INSTALLATION MANUAL. System air conditioner RXYN10AY1. English. Deutsch. Français. Español. Italiano. Nederlands. Portugues

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1 INSTALLATION MANUAL System air conditioner English Deutsch Français Español RXYN10AY1 Italiano ÅëëçíéêÜ Nederlands Portugues Ðóññêèé Türkçe

2 DAIKIN INDUSTRIES, LTD. Noboru Murata Manager Quality Control Department 1st of October 2008 Umeda Center Bldg., , Nakazaki-Nishi, Kita-ku, Osaka, Japan DAIKIN.TCF.024C19/ TÜV Rheinland EPS B.V RXYN10AY1 FXSN20AV1, FXSN25AV1, FXSN32AV1, FXSN40AV1, FXSN50AV1, FXSN63AV1, FXSN100AV1 BEVN32AV1, BEVN50AV1, BEVN125AV1 Low Voltage 2006/95/EC Machinery Safety 98/37/EC Electromagnetic Compatibility 2004/108/EC EN , 2P

3 RXYN10AY1 VRV System air conditioner Installation manual CONTENTS 1. FIRST OF ALL Safety precautions BEFORE INSTALLATION About this product Standard supplied accessories Combination Option accessory SELECTION OF LOCATION HANDING THE UNIT PLACING THE UNIT REFRIGERANT PIPING Selection of piping material and Refrigerant branching kit Installation tools Protection against contamination when installing pipes Pipe connection Connecting the refrigerant piping FIELD WIRING Wiring Connection Example for Whole System Leading wire Procedure Transmission Wiring Connection Procedure Power Wiring Connection Procedure Procedure for Wiring Inside Units INSPECTION AND PIPE INSULATION Testing Instruments Operation method of Operation method of service port Air tight test and vacuum drying method Pipe insulation Checking of device and installation conditions PROCEDURE OF ADDING REFRIGERANT CHARGING AND CHECK OPERATION Procedure of adding refrigerant charging Check operation TEST RUN FIRST OF ALL This document is an installation manual for the Daikin RXYN10AY1 Series VRV Inverter. Before installing the unit, read this manual thoroughly, and following the instructions contained in it. After installation, do a test run to make sure the unit runs properly, and then explain how to operate and take care of the unit to the customer, using the operation manual. Lastly, make sure the customer keeps this manual, along with the operation manual, in a safe place. This manual does not describe how to install the indoor unit. Refer to the installation manual included with the indoor unit for that. 1-1 Safety precautions Please read these Safety precautions carefully before installing air conditioning unit and be sure to install it correctly. After completing installation, conduct a trial operation to check for faults and explain to the customer how to operate the air conditioner and take care of it with the aid of the operation manual. Ask the customer to store the installation manual along with the operation manual for future reference. Meaning of WARNING and notices WARNING...Failure to follow these instructions properly may result in personal injury or loss of life....failure to observe these instructions properly may result in property damage or personal injury, which may be serious depending on the circumstances. WARNING Ask your dealer or qualified personnel to carry out installation work. Do not attempt to install the air conditioner yourself. Improper installation may result in water leakage, electric shocks or fire. Install the air conditioner in accordance with the instructions in this installation manual. Improper installation may result in water leakage, electric shocks or fire. When installing the unit in a small room, take measures against to keep refrigerant concentration from exceeding allowable safety limits in the event of refrigerant leakage. Contact the place of purchase for more information. Excessive refrigerant in a closed ambient can lead to oxygen deficiency. Be sure to use only the specified accessories and parts for installation work. Failure to use the specified parts may result in the unit falling, water leakage, electric shocks or fire. Install the air conditioner on a foundation strong enough to withstand the weight of the unit. A foundation of insufficient strength may result in the equipment falling and causing injury. Carry out the specified installation work after taking into account strong winds, typhoons or earthquakes. Failure to do so during installation work may result in the unit falling and causing accidents. Make sure that a separate power supply circuit is provided for this unit and that all electrical work is carried out by qualified personnel according to local laws and regulations and this installation manual. An insufficient power supply capacity or improper electrical construction may lead to electric shocks or fire. Make sure that all wiring is secured, the specified wires are used, and that there is no strain on the terminal connections or wires. Improper connections or securing of wires may result in abnormal heat build-up or fire. When wiring the power supply and connecting the remote controller wiring and transmission wiring, position the wires so that the EL.COMPO.BOX 1 lid can be securely fastened. Improper positioning of the EL.COMPO.BOX 1 lid may result in electric shocks, fire or the terminals overheating. If refrigerant gas leaks during installation, ventilate the area immediately. Toxic gas may be produced if the refrigerant comes into contact with fire. After completing installation, check for refrigerant gas leakage. Toxic gas may be produced if the refrigerant gas leaks into the room and comes into contact with a source of fire, such as a fan heater, stove or cooker. Do not directly touch refrigerant that has leaked from refrigerant pipes or other areas, as there is a danger of frostbite. Be sure to switch off the unit before touching any electrical parts. Do not allow children to climb on the outdoor unit and avoid placing objects on the unit. Injury may result if the unit becomes loose and falls. Be sure to earth the air conditioner. Do not earth the unit to a utility pipe, lightning conductor or telephone earth lead. Imperfect earthing may result in electric shocks or fire. A high surge current from lightning or other sources may cause damage to the air conditioner. Be sure to install an earth leakage breaker. Failure to install an earth leakage breaker may result in electric shocks or fire. English 1

4 While following the instructions in this installation manual, install drain piping to ensure proper drainage and insulate piping to prevent condensation. Improper drain piping may result in indoor water leakage and property damage. Install the indoor and outdoor units, power cord and connecting wires at least 1 meter away from televisions or radios to prevent picture interference and noise. (Depending on the incoming signal strength, a distance of 1 meter may not be sufficient to eliminate noise.) Remote controller (wireless kit) transmitting distance can be shorter than expected in rooms with electronic fluorescent lamps (inverter or rapid start types). Install the indoor unit as far away from fluorescent lamps as possible. Make sure to provide for adequate measures in order to prevent that the outdoor unit be used as a shelter by small animals. Small animals making contact with electrical parts can cause malfunctions, smoke or fire. Please instruct the customer to keep the area around the unit clean. Do not install the air conditioner in the following locations: 1. Where there is a high concentration of mineral oil spray or vapour (e.g. a kitchen). Plastic parts will deteriorate, parts may fall off and water leakage could result. 2. Where corrosive gas, such as sulphurous acid gas, is produced. Corroding of copper pipes or soldered parts may result in refrigerant leakage. 3. Near machinery emitting electromagnetic radiation. Electromagnetic radiation may disturb the operation of the control system and result in a malfunction of the unit. 4. Where flammable gas may leak, where there is carbon fibre or ignitable dust suspensions in the air, or where volatile flammables such as paint thinner or gasoline are handled. Operating the unit in such conditions may result in fire. When installing the indoor unit, refer to the installation manual provided for the indoor unit. Optional accessories are required for the installation of the product. Refer to the information on optional accessory. 2-2 Standard supplied accessories The following accessories are included. The storage location of the accessories is shown in the figure. Do not throw away any of the accessories until installation is complete. Name Clamp (1) Clamp (2) Clamp (3) Gas side accessory pipe (1) Gas side accessory pipe (2) Quantity 8 pcs. 2 pcs. 1 pc. 1 pc. 1 pc. Shape Name Small Large Thick accessory pipe (1) accessory pipe (2) Muffler Quantity 1 pc. 1 pc. 1 pc. Shape Thin 2. BEFORE INSTALLATION 2-1 About this product 1. This product uses R744 (CO2) refrigerant. The utmost attention is required to handle R744 refrigerant, and strict measures must be taken to keep impurities (including mineral oil and other types of oil as well as moisture) out of the system. Be sure to follow the instructions in 6. REFRIGERANT PIPING. 2. The design pressure is 12.3 MPa (4.0 MPa for R410A). Therefore, the following conventional parts cannot be used. Connection pipes Thick-walled pipes are required. Refer to 6. REFRIGERANT PIPING for the specifications of the pipes. Flare nut connections Unavailable. Perform brazing connections. Pipe brazing joints Pipes with a maximum diameter of 12.7mm... Make brazing connections with sleeve flare processing. Pipes with a diameter of 15.9mm... Use sockets sold as optional accessories. Elbows Use products sold as optional accessories. Installation instruments that must withstand high pressures, such as charge hoses and pressure gauges Use pressure-resistant instruments that withstand a minimum pressure of 12.3 MPa. 3. The indoor unit is an R744-dedicated unit. The following indoor unit models are connectable. (Do not connect other indoor unit models, or otherwise an inner piping rupture will result.) Name Thermal insulation tube Others Quantity 1 pc. 1 pc. about each item Shape Operation manual Installation manual Electric wiring diagram booklet Declaration of conformity REQUEST FOR THE INDICATION label (Installation records) 2-3 Combination The indoor units can be installed in the following range. Indoor unit Total capacity of indoor units Total quantity of indoor units units 2-4 Option accessory The following refrigerant branching kit as an optional accessory is required for piping. Refer to 6. REFRIGERANT PIPING to select the refrigerant branching kit. REFNET joint Operation manual Installation manual Clamps Accessory pipes BHRN26A33T 2 English

5 0 The sleeve flare processing of pipes with a diameter of 15.9 mm is difficult. Use the following socket as an optional accessory to connect pipes. Socket BHFN5A10S Connection with 15.9 dia. in size Be sure to use piping materials withstanding a pressure of 12.3 MPa. Use a different elbow sold as an optional accessory if the bending radius needs to be reduced. This is particularly important for the bending portions of pipes with a diameter of 15.9 mm. Elbow BHFN2A10L BHFN3A10L BHFN4A10L BHFN5A10L Connection with 6.4 dia. in size Connection with 9.5 dia. in size Connection with 12.7 dia. in size Connection with 15.9 dia. in size 3. SELECTION OF LOCATION Select a location for installation that meets the following conditions. Get the customer s permission. 1. There is no danger of fire due to leakage of inflammable gas. 2. Select the location of the unit in such a way that neither the discharged air nor the sound generated by the unit disturb anyone. 3. The foundation is strong enough to support the weight of the unit and the floor is flat to prevent vibration and noise generation. 4. The piping length between the outdoor unit and the indoor unit may not exceed the allowable piping length. (Refer to 6. REFRIGERANT PIPING ) 5. Locations where the unit s suction vent and outlet vent do not generally face the wind. Wind blowing directly into the suction or outlet vents will interfere with the unit s operation. If necessary, install some kind of obstruction to block the wind. 6. The space around the unit is adequate for servicing and the minimum space for air inlet and air outlet is available. (See the Installation Space Examples for the minimum space requirements.) Installation Space Examples The installation space requirement shown in the following figure is a reference for cooling operation when the outdoor temperature is 35 C. If the design outdoor temperature exceeds 35 C or the heat load exceeds maximum capacity in all the outdoor unit, take an even large space on the intake shown in the following figure. During installation, install the units using the most appropriate of the patterns shown in the following figure for the location in question, taking into consideration human traffic and wind. If the number of units installed is more than that shown in the pattern in the following figure, install the units so there are no short circuits. As regards space in front of the unit, consider the space needed for the local refrigerant piping when installing the units. If the work conditions in the following figure do not apply, contact your dealer or Daikin directly. < If installed as a single unit > (Pattern 1) NOTE) NOTE) For Patterns 1 and 2 Wall height for front side no higher than 1500 mm. Wall height on the suction side no higher than 500 mm. Wall height for sides no limit. If the height is exceeded the above, calculate h1 and h2 shown in the figure below, and add h1/2 to the service space of front side and h2/2 to the service space of suction side. 300 of suction side Front 20 side (Pattern 2) NOTE) Front side (Pattern 2) NOTE) (Pattern 3) (Pattern 3) Front side A No limit to wall height Branch switch, overcurrent breaker Personal computer or radio h1 of front side of suction side of front side Front side Indoor unit 0 < When installed in serial > (Pattern 1) NOTE) Front side Front side An inverter air conditioner may cause electronic noise generated from AM broadcasting. Examine where to install the main air conditioner and electric wires, keeping proper distances away from stereo equipment, personal computers, etc. Particularly for locations with weak reception, ensure there is a distance of at least 3 meters for indoor remote controllers, place power wiring and transmission wiring in conduits, and ground the conduits. 2. If condensate may drip on downstairs (or walkway) depending on the floor condition, take a measure such as the installation of central drain pan kit (sold separately). 300 Front side Suction side h1 = A (Actual height) 1500 h2 = B (Actual height) Remote controller COOL/ HEAT selector No limit to wall height 500 h2 B (mm) of suction side of front side of suction side of front side Branch switch, overcurrent breaker English 3

6 3. The refrigerant R744 itself is nontoxic, nonflammable and is safe. If the refrigerant should leak however, its concentration may exceed the allowable limit depending on room size. Due to this it could be necessary to take measures against leakage. See Engineering Data for details. 4. When installing in a locations where there is heavy snowfall, implement the following snow measures. Ensure the base is high enough that intakes are not clogged by snow. Remove the rear intake grille to prevent snow from accumulating on the fins. The product cannot be supported with four corners. Center of the product Center of the product Base form 4. HANDING THE UNIT 1. Decide on the transportation route. 2. If a forklift is to be used, pass the forklift arms through the large openings on the bottom of the unit. Hole (large) 765 (Depth of product) Foundation bolt point (φ15 dia. : 4 positions) 631 (Inner dimension of the base) 631 (Outer dimension of the base) Fork Fixed screws of transportation clasp If hanging the unit, use a cloth sling to prevent damaging the unit. Keeping the following points in mind, hang the unit following the procedure shown in the following figure. Use a sling sufficiently strong to hold the mass of the unit. Use 2 belts of at least 8m long. Place extra cloth or boards in the locations where the casing comes in contact with the sling to prevent damage. Hoist the unit making sure it is being lifted at its center of gravity. Belt sling 3. After installation, remove the transportation clasp attached to the large openings. Apply a filler cloth on a fork to prevent coating of the bottom frame from coming off and rust from occurring when bringing in the unit with anti-corrosion treatment type using a forklift. 5. PLACING THE UNIT Belt sling Transportation clasp (yellow) Board Hole (small) (Hole 40 30) Make sure the unit is installed level on a sufficiently strong base to prevent vibration and noise. The base should be bigger around than the width of the unit s legs (66 mm), and should support the unit. If protective rubber is to be attached, attach it to the whole face of the base. The height of the base should be at least 150mm from the floor. Secure the unit to its base using foundation bolts. (Use four commercially available M12-type foundation bolts, nuts, and washers.) The foundation bolts should be inserted 20 mm. 20 Base width and base bolt positions When installing on a roof, make sure the roof floor is strong enough and be sure to water-proof all work. Make sure the area around the machine drains properly by setting up drainage grooves around the foundation. Drain water is sometimes discharged from the outdoor unit when it is running. 6. REFRIGERANT PIPING To Piping Work Contractors Do not use flux at the time of brazing and connecting refrigerant pipes. Use phosphorous copper brazing filler metal (BCuP-2), which does not require flux. Chlorine-based flux causes piping corrosion. Furthermore, if fluoride is contained, the flux will have adverse influences on the refrigerant piping line, such as the deterioration of refrigerating machine oil. 6-1 Selection of piping material and Refrigerant branching kit Refer to the following table for pipe size section. The following types of refrigerant pipes are available. Material: Phosphorus deoxidized seamless copper pipe (C1220T- 1/2H or C1220T-H) Pipe wall thickness: Product withstanding 12.3 MPa Pipe wall thickness examples (length: mm) Pipe size (Outer diameter) Material Smallest thickness φ6.4 1/2H 0.8 φ9.5 1/2H 1.0 φ12.7 1/2H 1.3 φ15.9 1/2H 1.8 Use only pipes which are clean inside and outside and which do not accumulate harmful sulfur, oxidants, dirt, cutting oils, moisture, or other contamination. (Foreign materials inside pipes including oils for fabrication must be 30mg/10m or less.) For piping work, follow the maximum tolerated length, difference in height, and length after a branch indicated. The refrigerant branching kit sold as an optional accessory is required for the branching of piping. Select the kit according to the following Refrigerant branch kit selection. 4 English

7 Example of connection (In the case of connecting 8 indoor units and 8 BEV units.) Actual pipe length Maximum allowable length Between outdoor and indoor units Equivalent length Total extension length Allowable height length Between outdoor and indoor units Between indoor and indoor units Actual pipe length Difference in height Difference in height Allowable length after the branch Actual pipe length Refrigerant branch kit selection Refrigerant branch kits can only be used with R744 Pipe size selection How to calculate the additional refrigerant to be charged Additional refrigerant to be charged : R (kg) (R should be rounded off in units of 0.1 kg.) Outdoor unit REFNET joint (A-G) a b c d e A B C D E F G g p H1 h 1 k B1 B2 B3 B4 B5 B6 B m n H2 B8 8 B1 B8 BEV nuit 1 8 Indoor unit Actual pipe length between outdoor and indoor units 150m Example unit 8 : a + b + c + d + e + f + g + p 150m Equivalent pipe length between outdoor and indoor units 175m (assume equivalent pipe length of REFNET joint to be 0.5m) Total pipe length from outdoor unit to all indoor units 300m Actual piping length between each BEV unit and the corresponding indoor unit. Refer to the BEV unit installation manual. Difference in height between outdoor and indoor units (H1) 50m ( 40m if the outdoor unit is below) Difference in height between indoor units (H2) 15m Pipe length from first REFNET joint to indoor unit 40m Example unit 8 : b + c + d + e + f + g + p 40m All refrigerant branch kit (Example: REFNET joint (A-G)) BHRN26A33T Piping between outdoor unit and REFNET joint (Part a) Piping between REFNET joints Piping between REFNET joint and indoor unit Piping size (O.D.) Gas pipe Liquid pipe φ15.9 φ9.5 (Unit:mm) Select the pipes from the following table according to the total capacity of the indoor units connected downstream. (Unit:mm) Indoor unit total capacity index < Piping size (O.D.) Gas pipe Liquid pipe φ12.7 φ15.9 φ9.5 Select the pipes from the following table according to the capacity of the indoor unit. (Unit:mm) Piping size (O.D.) Indoor unit capacity type Gas pipe Liquid pipe 20~100 type φ9.5 φ6.4 R = Total length(m) of liquid piping size at φ Indoor unit total capacity index Total length(m) of liquid piping size at φ Indoor unit total capacity index INDOOR TYPE CAPACITY INDEX FXSN20 20 FXSN25 25 FXSN32 32 FXSN40 40 FXSN50 50 FXSN63 63 FXSN Example: In the case of connecting eight 32-type indoor units for refrigerant branching a : φ9.5 30m b : φ9.5 10m c : φ9.5 10m d : φ9.5 10m R = e : φ9.5 10m f : φ9.5 10m g : φ9.5 10m h : φ6.4 20m i : φ6.4 10m j : φ6.4 10m k : φ6.4 9m l : φ6.4 3m =6.758 a+b+c+d h+i+j+k 32 8 units +e+f+g +l+m+n+p 6.8 m: φ6.4 3m n : φ6.4 3m p : φ6.4 1m i j l f English 5

8 6-2 Installation tools Be sure to use dedicated tools so that the air conditioner will maintain proper pressure resistance and the contamination of impurities will be prevented. Compatibility with conventional tools (other refrigerants) Name Compatibility Remarks Pipe cutter Use a cutter suitable to the piping thickness. 6-5 Connecting the refrigerant piping 1. Derection to bring out the pipes The local interunit piping can be connected either forward or to the sides (taken out through the bottom) as shown in the following figure. When passing out through the bottom, use the knock hole in the bottom frame. Pipe bender Expander (pipe expansion tool) Use a different elbow sold as an optional accessory if the bending radius needs to be reduced. Use a different elbow sold as an optional accessory for the bending portions of pipes with a diameter of 15.9mm. Use a different socket sold as an optional accessory for pipes with a diameter of 15.9mm, however, due to difficulty in expanding them. Front connection Left-side connection Right-side connection 6-3 Protection against contamination when installing pipes Protect the piping to prevent moisture, dirt, dust, etc. from entering the piping. Place Installation period Protection method Outdoor Indoor More than a month Less than a month Regardless of the period Pinch the pipe Pinch or tape the pipe Exercise special caution to prevent dirt or dust when passing piping through holes in walls and when passing pipe edges to the exterior. 6-4 Pipe connection Be sure to perform nitrogen permutation or nitrogen blow when brazing. Refrigerant pipe Location to be brazed Nitrogen Taping Handy valve Regulator Nitrogen Brazing without performing nitrogen permutation or nitrogen blow into the piping will create large quantities of oxidized film on the inside of the pipes, adversely affecting valves and compressors in the refrigerating system and preventing normal operation. The pressure regulator for the nitrogen released when doing the brazing should be set to 0.02 MPa (about 0.2kg/cm 2 :Enough to feel a slight breeze on your cheek). Do not use anti-oxidants when brazing the pipe joints. Residue can clog pipes and break equipment. Precautions when knocking out knock holes Open knock hole in the base frame by drilling the 4 concave around it with a 6mm bit. Be sure to avoid damaging the casing After knocking out the holes, we recommend you remove any burrs and paint them using the repair paint to prevent rusting. When passing electrical wiring through the knock holes, protect the wiring with a conduit or bushings, making sure not to damage the wiring. 2. Removing Pinch Piping In the case of connecting refrigerant piping to the outdoor unit, remove the span piping as in the following procedure. Refer to Operation method of for handling of the. Procedure 1 Confirm the shutoff valve is closed. On-site piping Pinch piping (Large) Pinch piping (Small) Knock hole Cut off Part of pinch piping datail figure Drill Concave section (4 places) Procedure 2 Connect a charge hose to the service port of the liquid side and gas side s and remove the gas from the pinch piping. Pinch piping (Small) Procedure 4 Melt the brazing material with a burner and remove the pinch piping (large) after the gas in the pinch piping is discharged. Procedure 3 Cut off the pinch piping (small) with an appropriate tool, such as a pipe cutter, and open the cross section to check that there is no residual oil. : If oil comes out of the cross section, cut off the pinch piping (large) with a pipe cutter and remove the pinch piping. 6 English

9 WARNING Remove the pinch piping (large) after discharging the oil and gas in the piping. Do not melt the brazing material while there remain oil and gas in the piping, or otherwise the oil may catch fire or the piping may be blown away and injury may result. 3. Connecting refrigerant piping to outdoor units If connected to the front Remove the cover to connect. 5. Connecting Muffler Connect the provided muffler to the gas pipe. Install the muffler within 1 m of the gas side. The refrigerant piping and indoor unit may generate noise unless the muffler is installed correctly. Gas side Gas side Gas side accessory pipe (1) Brazing Gas side accessory pipe (1) Brazing accessory pipe (1) On-site piping Muffler About 1 m accessory pipe (1) On-site piping When connected at lateral side (bottom) Remove the knock hole on the bottom frame and route the piping under the bottom frame. Gas side Gas side accessory pipe (2) Brazing piping (field supply) Gas side piping (field supply) Brazing Brazing Knockout hole Punch the knock hole. accessory pipe (2) accessory pipe (1) Gas side accessory pipe (1) When connecting the piping on site, be sure to use the accessory piping. Make sure the onsite piping does not come into contact with other piping or the bottom frame or side panels of the unit. 4. Branching the refrigerant piping Heed the restrictions below when installing the refrigerant branching kit and read the installation instruction manual with the kit. (Improper installation could lead to malfunctioning or breakdown of the outdoor unit.) <REFNET joint> Install the REFNET joint so it splits horizontally or vertically. Horizontal surface ±30 or less Set the muffler horizontally. Make sure that the inclination of the upper and lower sides does not exceed an angle of ±10 at the time of installation. A malfunction may result if the inclination exceeds the above angle. Brazing Wrap the provided thermal insulation tube around the muffler and secure both ends of the muffler to an appropriate object, such as the wall or ground. Thermal insulation tube (on-site piping) Muffler Thermal insulation tube (accessory) ±10 max. Brazing Thermal insulation tube (on-site piping) Dew condensation may result if the muffler is exposed. Furthermore, the weight of the muffler may break the piping unless the muffler is secured. Horizontal A-arrow view Vertical English 7

10 7. FIELD WIRING To Electric Engineering Contractors Be sure to install an earth leakage breaker. The product incorporates inverter equipment. In order to prevent the malfunctioning of the earth leakage breaker, make sure that the earth leakage breaker withstands harmonic interference. Do not operate the air conditioner until refrigerant piping work is completed, or otherwise the compressor will malfunction. Do not remove any electrical components such as thermistors or sensors when connecting power supply wires or transmission wires. The compressor may malfunction if the air conditioner is operated with such electrical components removed. All field wiring and components must be installed by a licensed electrician and must comply with relevant local and national regulations. Be sure to use a dedicated power circuit. Never use a power supply shared by another appliance. Never install a phase advancing capacitor. As this unit is equipped with an inverter, installing a phase advancing capacitor will not only deteriorate power factor improvement effect, but also may cause capacitor abnormal heating accident due to high-frequency waves. Only proceed with wiring work after blocking off all power. Always ground wires in accordance with relevant local and national regulations. This machine includes an inverter device. Connect earth and leave charge to eliminate the impact on other devices by reducing noise generated from the inverter device and to prevent leaked current from being charged in the outer hull of the product. Do not connect the ground wire to gas pipes, sewage pipes, lightning rods, or telephone ground wires. Gas pipes: can explode or catch fire if there is a gas leak. Sewage pipes: no grounding effect is possible if hard plastic piping is used. Telephone ground wires and lightning rods: dangerous when struck by lightning due to abnormal rise in electrical potential in the grounding. Be sure to install an earth leakage circuit breaker. This unit uses an inverter, so install the earth leakage circuit breaker that be capable of handling high harmonics in order to prevent malfunctioning of the earth leakage circuit breaker itself. Earth leakage circuit breaker which are especially for protecting ground-faults should be used in conjunction with main switch or fuse for use with wiring. Electrical wiring must be done in accordance with the wiring diagrams and the description herein. Do not operate until refrigerant piping work is completed. (If operated before complete the piping work, the compressor may be broken down.) Never remove thermistor, sensor or etc. when connecting power wiring and transmission wiring. (If operated with thermistor, sensor or etc. removed, the compressor may be broken down.) This product have reversed phase protection detector that only works when the power is turned on. If there exists black out or the power goes on and off which the product is operating, attach a reversed phase protection circuit. Running the product in reversed phase may break the compressor and other parts. Attach the power wire securely. Introducing power with a missing N-phase or with a mistaken N-phase will break the unit. Never connect the power supply in reversed phase. The unit can not operate normally in reversed phase. If you connect in reversed phase, replace two of the three phases. Make sure the electrical unbalance ratio is no greater than 2%. If it is larger than this, the unit s lifespan will be reduced. If the ratio exceeds 4%, the unit will shut down and an malfunction code will be displayed on the indoor remote controller. Connect the wire securely using designated wire and fix it with attached clamp without applying external pressure on the terminal parts (terminal for power wiring, terminal for transmission wiring and earth terminal). 7-1 Wiring Connection Example for Whole System Power supply 400V B B Outdoor unit 16V Power supply 230V 16V 16V Use conduit for power supply wiring. Make sure the weak electric wiring (i.e. for the remote controller, between units, etc.) and the power wiring do not pass near each other, keeping them at least 50 mm apart. Proximity may cause electrical interference, malfunctions, and breakage. Be sure to connect the power wiring to the power wiring terminal block and secure it as described in 7-3 Transmission Wiring Connection Procedure. Transmission wiring should be secured as described in 7-4 Power Wiring Connection Procedure. Secure wiring with clamp such as insulation lock ties to avoid contact with piping. Shape the wires to prevent the structure such as the EL. COMPO. BOX 1 lid deforming. And close the cover firmly. This equipment complies with EN provided that shortcircuit power Ssc is greater than or equal to 1453 at the interface point between the user s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution network operator if necessary, that the equipment is connected only to a supply with a short-circuit power Ssc greater than or equal to Leading wire Procedure The power wiring and ground wiring are passed out from the power wiring hole on the sides, the front (knock hole) or the bottom frame (knock hole). The transmission wiring is passed out from the wiring hole (knock hole) on the front of the unit or from a piping hole. Open the knock holes with a hammer or the like. After knocking out the holes, we recommend you remove any burrs and paint them using the repair paint to prevent rusting. When passing electrical wiring through the knock holes, protect the wiring with a conduit or bushings, making sure not to damage the wiring. B Indoor unit BEV unit Remote controller COOL/HEAT selector Earth leakage circuit breaker (Used for ground fault, overload, short-circuit protection.) Through cover Cut off the shaded zones before use. For power wiring and ground wiring Conduit Pipe opening EL.COMPO. BOX 2 (Left-side) EL.COMPO. BOX 1 (Right-side) Electrical wiring diagram (On the back of the EL.COMPO. BOX 1 (Right-side) lid.) Power wiring, ground wiring (inside conduit) (When the wiring is routed out through the right side.) Wiring routed out through (Front) Transmission wiring 8 English

11 If small animals might enter the unit, block off any gaps (hatching parts) with material (field supply). Knockout hole (For transmission wiring) Knockout hole (For power wiring and ground wiring) As shown below, secure the transmission cable with the accessory clamp (1) at three points in the EL. COMPO. BOX1. In the EL. COMPO. BOX1 (A1P) Burr 7-3 Transmission Wiring Connection Procedure Referring to the following figure connect the transmission wiring. Prohibited Do not open the lid of EL. COMPO. BOX 2 (on the left-hand side), which is not touched during the installation work. Use the accessory clamp (1) and fix the cable to the spacer on the upper righthand side of the PCB (A5P). Use the accessory clamp (1) to fix to the EL. COMPO. BOX1. ABC EL. EL. COMPO. BOX 1 COMPO. A5P A1P BOX 2 IN/D OUT/D A B C F1 F2 F1 F2 Do not connect power supply wirings by any means. Prohibited To outdoor unit of another refrigerant system Outside the units, the transmission wiring must be finished simultaneously with the local refrigerant piping, and wound with tape (field supply). Gas pipe Transmission wiring Connect the line (with polarity-sensitive terminals) so that the terminal signs coincide. COOL/HEAT selector Use two-conductor transmission wirings (with no polarity). F1 F2 F1 F2 Outdoor unit side Indoor unit side F1 F2 Indoor unit F1 F2 F1 F2 Outdoor unit side Indoor unit side BEV unit 1 BEV unit 2 F1 F2 Indoor unit Do not connect the power wiring to terminals for the transmission wiring. Doing so would destroy the entire system. Do not coat stranded wires with solder. When connecting wires to the terminal block on the PC-board, too much heat or tightening could damage the PC-board. Attach with care. See the table below for the tightening torque of the transmission wiring terminals. Screw size Tightening torque (N m) M3 (A5P) M3.5 (A1P) All transmission wiring is to be procured on site. All wiring should use sheathed vinyl cord mm 2 or cable (duplex). (Triplex only for the COOL/HEAT selector.) Liquid pipe Finishing tape Insulation material Transmission wiring should be done within the following limitations. If they are exceeded, transmission problems may occur. Between outdoor unit and indoor unit Between outdoor unit and outdoor unit of other systems Max. wiring length : 1,000 m Max. total wiring length : 2,000 m Max. no. of branches : 16 [] No branch is allowed after branch Max. no. of outdoor units of other system that can be connected : 10 Transmission wiring to COOL/HEAT selector Max. wiring length : 500 m Branch Subbranching F1 F2 F1 F2 F1 F2 F1 F2 F1 F2 7-4 Power Wiring Connection Procedure Be sure to connect the power supply wiring to the power supply terminal block and hold it in place using the accessory clamp (1) as shown in the following figure. The ground wiring should be bound to the power wiring using the accessory clamp (1) to prevent outside force from being applied to the terminal area. English 9

12 Power supply (3N~50Hz 400V) Do not open the lid of EL. COMPO. BOX 2 (on the left-hand side), which is not touched Prohibited during the installation work. Earth leakage circuit breaker (Used for ground fault, overload, shortcircuit protection.) Ground wire EL. COMPO. BOX 2 EL. COMPO. BOX 1 When pulling the ground wire out, wire it so that it comes through the cut out section of the cup washer. (See the figure below.) An improper ground connection may prevent a good ground from being achieved. Crimp-style terminal Cup washer Cut out section When two wires are connected to a single terminal, connect them so that the rear sides of the crimp contacts face each other. Also, make sure the thinner wire is on top, securing the two wires simultaneously to the resin hook using the accessory clamp (1). Attach insulation sleeves L1 L2 L3 N Power supply terminal block Terminal block Crip style terminal Wire: narrow Wire: thick Resin hook Clamp (1) (accessory) Ground terminal Ground wire Clamp (1) (accessory) Power circuit, safety device, and cable requirements A power circuit (see the following table) must be provided for connection of the unit. This circuit must be protected with the required safety devices, i.e. a main switch, a slow blow fuse on each phase and an earth leakage circuit breaker. When using residual current operated circuit breakers, be sure to use a high-speed type (1 second or less) 200mA rated residual operating current. Use copper conductors only. Use insulated wire for the power cord. Select the power supply cable type and size in accordance with relevant local and national regulations. Specifications for local wiring are in compliance with IEC Use wire type H05VV when protected pipes are used. Use wire type H07RN-F when protected pipes are not used. Phase and frequency Voltage MCA MFA φ 3, 50Hz V 24.1A 30A 7-5 Procedure for Wiring Inside Units Referring to the following figure, secure and wire the power and transmission wiring using the accessory clamp (1), (2), and (3). Lay the ground wire so that it will not come in contact with the lead wires of the compressor. Other equipment will be adversely affected if the ground wire comes in contact with the lead wires of the compressor. Make sure all wiring do not contact to the pipes (hatching parts in the figure). The transmission wiring must be at least 50 mm away from the power wiring. After wiring work is completed, check to make sure there are no loose connections among the electrical parts in the EL.COMPO.BOX 1. When routing out the power/ ground wires from the left side. Conduit Stay Transmission wiring When routing out the power/ ground wires from the right side. Do not coat stranded wires with solder. Be sure to use crimp-style terminal with insulating sleeves for connections. (See the figure below.) Crimp-style terminal Insulating sleeve Power wire For wiring, use the designated power wire and connect firmly, then secure to prevent outside pressure being exerted on the terminal board. Use an appropriate screwdriver for tightening the terminal screws. A screwdriver with a small head will strip the head and make proper tightening impossible. Over-tightening the terminal screws may break them. See the following table for the tightening torque of the terminal screws. When routing out the transmission wiring from the opening for piping. When routing out the power/ ground wires from the front. When routing out the transmission wiring from the knockout hole. Clear over 50 mm. Retain to the back of the column support with the accessory clamp (2). After wiring work is completed, check to make sure there are no loose connections among the electrical parts in the EL.COMPO.BOX English

13 8. INSPECTION AND PIPE INSULATION To Piping and Electric Wiring Contractors Be sure to use nitrogen gas for airtight tests. Do not open a until the insulation of the main power supply circuit is measured. Insulation degradation may result if the insulation is measured with the opened. 8-1 Testing Instruments <State before shipping> Inside equipment Shaft Service port (1/4Swagelok) Packing bush Valve cover packing Cap Name Charge hose Gauge manifold Reguretar (Pressure regulator) Vacuum pump Compatibility with conventional tool (for other types of refrigerant) Use a pressure-resistant product withstanding a minimum pressure of 12.3 MPa. Use an end connector suited to the shape of the service ports of the outdoor unit. Shape of service ports of outdoor unit (on liquid and gas sides): 1/4Swagelok Use a pressure-resistant pressure gauge and valve withstanding a minimum pressure of 12.3 MPa. At the time of vacuum drying, connect a negative pressure gauge to the outlet of the vacuum pump and check the degree of vacuum. Use a pressure-resistant product withstanding a minimum pressure of 12.3 MPa. Pay the utmost attention that pump oil will not flow back to the system while the pump is not in operation. Use a product that makes evacuation possible down to kpa (5 Torr, 755 mmhg). 8-2 Operation method of Take the following procedure to operate the. Do not open the until all the items specified in 8-6 Checking of device and installation conditions in the installation manual are completed. The is of back seat type. Be sure to turn and loosen the packing bush 1/4 rotation when opening or closing the valve. Be sure to tighten the packing bush securely after the valve is opened or closed. After the operation of the valve is completed, be sure to mount the valve cover packing provided to the valve and tighten the cap. After tightening the packing bush and cap, be sure to check that there is no refrigerant gas leakage. Be sure to use a dedicated tool at the time of handling the shutoff valve. The valve may be damaged if excessive force is imposed. If the is left opened without power supplied, refrigerant will be condensed in the compressor and the insulation of the main power circuit will be degraded. Front seat Back seat Outside equipment (onsite piping side) Method of opening (1) Remove the cap and turn the packing bush counterclockwise 1/4 rotation. (2) Tighten the shaft until the shaft comes in contact with the front seat. (3) Turn and loosen the packing bush clockwise 1/4 rotation. (4) Check that there is no refrigerant gas leakage from the valve packing or shaft. (If there is leakage, further tighten the shaft.) (5) Insert the valve cover packing into the cap, and tighten the cap securely. Method of closing (1) Remove the cap and turn the packing bush counterclockwise 1/4 rotation. (2) Tighten the shaft until the shaft comes in contact with the back seat. (3) Turn and loosen the packing bush clockwise 1/4 rotation. (4) Check that there is no refrigerant gas leakage from the valve packing or shaft. (If there is leakage, further tighten the shaft.) (5) Insert the valve cover packing into the cap, and tighten the cap securely. 8-3 Operation method of service port Conduct an airtight test and vacuum drying infallibly through the service port for both liquid and gas s. Refer to the integrated label on the front panel of the outdoor unit for the position of the service port. Label Connecting charge hose (1) Remove the nut of the service port after loosening the nut a little with a spanner and checking that no gas is coming out. (2) Apply PAG oil to the seal, and hold and screw in the nut of the charge hose by hand. (3) Further tighten the nut with a spanner by 30 to 45. (4) Check that there is no refrigerant gas leakage from the nut and plug. If there is any refrigerant gas leakage, further tighten them. <Opening or closing state before shipping> Tightening torque Check the sizes of s mounted to each model and the tightening torque of each valve from the following table. Shutoff valve position Gas side Tightening torque N m (Turn clockwise to close) Shaft (valve body) Shutoff valve open Shutoff valve closes Cap (valve lid) Service port Inside equipment Seal Charge hose Nut of service port Outside equipment (onsite piping side) English 11

14 Removing charge hose after refrigerant replenishment (1) Close both liquid and gas s, loosen the nut of the charge hose a little with a spanner, and check that no gas comes out. (2) Remove the charge hose. (3) Apply PAG oil to the seal, and hold and screw in the nut by hand. (4) Further tighten the nut with a spanner by 30 to 45. (5) Check that there is no refrigerant gas leakage from the nut and plug. If there is any refrigerant gas leakage, further tighten them. <Opening or closing state on completion of refrigerant replenishment> Plug Inside equipment Seal Nut of service port Service port WARNING Fully open the stop valve and disconnect the charge hose from the service port on completion of refrigerant replenishment. High-pressure refrigerant will be discharged because there is no valve core, which will result in a very dangerous state. 8-4 Air tight test and vacuum drying method After finished piping work, carry out air tight test and vacuum drying. Inspection system Refer to the following connection diagram and connect the nitrogen bottle, refrigerant bottle, and vacuum pump to the outdoor unit. Gauge manifold Gas side Outdoor unit Meter Outside equipment (onsite piping side) Charge hose Shutoff valve service port Valve A Take the following procedure if the air conditioner is installed in the rainy season, if dew condensation in the pipe is feared because the period of installation work is long, or if the penetration of moisture including rainwater is feared during the period of installation work. (1) After performing the vacuum drying for two hours, pressurize to 0.05 MPa (i.e., vacuum breakdown) with nitrogen gas, then evacuate the system to kpa for an hour using the vacuum pump (vacuum drying). (2) If the pressure does not reach kpa or below after evacuating for 2 hours or more, repeat a vacuum breakdown and vacuum drying. 8-5 Pipe insulation Insulation of pipes should be done after performing AIR TIGHT TEST AND VACUUM DRYING. Always insulate the liquid side piping and gas side piping in the interunit piping and refrigerant branching kit. Failing to insulate the pipes could cause leaking or burns. (The gas side piping can reach temperatures of 120 C. Be sure the insulation used can withstand such temperatures.) Reinforce the insulation on the refrigerant piping according to the installation environment. Condensation might form on the surface of the insulation. Ambient temperature: 30 C, humidity: 75% to 80% RH: min. thickness: 15 mm. If the ambient temperature exceeds 30 C and the humidity 80% RH, then the min. thickness is 20 mm. If there is a possibility that condensation on the might drip down into the indoor unit through gaps in the insulation and piping because the outdoor unit is located higher than the indoor unit, etc., this must be prevented by caulking the connections, etc. Indoor interunit piping Gas side Coking, etc. Insulation material The piping lead-out hole lid should be attached after opening a knock hole. If small animals and the like might enter the unit through the piping lead-out hole, close the hole with blocking material (procured on site) after completion of 9. PROCEDURE OF ADDING REFRIGERANT CHARGING AND CHECK OPERATION. The piping outlet port is used to draw in the charge hose at the time of work specified in 9. PROCEDURE OF ADDING REFRIG- ERANT CHARGING AND CHECK OPERATION. Nitrogen Vacuum pump R744 tank (with siphon) Valve B :Field pipings Piping lead-out hole lid Block piping Method of airtight test Keep applying a maximum pressure of 12.3 MPa from both liquid and gas pipes (and make sure that the pressure will not exceed 12.3 MPa). The air conditioner will pass the test if there is no pressure fall for 24 hours. If there is a pressure fall, make a leakage check, remedy the problem, and conduct an airtight test again. Method of vacuum drying Evacuate the system from the liquid and gas pipes by using a vacuum pump for more than 2 hours and bring the system to kpa or less. After keeping the system under that condition for more than 1 hour, check that the vacuum gauge does not rise. If it rises, the system may either contain moisture inside or have leaks. Open a knock hole at Gas side piping After knocking out the holes, we recommend you remove burrs in the knock holes and paint the edges and areas around the edges using the repair paint. 12 English

15 8-6 Checking of device and installation conditions Be sure to check the followings. For those doing electrical work 1. Make sure there is no faulty transmission wiring or loosing of a nut. See 7-3 Transmission Wiring Connection Procedure. 2. Make sure there is no faulty power wiring or loosing of a nut. See 7-4 Power Wiring Connection Procedure. 3. Has the insulation of the main power circuit deteriorated? Measure the insulation and check the insulation is above regular value in accordance with relevant local and national regulations. For those doing pipe work 1. Make sure piping size is correct. See 6-1 Selection of piping material and Refrigerant branching kit. 2. Make sure insulation work is done. See 8-5 Pipe insulation. 3. Make sure there is no faulty refrigerant piping. See 6. REFRIGERANT PIPING. 9. PROCEDURE OF ADDING REFRIGER- ANT CHARGING AND CHECK OPER- ATION To Refrigerant Filling and Trial Operation Engineers Use dedicated R744 refrigerant for replenishment. Otherwise the air conditioner may not operate normally due to the difference in moisture control level. Warning Electric Shock Warning Make sure to close the EL. COMPO. BOX 1 lid before turning on the power when performing the refrigerant charging operation. Perform the setting on the PC-board (A1P) of the outdoor unit and check the LED display after the power is on via the inspection door which is in the EL. COMPO. BOX 1 lid. Use an insulated rod to operate the push buttons via the inspection door of EL. COMPO. BOX 1. There is a risk of electric shock if you touch any live parts, since this operation must be performed with the power on. EL. COMPO. BOX 1 Inspection door EL. COMPO. BOX 1 lid LED (H1-8P) Lift the protruding part to open the lid Service lid Push button Dip switch (DS1-1 ~ 4) Inspection port (upper right-hand side of EL. COMPO. BOX 1) WARNING Make sure to use the protect tool (protective groves and goggles) when charging the refrigerant. Do not perform the filling operation or check operation of the air conditioner while working on the indoor unit. While in filling operation or check operation, the indoor unit will operate as well. This will put you in danger. When opening the front panel, make sure to take caution to the fan rotation during the working. After the outdoor unit stops operating, the fan may keep rotation for a while. If operation is performed within 12 minutes after the indoor and outdoor units are turned on, H2P will be lit on and the compressor will not operate. In order to ensure uniform refrigerant distribution, it may take up to around 10 minutes for the compressor to start up after the unit starting operating. This is not a malfunction. Refer to 8-3 Operation method of service port for the handling of the charge hose. Refer to 8-2 Operation method of for the handling of the stop valve. When done or when pausing the refrigerant charging operation, close the valve of the refrigerant tank immediately. If the tank is left with the valve open, the amount of refrigerant which is properly charged may be off the point. More refrigerant may be charged by any remaining pressure after the machine is stopped. Make sure to perform the check operation after installation. Otherwise, the malfunction code U3 will be displayed and normal operation cannot be performed. And the failure of Check of miswiring may also cause abnormal operation. Performance may drop due to the failure of Judgment of piping length. Check operation must be performed for each refrigerant piping system. Checking is impossible if plural systems are being done at once. The individual problems of indoor units can not be checked. About these problems check by test run after the check operation is completed. (See 10. TEST RUN) The check operation cannot be performed in recovery or other service modes. While the outdoor temperature is below 20 C, the compressor may not start if the air conditioner is operated within 1 hour after the outdoor unit is turned on. 9-1 Procedure of adding refrigerant charging 1. Make sure the following works are complete in accordance with the installation manual. Piping work Wiring work Air tight test/vacuum drying Installation work for indoor unit 2. Calculate the additional charging amount using How to calculate the additional refrigerant to be charged in 6-1 Selection of piping material and Refrigerant branching kit. 3. Open the valve B, and charge the refrigerant of the additional charging amount from the liquid side shutout valve service port. 4. If part of refrigerant replenishment is left, perform the operation of charging the remaining refrigerant using the service port so that all the replenishment will be completed. 5. Record the charging amount on the accessory REQUEST FOR THE INDICATION label and attach it to the back side of the front panel. Gauge manifold Meter Charge hose Nitrogen Vacuum pump R744 tank (with siphon) Gas side Shutoff valve service port Valve A Valve B Outdoor unit :Field pipings English 13