

Ø19.1 x (Ø15.9) 1pc

No.

diameter of the

connected pipe

Heat insulator

(gas side/liquid side)

Branching Joint

Ø 6.4 x (Ø 9.5) 2pcs

Ø 9.5 x (Ø12.7) 1pc

( )

external diameter

Gas side

Socket

of socket

Liquid side

socket

projection

Diameter of the

connecting pipe

Ø15.9

Ø9.5

Ø15.9

RBM-HY2083FERBM-HY2043FE

Ø22.2

Ø15.9

1pc 1pc

Ø15.9

1pc 1pc

Ø15.9

Ø9.5

Ø31.8

1pc 1pc

Ø15.9

1pc each

Ø12.7 x (Ø15.9) 8pcs

Ø 9.5 x (Ø15.9) 7pcs

Ø12.7 x (Ø15.9) 7pcs

060909

Ø34.9 x (Ø22.2) 1pc

Ø28.6 x (Ø31.8) 1pc

Ø34.9 x (Ø31.8) 1pc

275970

1pc each

Ø12.7 x (Ø15.9) 4pcs

Ø 9.5 x (Ø15.9) 2pcs

Ø12.7 x (Ø15.9) 2pcs

060909

(Ø 9.5) 3pcs

(Ø15.9) 3pcs

(Ø15.9) 7pcs

Ø 6.4 x (Ø 9.5) 7pcs

(Ø15.9) 1pc

Ø19.1 x (Ø15.9) 1pc

(Ø 9.5) 1pc

(Ø15.9) 3pcs

(Ø15.9) 1pc

Ø 6.4 x (Ø 9.5) 4pcs

(Ø15.9) 1pc

38.1

28.6

RBM-BY303FERBM-BY203FE

38.1

31.8

28.6 Ø

1pc 1pc

28.6 Ø

19.1 Ø

1pc 1pc

19.1 Ø

19.1

22.2 Ø

12.7Ø12.7 Ø

1pc 1pc

Ø12.7 x (Ø28.6) 1pc

Ø 9.5 x (Ø38.1) 1pc

Ø12.7 x (Ø38.1) 1pc

Ø15.9 x (Ø38.1) 1pc

Ø22.2 x (Ø38.1) 1pc

77767573715149204304071013

Ø34.9 x (Ø38.1) 1pc

Ø19.1 x (Ø28.6) 1pc

Ø28.6 x (Ø38.1) 2pcs

Ø34.9 x (Ø38.1) 2pcs

Ø28.6 x (Ø31.8) 1pc

1pc each 1pc each

Ø12.7 x (Ø19.1) 1pc

Ø 9.5 x (Ø28.6) 1pc

Ø12.7 x (Ø28.6) 1pc

Ø15.9 x (Ø28.6) 1pc

4849164358105289020554

Ø22.2 x (Ø19.1) 2pcs

Ø22.2 x (Ø28.6) 2pcs

Ø34.9 x (Ø28.6) 1pc

x (Ø28.6) 1pc

Ø 6.4 x (Ø19.1) 1pc

Ø 9.5 x (Ø19.1) 1pc

Ø12.7 x (Ø19.1) 1pc

Ø22.2 x (Ø28.6) 2pcs

Sealed pipe

Ø15.9 x (Ø19.1) 1pc

Ø19.1 x (Ø22.2) 1pc

x (Ø19.1) 1pc

Ø 6.4 x (Ø12.7) 1pc

Ø 9.5 x (Ø12.7) 1pc

Ø28.6 x (Ø19.1) 1pc

Ø15.9 x (Ø12.7) 2pcs

Sealed pipe

Ø31.8

Ø22.2

Ø15.9

51 , 52 , 54 , 58 , 59 , 70 , 89 : without projection)

the indicated position, and others indicate diameter of the connecting pipe.

(

2. Please connect pipe to the side with a projection of the socket.

Ø15.9

Ø9.5

NOTE : 1. All dimensions are in millimeters. In the following tables, ( ) indicates diameter of

Ø28.6 x (Ø31.8) 1pc

275970

No. No. No. No.

1pc each

Ø 9.5 x (Ø15.9) 7pcs

0609060901

RBM-HY1083FE

Ø22.2

1pc 1pc

Ø22.2

1pc 1pc

Ø15.9

1pc 1pc

Ø15.9 x (Ø22.2) 1pc

1470851806

Ø19.1 x (Ø15.9) 1pc

Ø28.6 x (Ø22.2) 1pc

Ø34.9 x (Ø31.8) 1pc

(Ø15.9) 3pcs

(Ø15.9) 7pcs

Ø 6.4 x (Ø 9.5) 8pcs

Ø 9.5 x (Ø15.9) 8pcs

Ø12.7 x (Ø15.9) 8pcs

Ø 9.5 x (Ø15.9) 1pc

Ø12.7 x (Ø15.9) 1pc

Ø12.7 x (Ø22.2) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø28.6 x (Ø22.2) 1pc

(Ø 9.5) 3pcs

(Ø15.9) 1pc

RBM-BY103FERBM-BY53FE

1pc each

Ø15.9

Ø9.5

Ø15.9

Ø 9.5 x (Ø15.9) 4pcs

Ø12.7 x (Ø15.9) 4pcs

Ø 9.5 x (Ø15.9) 3pcs

Ø12.7 x (Ø15.9) 4pcs

0609060901

(Ø15.9) 3pcs

(Ø 9.5) 1pc

(Ø15.9) 1pc

Ø 6.4 x (Ø 9.5) 4pcs

31.8 Ø

19.1 Ø

22.2 Ø

12.7 Ø

19.1 Ø

1pc 1pc

12.7 Ø

22.2 Ø

19.1 Ø

22.2 Ø

12.7 Ø

19.1 Ø

1pc 1pc

12.7 Ø

15.9 Ø

12.7 Ø

15.9 Ø

9.5Ø9.5 Ø

12.7 Ø

1pc 1pc

Ø28.6 x (Ø31.8) 1pc

No. No. No. No.

Ø 9.5 x (Ø19.1) 1pc

Ø12.7 x (Ø19.1) 1pc

Ø15.9 x (Ø19.1) 2pcs

07101352891052

Ø28.6 x (Ø22.2) 1pc

1pc each 1pc each

Ø 9.5 x (Ø12.7) 2pcs

Ø15.9 x (Ø12.7) 2pcs

Ø28.6 x (Ø22.2) 1pc

Ø19.1 x (Ø15.9) 1pc

x (Ø19.1) 1pc

Ø 6.4 x (Ø12.7) 1pc

Ø12.7 x (Ø19.1) 2pcs

Ø22.2 x (Ø19.1) 1pc

Ø22.2 x (Ø19.1) 2pcs

Ø28.6 x (Ø19.1) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø 9.5 x (Ø12.7) 2pcs

Sealed pipe

020554

Ø12.7 x (Ø15.9) 1pc

x (Ø12.7) 1pc

Ø 9.5 x (Ø12.7) 2pcs

Ø 6.4 x (Ø 9.5) 2pcs

Ø15.9 x (Ø12.7) 1pc

Sealed pipe

Ø15.9 x (Ø12.7) 1pc

RBM-HY1043FE

Ø22.2

MODEL

Suction gas side

NAME

of the Air Conditioner.

Branching Header : RBM-HY1043FE / HY1083FE / HY2043FE / HY2083FE

Branching Joint : RBM-BY53FE / BY103FE / BY203FE / BY303FE

• Check the following parts in the package.

• For piping material and size of the refrigerant pipes, refer to the Installation Manual

Ø15.9

No. No. No. No.

Socket

Liquid side

Discharge gas side

Heat insulator (suction gas side/

discharge gas side/liquid side)

Ø 9.5 x (Ø15.9) 1pc

Ø12.7 x (Ø15.9) 1pc

Ø12.7 x (Ø22.2) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø15.9 x (Ø22.2) 1pc

Ø28.6 x (Ø22.2) 1pc

1470851806

diameter of the

connected pipe

Suction

gas side

( )

external

diameter

of socket

Liquid

side

Discharge

gas side

Branching Header

Outlet sealed pipe at suction gas side

Outlet sealed pipe at discharge gas side

Outlet sealed pipe at liquid side

15.9 Ø

MODEL

Suction gas side

Header sealed pipe at liquid side

NAME

Discharge gas side

12.7 Ø

Liquid side

Ø 9.5 x (Ø12.7) 1pc

external

diameter

of socket

No. No. No. No.

diameter of the

connected pipe

Ø12.7 x (Ø15.9) 1pc

( )

Socket

Heat insulator

(suction gas side/discharge gas side/liquid side)

Suction

gas side

Branching Joint

Discharge

gas side

Liquid

side

5-7. Branching Kit Connection Method

[1] Branch joint

Socket

Pipe in use on the site

Inlet

To outdoor unit

Socket

Gas side branch joint

Outlet (2)

Outlet (1)

Socket

Outlet (1)

Pipe in use on the site

Inlet

To outdoor unit

Socket

• Installation direction of branch pipe Install the branching pipes so that it branch either vertically or horizontally.

Outlet (2)

Gas/Liquid side branch joint

Both directions are possible.

Pipe in use on the site

To other branching pipe or indoor unit

Socket

To other branching pipe or indoor unit

Pipe in use on the site

Socket

NOTE :

Install the branch pipes horizontally or vertically so that they branch evenly.

Install the branching joint within ± 15 degrees.

Heat insulating for pipes (Branching Joint)

• In order to prevent dripping at the place where the insulation provided with the branching kit meets the insulating material obtained on the site, butt the two types of insulation up against each other, and then wrap the seam between the two types of insulation in at least 10mm of the insulating material (in use on the site).

Heat insulator for piping (in use on the site)

Heat insulator (in use on the site) by 10mm or more thickness.

Butt together

150

Branching joint

Heat insulator in package

Butt together

Heat insulator for piping (in use on the site)

Butt together

In case of vertical installation

(Horizontal line)

(A view)

(Horizontal line)

(B view)

NOTE :

• Install the branch pipes horizontally or vertically so that they are branched evenly.

• Install the branching joint within ±15 degrees.

Within ± 15

degrees

• On the gas-side pipe, use insulation that can withstand heat of 120°C or higher. For the branch pipe, either use a commercially available coupling cover (for T-shape) that is at least 10mm thick, or else insulate the pipe as shown in the figure at below.

• After applying insulation as outlined above, tape the insulation in place.

Taping (in use on the site)

Heat insulator

Heat insulator (in use on the site)

(in use on the site)

[2] Branch header

Branching Header

Select and install the socket that matches the diameter of a pipe to be connected to the indoor unit.

Pipe in use on the site

To outdoor unit

Socket

Pipe in use on the site

To indoor unit

<Liquid-side branch header>

Socket

Pipe in use on the site

To outdoor unit

Socket

Pipe in use on the site

To indoor unit

• If the number of indoor units to be connected is fewer than the maximum number of units that can be connected to the branch header, attach a sealed pipe to the unused connectors.

Outlet sealed pipe (Provided with branch header)

<Liquid-side branch header>

Outlet sealed pipe (Provided with branch header)

• Install the branch header so that it branches horizontally. It cannot be used in a vertical position.

(Horizontal line)

(A view)

(B view)

Within ± 15

Within ± 10

degrees

<Liquid-side>

(Horizontal line)

NOT GOOD

(C view)

When arranging the branching header at the liquid side, attach a header sealed pipe on the sealing side of the header as shown in the fiqure at below.

Be sure to install the branch pipe downward. Horizontal viewed from D point should be within ± 10 degrees same as view B.

• Supporting branching header After applying the insulation, set the hanging metals

as support. (in use on the site).

NOTE :

1. Install the branching header so that it branches

horizontally. It cannot be used in a vertical position.

2. Do not use T-type pipe for the branching section.

Inlet socket

Pipe in use on the site

Branching Header

(D view) Sealing side

Within ± 15

degrees

Header sealed pipe

Within ± 10

degrees

CAUTION

1. On the inlet side of a Y-type branch joint or branch header, allow for at least 300mm of straight pipe.

2. A Y-type branch joint can be installed so that it branches either vertically or horizontally; if branching horizontally, it should be within an angle of ± 15°.

3. A branch header should be installed so that it branches horizontally.

4. Do not use T-type branch joints.

CAUTION

In the multi air conditioning system, because the refrigerant pipes congregate at the rooftop pipeshaft outlet in the vertical pipeshaft, it is necessary to attach “labels” to each pipe in order to make clear to which system a given pipe belongs so as to prevent pipes from being connected incorrectly.

How to connect “Cooling Only” indoor unit

Branch joint

• When connecting a Cooling Only indoor unit, attach a sealed pipe to the unused connectors of the branching pipe of discharge gas side.

Suction gas side

* Discharge gas side

Liquid side

∗ Refer to above. There is the method of connecting without using branching joint pipe of discharge gas side.

For details, refer to the Installation Manual of the Air Conditioner.

Connect sealed pipe.

Flow selector unit

Indoor unit Cooling only

Indoor unit Heating and Cooling

Branch header

• When connecting a Cooling Only indoor unit, attach a sealed pipe to the unused connectors of the branching pipe of discharge gas side.

Suction gas side

Connect sealed pipe.

Discharge gas side

Liquid side

Flow selector unit

Indoor unit Cooling only

Indoor unit Heating and Cooling

[NOTE]

For cooling only indoor unit in Super-HRM system, item code (DN) setting from the wired remote controller is necessary. (Refer to the section “13-1.”)

[3] T-shape branching joint (For connection of outdoor unit)

RBM-BT13FE

Please read "Safety Cautions" described in the Installation Manual of the Air Conditioner.

• Check the following parts in the package.

• For piping material and size of the refrigerant pipes, refer to the Installation Manual of the Air Conditioner.

RBM-BT13E (T-shape branching joint)

Branching joint Socket

Ø38.1

Suction

Ø38.1

Gas side

1 pc

Ø28.6

Discharge gas side

Liquid side

Ø28.6

Ø22.2

Ø28.6

1 pc

Ø22.2

1 pc

Parts

NOTE :

All dimentions are in millimeters. In the following tables, ( ) indicates diameter of the

indicated position, and others indicate diameter of the connected pipe.

DiameterNo.

Ø34.9 x (Ø38.1) 1pc

Ø28.6 x (Ø38.1) 3pcs

Ø22.2 x (Ø38.1) 2pcs

Diameter of the connected pipe

(external diameter of soket)

Ø19.1 x (Ø28.6) 2pcs

Ø22.2 x (Ø28.6) 2pcs

Ø15.9 x (Ø22.2) 1pc

Ø19.1 x (Ø22.2) 1pc

Ø12.7 x (Ø22.2) 2pcs

Ø9.5

For balancing pipe

Ø9.5

To outdoor unit

To other branching pipe or outdoor unit

Pipe in use on the site

• When combining two units, connect directly between outdoor units.

Connect balancing pipe directly.

Pipe in use on the site

To other branching pipe or outdoor unit

Pipe in use on the site

Branching pipe for balancing pipe (Provided)

Follower unitHeader unit

1 pc

• Be sure to perform heat insulating at liquid side and gas side, and balancing pipes separately. (Heat insulator for balancing is not provided.)

• Use heat-resisting heat insulator (120°C or more) for pipes at gas side.

• To insulate heat of the branching pipes, use a joint cover (For T-shape) available on the market that is with 10mm or more thickness, or one applied with machining as shown in the figure.

• Seal the branching piping completely without clearance to prevent dewing or falling of water drops.

Heat insulating pipe for piping

Seal with vinyl tape

Cut the heat insulator at the right angle

ØD

90 degrees

ØD

90 degrees

Seal the joint with urethane foaming agent, etc.

Heat insulating pipe for piping

Heat insulator

Cut the heat insulator at the right angle

90 degrees

more then 100mm

Pipe in use on the site

To outdoor unit

Socket at suction gas/ discharge gas/liquid side (Provided)

To other branching pipe or branching section of main pipe

Pipe in use on the site

Use the attached socket at suction gas/

discharge gas/liquid sides along with the selected pipe size. (Figure shows a connecting example.)

To other branching pipe or branching section of main pipe

Branching pipe at suction gas/discharge gas/liquid side (Provided)

Socket at suction gas/discharge gas/liquid side (Provided)

To other branching pipe or outdoor unit

Pipe in use on the site

Socket at suction gas/discharge gas/liquid side (Provided)

To outdoor unit

• Installation of branching pipes to suction gas/discharge gas/liquid sides.

To other branching pipe or outdoor unit

GOOD

NOT GOOD

Do not install branch pipe in this direction

Header

outdoor unit

Header

outdoor unit

Follower

outdoor unit

Follower

outdoor unit

5-8. External Dimensions of Branch Connectors

(Outline drawings are shown on the following pages.)

Branching joints and headers

Model name Appearance

RBM-BY53FE

Y-shape branching joint (*3)

4-branching

header (*4) (*5)

8-branching

header (*4) (*5)

T-shape branching joint (For connection of outdoor units)

1 “Capacity code” can be obtained from page 6. (Capacity code is not actual capacity.)

2 If total capacity code value of indoor unit exceeds that of outdoor unit, apply capacity code of outdoor unit.

3 When using Y-shape branching joint for 1st branching, select according to capacity code of outdoor unit.

4 Max. 6.0 capacity code in total can be connected.

5 If the capacity code of outdoor unit is 26 or more, it is not used for 1st branching.

6 This is used for branching to “cooling only” indoor unit.

7 Model names for outdoor and indoor units described in this guide are shortened because of the space constraint.

RBM-BY203FE RBM-BY303FE

RBM-BY53E RBM-BY103E RBM-BY203E RBM-BY303E

RBM-HY1043FE RBM-HY2043FE

RBM-HY1043E

RBM-HY2043E RBM-HY1083FE RBM-HY2083FE

RBM-HY1083E

RBM-HY2083E

RBM-BT13FE

Indoor unit capacity code (*1) : Total below 6.4 Indoor unit capacity code (*1) : Total 6.4 or more and below 14.2RBM-BY103FE Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 Indoor unit capacity code (*1) : Total 25.2 or more Indoor unit capacity code (*1) : Total below 6.4 Indoor unit capacity code (*1) : Total 6.4 or more and below 14.2 Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 Indoor unit capacity code (*1) : Total 25.2 or more Indoor unit capacity code (*1) : Total below 14.2 Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 Indoor unit capacity code (*1) : Total below 14.2 Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 Indoor unit capacity code (*1) : Total below 14.2 Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 Indoor unit capacity code (*1) : Total below 14.2 Indoor unit capacity code (*1) : Total 14.2 or more and below 25.2 1 set 4 types T-shape joint pipes as described below: The required quantity is arranged and they are combined on site.

Connection piping Corresponded dia. (mm) Q'ty Balance pipe Piping at liquid side Piping at discharge gas side Piping at suction gas side

Usage

Ø12.7 to Ø22.2 Ø19.1 to Ø28.6 Ø22.2 to Ø38.1

For 3 piping

For 2

piping (*6)

For 3 piping For 2

piping (*6)

For 3 piping For 2

piping (*6)

Ø 9.5 1

1 1 1

5-9. Nitrogen Gas Blow Method (During Brazing)

• If nitrogen gas is not passed through the pipes during brazing, a film of oxidized material will form on the inner surfaces of the pipes. The presence of a such a film in the system will adversely affect the operation of the valves and compressor in the refrigerant system, and will prevent the system from operating normally.

• In order to prevent this from occurring, nitrogen gas is passed through the pipes while brazing is in progress. This process of replacing the air in the pipes with nitrogen is called the “nitrogen gas blow.”

This is the basic method that is used for brazing work.

CAUTION

1. Nitrogen gas must be used. (Oxygen, carbon dioxide, and fluorocarbons cannot be used.)

2. Always be sure to use a pressure-reducing valve.

Piping

Valve

Hose

Reducing valve

Nitrogen gas bomb

Piping at site

Brazing position

Copper pipe Ø6.4

Valve

Taping

Reducing valve

Pressure tight hose

Outside

Nitrogen

gas bomb

5-10. Brazing Work

1. Brazing work should be performed downwards or

(Recommended brazing)

sideways. Avoid brazing upwards (in order to avoid incomplete brazing). (Recommendation)

2. Always used the specified piping materials for

liquid pipes and gas pipes, and make sure that

GOOD NOT GOOD

Brazing material

they are installed in the proper direction and at the proper angle.

3. The “nitrogen gas blow” method should be used

when brazing.

(Direction downward) (Direction upward)

Lateral direction

Brazing material

CAUTIONS

1. Pay attention to fire prevention concerns. (Take preventative measures in the area where brazing work is

to be performed, such as keeping a fire extinguisher or water handy.)

2. Be careful not to burn yourself.

3. Make sure that any gaps between pipes and couplings are appropriate. (Do not miss brazing any joints.)

4. Make sure that pipes are adequately supported.

• The following table provides basic guidelines for the interval between supports for horizontal copper pipe.

Coupling size of brazed pipe

Connected section

External size Internal size

ØC

ØF

Interval between supports for copper pipe

Nominal dia.

Max. interval (m)

• Avoid securing copper pipes with metal brackets directly.

20 or less 25 to 40

1.0 1.5

(Unit: mm)

Connected section

Standard outer dia. of

connected copper pipe

6.35

9.52

12.70

15.88

19.05

22.22

28.58

34.92

External size Internal size

Standard outer dia. (Allowable difference)

6.35 (±0.03) 6.45 ( )

9.52 (±0.03) 9.62 ( )

12.70 (±0.03) 12.81 ( )

15.88 (±0.03) 16.00 ( )

19.05 (±0.03) 19.19 ( )

22.22 (±0.03) 22.36 ( )

28.58 (±0.04) 28.75 ( )

34.90 (±0.04) 35.11 ( )

+0.04 –0.02

+0.03 –0.03

+0.06 –0.02

+0.04 –0.04

Min. depth

of insertion

11 10

13 12

14 13

Oval value

0.06 or less

0.08 or less

0.10 or less

0.13 or less

0.15 or less

0.16 or less

0.20 or less

0.25 or less

Min. thickness

of coupling

0.50

0.60

0.70

0.80

0.82

1.00

1.20

∗ Gas brazing of refrigerant pipes must be performed by personnel qualified to do so under local ordinances.

Minmum wall thickness for R410A application

Soft (Coil)

Hard or Half hard

OD (Inch)

1/4

3/8

1/2

5/8

3/4

7/8

1.1/8

1.3/8

OD (mm)

6.35

9.52

12.70

15.88

19.05

22.20

28.58

34.92

Minium wall thickness

0.80

1.00

1.10

5-11. Flare Processing

Flare processing procedure

Parts and material : Copper pipe, flare nut. Flare nut shallbe of attached on the indoor unit or R410A exclusive. Tools : Flare tool (“Rigid” type), reamer, pipe cutter

Work procedure

Straighten the coiled copper pipe.

Cut the pipe with the pipe cutter.

Use the reamer to remove burrs from the cut surface of the pipe.

Pipe

Burr

Deburring

Key point

Uncoil the pipe.

1. Position the blade of the cutter so that it will cut the pipe at a perpendicular angle.

2. Rotate the pipe cutter to the left to cut the pipe.

3. Move the pipe cutter slowly.

1 . Keep the opening of the pipe

facing downwards.

2. Be careful not to scratch the inner surface of the pipe.

(Reason)

• It is difficult to cut the coiled pipe correctly, which increases the chance of failure.

• The cut surface will be at an angle.

• The cutter will bite too tightly.

• The copper pipe will be deformed.

• Scraps will get inside of the pipe.

• A gas leak could result.

Clear out the inside of the pipe by tapping on the end with a screwdriver.

Insert the flare nut.

Make sure that all scraps of metal are out of the tube by lightly tapping on the tube while the opening is pointing down.

Be certain to insert the flare nut before beginning the flare process.

• Metal scraps in the tube can damage the compressor.

• If the scraps adhere to the flared region, a gas leak may result.

• The flare nut will not fit inside the copper pipe after the flare process.

Work procedure

Key point

(Reason)

Attach the (“Rigid”) flare tool to the copper pipe.

Align the punch. (Align the arrow with the line adjacent to the next hole.)

1. Make sure that the inner surfaces of the flare tool are clean.

2. Determine the dimensions of the copper pipe in accordance with the flare tool.

45˚

Flare tool

Copper pipe

Align the arrow on the punch with the prescribed position on the flare tool.

• The copper pipe will slip out while the flaring process is in progress.

• The flared dimensions vary.

Dimensions to end of copper tube when flared with one tool surface

• Projection margin in flaring : A (Unit : mm)

Rigid (Clutch type)

Outer dia. of

copper pipe

6.4

9.5

12.7

15.9

R410A tool used

R410A R22

0 to 0.5 (Same as left)

Conventional tool used

R410A R22

1.0 to 1.5 0.5 to 1.0

Imperial (Wing nut type)

Outer dia. of copper pipe

6.4

9.5

12.7

15.9

R410A R22

1.5 to 2.0 1.0 to 1.5

2.0 to 2.5 1.5 to 2.0

Flare the pipe.

Remove the flare tool and check the flared surface.

Slowly and carefully turn the flare tool handle while it clicks, until it turns freely. Turn the handle to the left and raise it to the top.

If the handle is not raised to the top, the flare tool will scratch the extended portion of the pipe (the cone-shaped portion).

• If the “A” dimension is small, the flared contact surface is smaller and a gas leak becomes more likely.

• The pipe will not be flared fully.

• The extended portion of the pipe (the cone-shaped portion) will be scratched.

• Extruding margin of copper pipe with flare machining : A (Unit: mm)

Copper pipe outer dia.

9.5

12.7

15.9

13.2

16.6

19.7

+0.0

–0.4

Check list :

• Is the inner surface of the flared portion equal in width and shiny?

• Is the thickness of the flared portion equal?

• Is the flared portion of a suitable size?

5-12. Flushing

The flushing process uses gas pressure to remove foreign matter from the inside of pipes.

Three major effects

(1) Removes oxidation that formed inside of the pipe during brazing as a result of an inadequate “nitrogen gas

blow” procedure. (2) Removes foreign matter and moisture that has gotten inside of pipes due to improper handling. (3) Checks the connections in the pipe system between the indoor unit and the outdoor unit.

[Example work procedure]

1. Install a pressure reducing valve on a nitrogen cylinder. (Fluorocarbon gases and carbon dioxide carry a risk

of promoting condensation, while oxygen causes explosion.)

2. Connect the pressure reducing valve to a gauge manifold and then to the gas-side pipe and the liquid-side pipe

on the outdoor unit.

Indoor unit

Ø6.4 copper pipe

N21

Diff. size union

3. On the indoor unit side, plug all gas-side pipes except those for the

indoor units that are to be flushed.

4. Open the source valve on the nitrogen cylinder and increase the

pressure on the secondary side of the pressure reducing valve until it reaches 0.5MPa (5kg/cm2G), and then open the valve on the gauge manifold connected to the gas-side pipe.

5. Flushing

Press down on the end of the indoor-side gas pipe with your palm.

VLV

Gauge manifold valve

Source valve

Reducing valve

Nitrogen gas bomb

Plug (Brass)

1st side

Source valve

Flare nut

Copper pipe

2nd side

0.5MPa (5kg/cm²G)

When the pressure becomes so great that you can no longer hold it against the end of the pipe, remove your hand from the pipe. (This is the first flush.) Press down against the end with your hand again.

Flush the pipe a second time. (When flushing, place a piece of gauze, etc., on the end of the pipe, and then check the gauze for debris or moisture. Repeat the flushing process until nothing more comes out of the pipe.)

6. Close the gauge manifold valve, and repeat the above process for next

indoor unit (No. 2 to No. N). Close the gauge manifold valve, open the valve on the gauge manifold that is connected to the liquid-side pipe to allow the nitrogen to flow, and flush that liquid-side pipe.

Nitrogen

Hand

gas

Reducing valve

Pressure

0.5MPa (5kg/cm²G)

5-13. Pipe Connections to the Indoor Unit

1. Once you remove the flare nut from the pipe on

the indoor unit (always use a torque wrench), a small amount of gas will escape, but this is simply nitrogen gas with atmospheric pressure that was sealed inside to prevent corrosion, and does not indicate a problem.

2. Flare the pipe according to the procedure

described previously.

3. Centering

Center the pipes be seating the tapered portion of the half union in the flared portion of the pipe.

4. Tightening the flare nut

First hand-tighten the flare nut as much as possible, and then use a torque wrench to tighten the nut completely.

Center

Brazing union (half union)

Tapered portion

Flared portion

Flare nut

Connecting pipe outer dia.

(mm)

Ø6.4

Ø9.5

Ø12.7∗

Ø15.9∗

Tightening torque

(N•m)

14 to 18 (1.4 to 1.8 kgf•m)

34 to 42 (3.4 to 4.2 kgf•m)

50 to 62 (5.0 to 6.2 kgf•m)

68 to 82 (6.8 to 8.2 kgf•m)

∗ : R410A torque wrench required.

Turn flare nut with a wrench

Secure half union in place with a wrench

Tightening the flare nut with a torque wrench

* Avoid initially tightening the nut with a wrench. * When tightening a 6.4mm-diameter pipe, tighten the nut lightly with a wrench, and then tighten the nut about 90°

to 120° (1.5 to 2 corners of the nut) with a torque wrench.

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