Panasonic 2Way VRF System v2 Installation Instructions
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External diameter of service port R410A: 5/16"NOTE
This air conditioner uses the refrigerant R410A.
INSTALLATION INSTRUCTIONS 2WAY VRF System Air Conditioner
85464369527012 CV6233186894
U
Type
Type
Type
2WAY VRF System U-72ME1U9 U-96ME1U9
U-72ME1U9E* U-96ME1U9E*
Outdoor Unit Type 9672
Outdoor Units
Model No.
*1 Necessary to install the External Electronic Expansion Valve Kit (Optional : CZ-P56SVK1U)
* Salt-Air Damage Resistant Specifications.
Indoor Unit Type 7 9 12 15 18
S-12MD1U6S-09MD1U6S-07MD1U61-Way CassetteD1
S-18MU1U6S-12MU1U64-Way CassetteU1
Y1 4-Way Cassette 60 60 S-12MY1U6 S-18MY1U6
K1 Wall Mounted S-07MK1U6 S-09MK1U6 S-12MK1U6 S-18MK1U6
S-18MT1U6S-12MT1U6CeilingT1
F1 Low Silhouette Ducted S-07MF1U6 S-09MF1U6 S-12MF1U6 S-15MF1U6 S-18MF1U6
S-07MM1U6 S-09MM1U6 S-12MM1U6 S-15MM1U6 S-18MM1U6M1 Slim Low Static Ducted
E1 High Static Pressure Ducted
S-18MP1U6S-15MP1U6S-12MP1U6S-09MP1U6S-07MP1U6
S-18MR1U6S-15MR1U6S-12MR1U6S-09MR1U6S-07MR1U6
Floor StandingP1
R1 Concealed Floor Standing
Indoor Unit Type 19 24 36 48 54
D1 1-Way Cassette
U1 4-Way Cassette S-36MU1U6
Y1 4-Way Cassette 60 60
S-19MS1U6*1Wall MountedK1
T1 Ceiling S-24MT1U6
F1 Low Silhouette Ducted S-24MF1U6
S-24MU1U6
S-24MK1U6
S-36MF1U6 S-48MF1U6 S-54MF1U6
M1 Slim Low Static Ducted
E1 High Static Pressure Ducted S-36ME1U6 S-48ME1U6
P1 Floor Standing S-24MP1U6
S-24MR1U6R1 Concealed Floor Standing
Indoor Units
2
IMPORTANT! Please Read Before Starting This air conditioning system meets strict safety and oper- ating 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 fail- ure to follow the instructions in this document.
SPECIAL PRECAUTIONS
WARNING When Wiring
ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. ONLY A QUALIFIED, EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM.
are completed or reconnected and checked.
Do not supply power to the unit until all wiring and tubing
Highly dangerous electrical voltages are used in this system. Carefully refer to the wiring diagram and these instructions when wiring. Improper connections and inad- equate grounding can cause accidental injury or death.
Ground the unit following local electrical codes.
Connect all wiring tightly. Loose wiring may cause over- heating at connection points and a possible fire hazard.
To prevent possible hazards from insulation failure, the unit must be grounded.
WARNING
CAUTION
When Installing
When Connecting Refrigerant Tubing
Select an installation location which is rigid and strong enough to support or hold the unit, and select a location for easy maintenance.
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.
WARNING
Keep the fire alarm and the air outlet at least 5 feet away from the unit.
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 performing piping work do not mix air except for speci- fied refrigerant (R410A) in refrigeration cycle. It causes capacity down, and risk of explosion and injury due to high tension inside the refrigerant cycle.
Refrigerant gas leakage may cause fire.
Do not add or replace refrigerant other than specified type. It may cause product damage, burst and injury etc.
Do not leak refrigerant while piping work for an installation or re-installation, and while repairing refrigeration parts.
Handle liquid refrigerant carefully as it may cause frostbite.
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 con- nection.
Check carefully for leaks before starting the test run.
CAUTION
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.
Ch The inst era limi The er, i and laye risk foca With buil sys tive tion Mos to r con the sma ced den eme occ
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Check of Density Limit The room in which the air conditioner is to be installed requires a design that in the event of refrig- erant gas leaking out, its density will not exceed a set limit. The refrigerant (R410A), which is used in the air condition- er, 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. Suf- focation 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 effec- tive use of floor space, individual control, energy conserva- tion 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 pro- cedure 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 safe- guards 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
When Servicing Turn the power OFF at the main power box (mains)
before opening the unit to check or repair electrical parts and wiring.
parts.
Keep your fingers and clothing away from any moving
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.
Do not touch the air inlet or the sharp aluminum fins of the outdoor unit. You may get injured.
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.
WARNING Do not clean inside the indoor and
outdoor units by users. Engage authorized dealer or specialist for cleaning.
In case of malfunction of this appliance, do not repair by yourself. Contact to the sales dealer or service dealer for a repair.
CAUTION
CAUTION
Others
Do not touch the air inlet or the sharp aluminum fins of the outdoor unit. You may get injured.
Do not sit or step on the unit, you may fall down accidentally.
Do not stick any object into the FAN CASE. You may be injured and the unit may be damaged.
New tool?
1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A refriger- ant deterioration and compressor defects. Due to the features of the refrigerant and refrigerating machine oil, the prevention of water and other impurities becomes more important than ever.
2. Be sure to recharge the refrigerant only in liquid form.
2-1. Since R410A is a non-azeotrope, recharging the refrigerant in gas form can lower performance and cause defects in the unit.
2-2. Since refrigerant composition changes and performance decreases when gas leaks, collect the remaining refriger- ant and recharge the required total amount of new refrigerant after fixing the leak.
3. Different tools required
3-1. Tool specifications have been changed due to the characteristics of R410A. Some tools for R22- and R407C-type refrigerant systems cannot be used.
Material O
Copper tube Outer diameter 1/4 (6.35) 3/8 (9.52) 1/2 (12.7) 5/8 (15.88) 3/4 (19.05)
Wall thickness 1/32 (0.8) 1/32 (0.8) 1/32 (0.8) 5/128 (1.0) over 5/128 (1.0)
Material 1/2 H, H
Copper tube Outer diameter 7/8 (22.22) 1 (25.4) 1-1/8 (28.58) 1-1/4 (31.75) 1-1/2 (38.1) 1-5/8 (41.28)
Wall thickness 5/128 (1.0) 5/128 (1.0) 5/128 (1.0) 3/64 (1.1) over 3/64 (1.15) over 3/64 (1.20)
Precautions for Installation Using New Refrigerant
1. Care regarding tubing
1-1. Process tubing Material: Use C1220 phosphorous deoxidized copper specified in JIS H3300 Copper and Copper Alloy Seamless
Pipes and Tubes. For tubes of 7/8" (22.22 mm) or larger, use C1220 T-1/2H material or H material, and do not bend the tubes.
Tubing size: Be sure to use the sizes indicated in the table below.
Use a tube cutter when cutting the tubing, and be sure to remove any flash. This also applies to distribution joints (optional).
When bending tubing, use a bending radius that is 4 times the outer diameter of the tubing or larger.
* Using tools for R22 and R407C and new tools for R410A together can cause defects.
Manifold gauge
Vacuum pump
Outlet Inlet
CAUTION
Use sufficient care in handling the tubing. Seal the tubing ends with caps or tape to prevent dirt, moisture, or other foreign substances from entering. These substances can result in system malfunction.
R407C tools Item compatible Remarks
with R410A?
Manifold gauge Yes No Types of refrigerant, refrigerating machine oil, and pressure gauge are different.
Charge hose Yes No To resist higher pressure, material must be changed.
Vacuum pump Yes Yes Use a conventional vacuum pump if it is equipped with a check valve. If it has no check valve, purchase and attach a vacuum pump adapter.
Leak detector Yes No Leak detectors for CFC and HCFC that react to chlorine do not function because R410A contains no chlorine. Leak detector for HFC134a can be used for R410A.
Flaring oil Yes No For systems that use R22, apply mineral oil (Suniso oil) to the flare nuts on the tubing to prevent refrigerant leakage. For machines that use R407C or R410A, apply synthetic oil (ether oil) to the flare nuts.
Unit: in. (mm)
Unit: in. (mm)
4
5
Valve
Liquid
3-2. Use R410A exclusive cylinder only.
Single-outlet valve
(with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown.
New refrigerant R410A cannot be used for earlier models
1. Compressor specifications are different.
If recharging a R22 or R407C compressor with R410A, durability will significantly decrease since some of the materials used for compressor parts are different.
2. Existing tubing cannot be used (especially R22).
Completely cleaning out residual refrigerating
machine oil is impossible, even by flushing.
3. Refrigerating machine oil differs (R22).
Since R22 refrigerating machine oil is mineral oil, it does not dissolve in R410A. Therefore, refrigerating machine oil discharged from the compressor can cause compressor damage.
R22 refrigerating machine oil Mineral oil (Suniso oil)
R407C refrigerating machine oil Synthetic fluid (ether oil)
R410A refrigerating machine oil Synthetic fluid (ether oil)
6
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. Check of Limit Density 1-11. Installing Distribution Joint 1-12. Optional Distribution Joint Kits 1-13. Example of Tubing Size Selection and
Refrigerant Charge Amount
2. SELECTING THE INSTALLATION SITE . . . . . 16 2-1. Outdoor Unit 2-2. Removing Fin Guard for Heat Exchanger 2-3. Shield for Horizontal Exhaust Discharge 2-4. Installing the Outdoor Unit in Heavy Snow
Areas 2-5. Precautions When Installing in Heavy Snow
Areas 2-6. Dimensions of Wind Ducting 2-7. Dimensions of Snow Ducting
3. HOW TO INSTALL THE OUTDOOR UNIT . . . 20
3-1. Transporting 3-2. Installing the Outdoor Unit 3-3. Routing the Tubing 3-4. Prepare the Tubing 3-5. Connect the Tubing
4. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 24
4-1. General Precautions on Wiring 4-2. Recommended Wire Length and Wire
Diameter for Power Supply System 4-3. Wiring System Diagram
5. HOW TO PROCESS TUBING . . . . . . . . . . . . 28
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 . . . . . . . . . . . . . . . . . . . . . . . . . 32
Air Purging with a Vacuum Pump (for Test Run) Preparation
7. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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
CONTENTS
Page Page
7
Table 1-1 Outdoor Unit
1-2. Accessories Supplied
See Table 1-1.
1-1. Tools Required for Installation (not supplied)
1. Flathead screwdriver
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
5. Level gauge
6. Sabre saw or key hole saw
7. Hacksaw
8. Core bits
9. Hammer
10. Drill
11. Tube cutter
12. Tube flaring tool
13. Torque wrench
14. Adjustable wrench
15. Reamer (for deburring)
1-3. Type of Copper Tube and Insulation Material
If you wish to purchase these materials separately from a
local source, you will need:
1. Deoxidized annealed copper tube for refrigerant tubing.
2. Foamed polyethylene insulation for copper tubes as
required to precise length of tubing. Wall thickness of the
insulation should be not less than 5/16".
3. Use insulated copper wire for field wiring. Wire size varies
with the total length of wiring.
Refer to 4. ELECTRICAL WIRING for details.
1-4. Additional Materials Required for Installation
1. Refrigeration (armored) tape
2. Insulated staples or clamps for connecting wire
(See your local codes.)
3. Putty
4. Refrigeration tubing lubricant
5. Clamps or saddles to secure refrigerant tubing
6. Scale for weighing
CAUTION Check local electrical codes and
regulations before obtaining
wire. Also, check any specified
instructions or limitations.
1. GENERAL
This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for the outdoor unit and make sure all accessory parts listed are with the system before beginning.
Figure
Qty
0
1 1
1
1
U-72ME1U9 U-72ME1U9E
(6 ton)
U-96ME1U9 U-96ME1U9E
(8 ton)
1Instruction manual paper
Connection tubing
Part name
Outer diameter
Outer diameter
Inner diameter o3/4"(o19.05)
Inner diameter
o1-1/8"(o28.58)
o7/8"(o22.22) o3/4"(o19.05)
Explanation of symbols
Distribution joint (CZ : purchased separately)
Solidly welded shut (pinch weld)
Balance tubing (1/4")
Ball valve (field supply)
T-joint (field supply)
L5
LO
LA
LF
LM
LB LC
L2
L4
LG
LD L3
LHMax. 1.3 ft
Max. 1.3 ft
For extension
For extension
H2
H3
H1
L1
2 3
1
54
AB
C
38 39 40
Table 1-2 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights
Item Mark Contents Length(ft.)
Allowable tubing length
L1 Max. tubing length Actual length 492
Equivalent length 574
L (L2 L4) Difference between max. length and min. length from the No.1 distribution joint
131
LM Max. length of main tubing (at max. diameter) 262*
1, 2~ 40 Max. length of each distribution tube 98
L1 + 1 + 2~ 39 + A + B + LF + LG + LH
Total max. tubing length including length of each distribution tube (only liquid tubing)
984
L5 Distance between outdoor units 32
Allowable elevation difference
H1 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 49
H3 Max. difference between outdoor units 13
Allowable length of joint tubing
L3 T-joint tubing (field-supply); Max. tubing length between the first T-joint and solidly welded-shut end point
6.6
L = Length, H = Height
R410A distribution joint CZ-P680PJ1U (for outdoor unit) CZ-P1350PJ1U (for outdoor unit) CZ-P160BK1U (for indoor unit) CZ-P680BK1U (for indoor unit) CZ-P1350BK1U (for indoor unit)
1. Main tubing length LM = LA + LB 262 ft 2. Main distribution tubes LC LH are selected according to the capacity after the distribution joint. 3.
4. Sizes of indoor unit connection tubing 1 40 are determined by the connection tubing sizes on the indoor units.
The outdoor connection main tubing (LO portion) is determined by the total capacity of the outdoor units that are connected to the tube ends.
Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown in the figure below.
Do not use commercially available T-joints for the liquid tubing and parts.
* Be sure to use special R410A distribution joints (CZ:purchased separately) for outdoor unit connections and tubing branches.
NOTE
1-5. Tubing Length
1: The outdoor connection main tubing (LO portion) is determined by the total capacity of the outdoor units that are connected to the tube ends.
2: If the longest tubing length (L1) exceeds 295 ft. (equivalent length), increase the sizes of the main tubes (LM) by 1 rank for gas tubes and liquid tubes. (Use a field supply reducer.) (Select the tube size from the table of main tube sizes (Table 1-3) on the following page (LA table), and from the table of refrigerant tubing sizes (Table 1-8) on the second following page.)
3: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the gas tubes. (Use a field supply reducer.) (For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table on the following page.)
4: If the size of the existing tubing is already larger than the standard tubing size, it is not necessary to further increase the size. * If the existing tubing is used, and the amount of on-site additional refrigerant charge exceeds the value listed below, then
change the size of the tubing to reduce the amount of refrigerant. Max. additional charge for 1 outdoor unit: 62 lbs Max. additional charge for 2 outdoor units: 111lbs
NOTE
8
18
192,000 (56.3)
166
72,000 (21.1)
96,000 (28.1)
8
U-72ME1U9(E) U-72ME1U9(E)
U-72ME1U9(E) U-96ME1U9(E)
U-96ME1U9(E) U-96ME1U9(E)
U-72ME1U9(E) U-72ME1U9(E) U-72ME1U9(E)
139,000 (40.7)
168,000 (49.2)
12 14
203,000 (59.5)
22
240,000 (70.3)
20
U-96ME1U9(E) U-72ME1U9(E) U-72ME1U9(E)
U-96ME1U9(E) U-96ME1U9(E) U-72ME1U9(E)
264,000 (77.4)
24
U-96ME1U9(E) U-96ME1U9(E) U-96ME1U9(E)
288,000 (84.4)
U-96ME1U9(E)U-72ME1U9(E)
BTU/h (kW)
Total system tonnage
Combined outdoor models
Gas tubing
Liquid tubing
Unit: in. (mm)
o7/8" (o22.22)
o3/4" (o19.05)
o3/8" (o9.52)
o1-1/8" (o28.58)
o1/2" (o12.7) (o15.88)
o5/8"
o1-3/8" (o34.92)
o3/4" (o19.05)
9
1-6. Tubing Size
Table 1-3 Main Tubing Size (LA)
*1: If future extension is planned, select the tubing diameter based on the total tonnage after extension. However extension is not possible if the resulting tubing size is two ranks higher.
*2: The balance tube (outdoor unit tube) diameter is 1/4". *3: Type 1 tubing should be used for the refrigerant tubes. *4: If the length of the longest tube (L1) exceeds 295 ft. (equivalent length), increase the main tube (LM) size by 1 rank for the gas
and liquid tubes. (Use field-supply reducers.) (Select from Table 1-3 and Table 1-9.) *5: If the longest main tube length (LM) exceeds 164 ft., increase the main tube size at the portion before 164 ft. by 1 rank for the
gas tubes. (For the portion that exceeds 164 ft., set based on the main tube sizes (LA) listed in the table above.)
Size of tubing (LO) between outdoor units Select the size of tubing between outdoor units based on the main tubing size (LA) as given in the table above.
( A C)
3/4" *1
(19.05) *1
3/8" (9.52)
1/4" (6.35)
72,000 (21.1)
96,000 (28.1)
Flare connection
Brazing connection
3/8" (9.52)
Flare connection Balance tubing
Liquid tubing
Gas 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 7/8" (22.22).
*2 If the size of tubing (LA) is less than 16.4 feet, it is recommended that the tubing diameter be larger than 1-1/8" (28.58).
7/8" *2
(22.22)*2
Note: In case the total capacity of connected indoor units exceeds the total capacity of the outdoor units, select the main tubing size for the total capacity of the outdoor units. (Especially the main tubing segments of LA, LB and LF.)
Table 1-5 Outdoor Unit Tubing Connection Size
Balance tube
Liquid tube Gas tube
3/4" (19.05)
1-3/8" (34.92)
3/4" (19.05)
1-3/8" (34.92)
5/8" (15.88)
1-1/8" (28.58)
1/2" (12.7)
1-1/8" (28.58)
3/8" (9.52)
3/4" (19.05)
3/8" (9.52)
5/8" (15.88)
3/8" (9.52)
1/2" (12.7)Gas tubing
Liquid tubing
238,900
178,800
1/2" (12.7)
1-1/8" (28.58)
178,800
143,30024,200
24,200 334,400
334,40054,600
54,600
238,900
76,800
3/8" (9.52)
7/8" (22.22)
76,800
102,400
102,400
Below BTU/h
Over BTU/h
143,300
Tubing size
Total capacity after distribution
Table 1-4 Main Tubing Size After Distribution (LB, LC...) Unit: in. (mm)
Table 1-6 Refrigerant Charge Amount at Shipment (for outdoor unit)
DC U-72ME1U9, U-72ME1U9E U-96ME1U9, U-96ME1U9E
(oz) 416 416
Gas tubing
Liquid tubing
Indoor unit type 7 9 12 15 18 19 24 36 48 54
Unit: in. (mm)
o1/2" (o12.7)
o1/4" (o6.35)
o5/8" (o15.88)
o3/8" (o9.52)
Table 1-7 Indoor Unit Tubing Connection Size
Note: Use C1220T-1/2H material for tubing over 3/4" (22.22).
10
1-9. System Limitations
Max. No. allowable connected outdoor units 3 *1
Max. capacity allowable connected outdoor units 288,000 BTU/h (24 ton, 84.4 kW)
Max. connectable indoor units 40
Max. allowable indoor/outdoor capacity ratio 50 130 %
*1: Up to 3 units can be connected if the system has been extended.
1-7. Straight Equivalent Length of Joints
Design the tubing system by referring to the following table for the straight equivalent length of joints.
Table 1-8 Straight Equivalent Length of Joints
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)
1-3/8" (34.92)
1-5/8" (41.28)
90 elbow 1 1.1 1.4 1.6 1.7 1.9 2.5 2.8
45 elbow 0.8 0.9 1 1.2 1.3 1.4 1.8 2.0
U-shape tube bent (R2-3/8" 4" (60 100)) 3 3.4 4.1 4.7 5.1 5.6 7.4 8.4
Trap bend 7.5 9.2 10.5 12.5 14.1 15.4 19.2 22.3
Y-branch distribution joint Equivalent length conversion not needed.
Ball valve for service Equivalent length conversion not needed.
Table 1-9 Refrigerant tubing (Existing tubing can be used.)
Tubing size (in. (mm))
Material O Material 1/2H H
1/4" (6.35) t1/32" (t0.8) 7/8" (22.22) t5/128" (t1.0)
3/8" (9.52) t1/32" (t0.8) 1" (25.4) t5/128" (t1.0)
1/2" (12.7) t1/32" (t0.8) 1-1/8" (28.58) t5/128" (t1.0)
5/8" (15.88) t5/128" (t1.0) 1-1/4" (31.75) t3/64" (t1.1)
3/4" (19.05) over t5/128" (t1.0) 1-1/2" (38.1) over t3/64" (t1.15)
1-5/8" (41.28) over t3/64" (t1.20)
* When bending the tubes, use a bending radius that is at least 4 times the outer diameter of the tubes. In addition, take sufficient care to avoid crushing or damaging the tubes when bending them.
1-8. Additional Refrigerant Charge
Additional refrigerant charge amount is calculated from the liquid tubing total length and a type of outdoor unit as follows.
Liquid tubing size Amount of additional (in. (mm)) refrigerant charge (oz/ft.)
1/4" (6.35) 0.279
3/8" (9.52) 0.602
1/2" (12.7) 1.38
5/8" (15.88) 1.99
3/4" (19.05) 2.78
7/8" (22.22) 3.93
Required amount of additional refrigerant charge = [(Amount of additional refriger- ant charge per ft. of each size of liquid tube its tube length) + (...) + (...)] + [Nec- essary amount of additional refrigerant charge per outdoor unit + (...) + (...)]
* Always charge accurately using a scale for weighing.
* If the existing tubing is used, and the amount of on-site additional refrigerant charge exceeds the value listed below, then change the size of the tubing to reduce the amount of refrigerant. Max. additional charge for 1 outdoor unit :62 lbs Max. additional charge for 2 outdoor units :111 lbs
Unit: ft.
Table 1-11 System Limitations
Table 1-10-1 Amount of Additional Refrigerant Charge Per ft., According to Liquid Tubing Size
Table 1-10-2 Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit
Further charge a certain amount listed below in addition to the amount of refrigerant charge.
U-72ME1U9, U-72ME1U9E U-96ME1U9, U-96ME1U9E
42 oz/unit 42 oz/unit
WARNING Always check the gas density limit for the room in which the unit is installed.
1-10. Check of Limit Density
When installing an air conditioner in a room, it is necessary to ensure that even if the refrigerant gas accidentally leaks out, its density does not exceed the limit level for that room.
15 to
3 0
B
A B
A
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 8 inch
Indoor unit (more than 2 units)
Horizontal
Indoor unit is directed downward
CAUTION
Pay special attention to any location, such as a basement, etc., where leak- ing refrigerant can accumulate, since refrigerant gas is heavier than air.
1-11. Installing Distribution Joint
(1) Refer to HOW TO ATTACH DISTRIBUTION JOINT enclosed with the optional distribution joint kit (CZ-P680PJ1U, CZ-P1350PJ1U, CZ-P160BK1U, CZ-P680BK1U, CZ-P1350BK1U).
(2) When creating a branch using a commercially available T-joint (header joint system), orient the main tubing so that it is either horizontal (level) or vertical. In order to prevent accumu- lation of refrigerant oil in stopped units, if the main tubing is horizontal then each branch tubing length should be at an angle that is greater than horizontal. If the main tubing is verti- cal, provide a raised starting portion for each branch.
(3) If there are height differences between indoor units or if branch tubing that follows a distribution joint is connected to only 1 unit, a trap or ball valve must be added to that distribution joint. (When adding the ball valve, locate it within 1.3 ft. of the distribution joint.) If a trap or ball valve is not added, do not operate the sys- tem before repairs to a malfunctioning unit are completed. (The refrigerant oil sent through the tubing to the malfunctioning unit will accumulate and may damage the compressor.)
11
12
1-12. Optional Distribution Joint Kits
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. CZ-P680PJ1U 232,000 BTU/h (68.0 kW) or less For outdoor unit
2. CZ-P1350PJ1U 460,700 BTU/h (135.0 kW) or less For outdoor unit
3. CZ-P160BK1U 76,400 BTU/h (22.4 kW) or less For indoor unit
4. CZ-P680BK1U 232,000 BTU/h (68.0 kW) or less For indoor unit
5. CZ-P1350BK1U 460,700 BTU/h (135.0 kW) or less For indoor unit
Tubing size (with thermal insulation)
C D E F
H I
H I
C
C
G
G
G
6-59/64
5-5/16
4-21/64
3-13/16 4
6 /
1 3
- 4 3 5
- 2
/ 4 6
Insulation
Distr ib ution Joint
Reducing Joints
Insulation
Distr ib ution Joint
Reducing Joints
Gas tubing Liquid tubing
1. CZ-P680PJ1U For outdoor unit (Capacity after distribution joint is 232,000 BTU/h (68.0 kW) or less.)
Example:
Unit: in.
Table 1-14 Size of connection point on each part (Shown are inside diameters of tubing)
Table 1-13 Size of connection point on each part (Shown are inside diameters of tubing)
2. CZ-P1350PJ1U For outdoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than
460,700 BTU/h (135.0 kW).)
Size Part A Part B Part C Part D Part E Part F Part G Part H Part I
in. (mm) 1- 3/8" 1-1/4" 1-1/8" 1" 7/8" 3/4" 5/8" 1/2" 3/8"
(34.92) (31.75) (28.58) (25.4) (22.22) (19.05) (15.88) (12.7) (9.52)
Size Part A Part B Part C Part D Part E Part F Part G Part H Part I
in. (mm) 1-3/8" 1-1/4" 1-1/8" 1" 7/8" 3/4" 5/8" 1/2" 3/8"
(34.92) (31.75) (28.58) (25.4) (22.22) (19.05) (15.88) (12.7) (9.52)
Insulation
B
F
H I
H I
G
G
G B
B
(A)
(A) (A)
6-57/64
5-5/16
4-21/64
3-13/16
C C
C
D D
D
4 6 /
1 3
- 4 3 5
- 2
/ 4 6
E
F Reducing Joints
Distr ib ution Joint
Insulation
( ): Outside dimension
Distr ib ution Joint
Reducing Joints
Gas tubing Liquid tubing Example:
Unit: in.
13
4-21/64 3-13/16
4-21/64 3-13/16
4 6 /
3 5
- 2
4 6
/ 3
5 -
2
Insulation
B A D
B
B C
C
C D E A
C D E
C
Distr ib utio n Joint Insulation
Distr ib utio n Joint
Gas tubing Liquid tubing
6-57/64 5-5/16
4-21/64 3-13/16
E
E
F G
F G H
B C D
E F
E B C D F G H D C B E F
4 6 /
1 3
- 4
4 6 /
3 5
- 2
Distr ib ution Joint
Distr ib ution Joint
Insulation
Insulation
Reducing Joints
Reducing Joints
A
A
A
Gas tubing Liquid tubing
6-57/64 5-5/16
4-21/64 3-13/16
H I J
C D
E F
G H
4 6 /
1 3
- 4
4 6
/ 3
5 -
2
G
F F
H
G
G
Distr ib ution Joint
Distr ib ution Joint
Insulation
Insulation Reducing Joints
Reducing Joints
B C D
B
B
(A)
(A)
(A) C D
Gas tubing Liquid tubing
( ): Outside dimension
Example:
Example:
Example:
Size Part A Part B Part C Part D Part E Part F Part G Part H
in. (mm) 1-1/8" 1" 7/8" 3/4" 5/8" 1/2" 3/8" 1/4"
(28.58) (25.4) (22.22) (19.05) (15.88) (12.7) (9.52) (6.35)
Size Part A Part B Part C Part D Part E
in. (mm) 3/4" 5/8" 1/2" 3/8" 1/4"
(19.05) (15.88) (12.7) (9.52) (6.35)
Unit: in.
Unit: in.
Unit: in.
Table 1-15 Size of connection point on each part (Shown are inside diameters of tubing)
4. CZ-P680BK1U Use: For indoor unit (Capacity after distribution joint is greater than 76,400 BTU/h (22.4 kW) and no more than 232,000 BTU/h (68.0 kW).)
Table 1-17 Size of connection point on each part (Shown are inside diameters of tubing)
Table 1-16 Size of connection point on each part (Shown are inside diameters of tubing)
5. CZ-P1350BK1U Use: For indoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW) and no more than 460,700 BTU/h (135.0 kW).)
3. CZ-P160BK1U Use: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.)
Size Part A Part B Part C Part D Part E Part F Part G Part H Part I Part J
in. (mm) 1-3/8" 1-1/4" 1-1/8" 1" 7/8" 3/4" 5/8" 1/2" 3/8" 1/4"
(34.92) (31.75) (28.58) (25.4) (22.22) (19.05) (15.88) (12.7) (9.52) (6.35)
1-13. Example of Tubing Size Selection and Refrigerant Charge Amount
1 2 3 4 LA
LB LC A B
Outdoor unit
96 type 96 type
48 type 48 type 48 type 36 type
Example:
Example of each tubing length
Main tubing Distribution joint tubing LA = 131 ft. Outdoor side Indoor side LB = 16 ft. A = 7 ft. 1 = 98 ft. LC = 16 ft. B = 7 ft. 2 = 16 ft.
3 = 16 ft. 4 = 65 ft.
CAUTION
1. R410A additional charging absolutely must be done through liquid charging.
2. The R410A refrigerant cylinder has a gray base color, and the top part is pink.
3. The R410A refrigerant cylinder includes a siphon tube. Check that the siphon tube is present. (This is indicated on the label at the top of the cylinder.)
4. Due to differences in the refrigerant, pres- sure, and refrigerant oil involved in installa- tion, it is not possible in some cases to use the same tools for R22 and for R410A.
Balance tube
Liquid tube
Gas tube
Use a flathead screwdriver and open by turning the part with the screw groove to the right, from to |.
Use a flathead screwdriver and open by turning the part with the screw groove to the right, from to |.
Use a hex wrench (width 5/32 inch) and turn to the left to open.
14
Additional refrigerant charging
Based on the values in Tables 1-3, 4, 5, 7, 10-1 and 10-2, use the liquid tubing size and length, and calculate the amount of addi-
tional refrigerant charge using the formula below.
= Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit + 3.93 (a) + 2.78 (b) + 1.99 (c) + 1.38 (d) + 0.602 (e) + 0.279 (f)
Required additional refrigerant charge (oz)
(a) : Liquid tubing Total length of 7/8" (ft.) (d) : Liquid tubing Total length of 1/2" (ft.)
(b) : Liquid tubing Total length of 3/4" (ft.) (e) : Liquid tubing Total length of 3/8" (ft.)
(c) : Liquid tubing Total length of 5/8" (ft.) ( f ) : Liquid tubing Total length of 1/4" (ft.)
Charging procedure
Be sure to charge with R410A refrigerant in liquid form.
1. After performing a vacuum, charge with refrigerant from the liquid tubing side. At this time, all valves must be in the fully
closed position.
2. If it was not possible to charge the designated amount, operate the system in Cooling mode while charging with refrigerant
from the gas tubing side. (This is performed at the time of the test run. For this, all valves must be in the fully open position.
However if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valves fully closed.)
Charge with R410A refrigerant in liquid form.
With R410A refrigerant, charge while adjusting the amount being fed a little at a time in order to prevent liquid refrigerant from
backing up.
After charging is completed, turn all valves to the fully open position.
Replace the tubing covers as they were before.
Obtain liquid tubing size from Tables 1-3, 4, 5, 7 and 10-1.
Main tubing
LA = 5/8 (ft.) (Total capacity of indoor unit is 179,400 BTU/h) The longest tubing length in this example
LB = 1/2 (ft.) (Total capacity of indoor unit is 131,600 BTU/h) (LA = 131 ft.)
LC = 3/8 (ft.) (Total capacity of indoor unit is 83,800 BTU/h)
Distribution joint tubing
Outdoor side A: 3/8 (ft.) B: 3/8 (ft.) (from outdoor unit connection tubing)
Indoor side 1: 3/8 (ft.) 2: 3/8 (ft.) 3: 3/8 (ft.) 4: 3/8 (ft.) (from indoor unit connection tubing)
Obtain additional charge amount for each tubing size.
Note 1: The charge amounts per 1 ft. are different for each liquid tubing size.
5/8 (ft.) LA : 131 ft. 1.99 oz/ft. = 261 oz
1/2 (ft.) LB : 16 ft. 1.38 oz/ft. = 22 oz
3/8 (ft.) LC + A B + 1 4 : 225 ft. 0.602 oz/ft. = 135 oz
Total 418 oz
Additional refrigerant charge amount is 418 oz.
Note 2: Necessary amount of additional refrigerant charge per outdoor unit (U-96ME1U9) is 42 oz. (See the Table 1-10-2.)
Note 1) Amount of additional charge per tubing length : 418 oz
Note 2) Amount of additional charge for outdoor unit : 84 oz (42+42)
Total of additional refrigerant charge amount : 502 oz
Therefore, the total of additional refrigerant charge amount reaches 502 oz.
Obtain overall refrigerant charge amount.
Overall refrigerant charge amount of the system indicates the calculated value shown above the additional charge amount
in addition to the total of the refrigerant charge amount (shown in the Table 1-6) at the shipment of each outdoor unit.
Refrigerant charge amount at shipment:
U-96ME1U9 : 416 oz
U-96ME1U9 : 416 oz
Additional charge amount : 502 oz
Grand total : 1334 oz
Therefore, overall refrigerant charge amount of the system reaches 1334 oz.
15
Be sure to check the limit density for the
room in which the indoor unit is installed. CAUTION
Remark:
Be sure to include the values in Table 1-10-2 Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit.
16
Fig. 2-1
Fig. 2-2
Fig. 2-3
2. SELECTING THE INSTALLATION SITE
2-1. Outdoor Unit
AVOID:
heat sources, exhaust fans, etc.
damp, humid or uneven locations
indoors (no-ventilation location)
DO:
choose a place as cool as possible.
choose a place that is well ventilated.
allow enough room around the unit for air intake/
exhaust and possible maintenance.
use lug bolts or equal to bolt down unit, reducing vibration
and noise.
Installation Space
Install the outdoor unit where there is enough space for ven-
tilation. Otherwise the unit may not operate properly. Fig. 2-2
shows the minimum space requirement around the outdoor
units when 3 sides are open and only 1 side is shuttered,
with open space above the unit. The mounting base should
be concrete or a similar material that allows for adequate
drainage. Make provisions for anchor bolts, platform height,
and other site-specific installation requirements.
CAUTION Leave space open above the
unit.
Construct louvers or other
openings in the wall, if nec- essary, to ensure adequate ventilation.
NOTE
Do not do any wiring or tubing within 1 ft. of the front
panel, because this space is needed as a servicing
space for the compressor.
Ensure a base height of 4" or more to ensure that
drainage water does not accumulate and freeze
around the bottom of the unit.
If installing a drain pan, install the drain pan prior to
installing the outdoor unit.
* Make sure there is at least 6" between the outdoor
unit and the ground.
Also, the direction of the tubing and electrical wiring