FLOW TEMP. CTROLLER 2B (Cased) PAC-IF032B-E INSTALLATI MANUAL FOR INSTALLER For safe and correct use, read this manual thoroughly before installing the unit. English OPERATI MANUAL FOR USER For safe and correct use, please read this operation manual thoroughly before operating the air-conditioner unit.
Contents 1. Safety precautions...2 2. Installing the unit...3 3. System...4 4. Electrical work...9 5. Dip switch setting...17 6. Before test run...22 7. Remote controller operation...23 8. Troubleshooting...30 9. Supplementary information...32 Local application factors...33 is the abbreviation of Flow Temperature Controller 2B, which is described as in this manual. Mitsubishi Electric is not responsible for the failure of locally supplied parts. 1. Safety precautions 2 Before installing the unit, make sure you read all the Safety precautions. Please report to your supply authority or obtain their consent before connecting this equipment to the power supply system. Warning: Precautions that must be observed to prevent injuries or death. Caution: Precautions that must be observed to prevent damages to the unit. Warning: The unit must not be installed by the user. Ask an installer or an authorized technician to install the unit. If the unit is installed improperly, electric shock, or fire may be caused. For installation work, follow the instructions in the Installation Manual and use tools and pipe components specifically made for use with refrigerant specified in the outdoor unit installation manual. The unit must be installed according to the instructions in order to minimize the risk of damages by earthquakes, typhoons, or strong winds. Improperly installed unit may fall down and cause damages or injuries. The unit must be securely installed on a structure that can sustain its weight. If the unit is mounted on an unstable structure, it may fall down and cause damages or injuries. All electric work must be performed by a qualified technician according to local regulations and the instructions given in this manual. The unit must be powered by dedicated power lines and the correct voltage and circuit breakers must be used. Power lines with insufficient capacity or incorrect electrical work may result in electric shock or fire. 1.1. Before installation (Environment) Caution: Do not install the unit in outdoor location as it is designed for indoor installation only. Otherwise electric shock or breakdown may be caused by water drop, wind or dust. Do not use the unit in an unusual environment. If the unit is installed or exposed to steam, volatile oil (including machine oil), or sulfuric gas, or exposed to briny air, the internal parts can be damaged. Do not install the unit where combustible gases may leak, be produced, flow, or accumulate. If combustible gas accumulates around the unit, it may cause fire or explosion. 1.2. Before installation or relocation Caution: Be fully careful when moving the units. Do not hold the packaging bands. Wear protective gloves to unpack and to move it, in order to avoid your hands be injured by parts. 1.3. Before electric work Caution: Be sure to install a circuit breaker. If it is not installed, there may be a risk to get an electric shock. For the power lines, use standard cables of sufficient capacity. Otherwise, it may cause a short circuit, overheating, or fire. When installing the power lines, do not apply tension to the cables. The cables may be cut or overheated resulting in a fire. 1.4. Before starting the test run Caution: Turn on the main power switch of the outdoor unit more than 12 hours before starting operation. Starting operation immediately after turning on the power switch can severely damage the internal parts. Keep the main power switch turned on during the operation period. Before starting operation, check that all protective parts are correctly installed. Make sure not to get injured by touching high voltage parts. 1.5. Electric booster and Immersion heaters Warning: has signal outputs for booster heaters however it can not isolate power to them in the event of overheating. All electrical heaters used on the water circuit must have After installation, perform the test run to ensure normal operation. Then explain your customer the Safety Precautions, use, and maintenance of the unit based on the information in the Operation Manual provided by local application manufacture. Both the Installation Manual and the Operation Manual must be given to the user. These manuals must always be kept by the actual users. : Indicates a part which must be grounded. Warning: Carefully read the labels attached to the unit. Only the specified cables can be used for wiring. Connections must be made securely without tension on the terminals. If cables are connected or installed improperly, It may result in overheating or fire. Terminal block cover panel of the unit must be firmly fixed. If the cover panel is mounted improperly, dust and moisture may enter the unit, and it may cause electric shock or fire. Make sure to use accessories authorized by Mitsubishi Electric and ask an installer or an authorized technician to install them. If accessories are improperly installed, it may cause electric shock, or fire. Do not remodel the unit. Consult an installer for repairs. If alterations or repairs are not performed correctly, it may cause electric shock or fire. The user should never attempt to repair the unit or transfer it to another location. If the unit is installed improperly, it may cause electric shock or fire. If the unit needs to be repaired or moved, ask an installer or an authorized technician. During installing a heat pump system, keep water from splashing on the unit. When installing sensors and parts, do not expose the terminals. When installing the unit in a hospital or in a building where communications equipment are installed, you may need to take measure to noise and electronic interference. Inverters, home appliances, high-frequency medical equipment, and radio communications equipment can cause the unit to malfunction or to breakdown. At the same time, the noise and electric interference from the unit may disturb the proper operation of medical equipment, and communications equipment. Be sure to safely dispose of the packaging materials. Packaging materials, such as nails and other metal or wooden parts may cause injuries. Do not wash the unit. You may receive an electric shock. Make sure to ground the unit. Do not connect the ground wire to gas or water pipes, lightning rods, or telephone grounding lines. If the unit is not properly grounded, there may be a risk to get an electric shock. Make sure to use circuit breakers (ground fault interrupter, isolating switch (+B fuse), and molded case circuit breaker) with the specified capacity. If the circuit breaker capacity is larger than the specified capacity, breakdown or fire may result. Do not touch any switch with wet hands. There may be a risk to get an electric shock. After stopping operation, make sure to wait at least 5 minutes before turning off the main power. Otherwise, it may cause breakdown. a) A thermostat to prevent overheating b) A non-self resetting thermal mechanism to prevent overheating
2. Installing the unit 1 2 4 5 6 2.1. Check the parts (Fig. 2.1.1) The unit should be supplied with the following parts. Part Name W/D symbol Q'ty 1 unit 1 2 Liquid refrigerant temp. thermistor (Lead wire: 5m/Red, Connector: 3p/Yellow) TH2 1 3 Flow water temp. and Return water temp. thermistor (Lead wire: 5m/Gray(Flow water temp.), /2 1 5m/Black(Return water temp.), Connector: 4p/Red) 4 Tank water temp. thermistor (Lead wire: 5m/Gray, Connector: 2p/White) 1 5 Remote controller cable (5m) 1 6 Remote controller 1 B <Fig. 2.1.1> A <Fig. 2.3.1> Top 2.2. Choosing the unit installation location Do not install the unit in outdoor location as it is designed for indoor installation only. (The circuit board and casing are not waterproof.) Avoid locations where the unit is exposed to direct sunlight or other sources of heat. Select a location where easy wiring access to the power source is available. Avoid locations where combustible gases may leak, be produced, flow, or accumulate. Select a level location that can bear the weight and vibration of the unit. Avoid locations where the unit is exposed to oil, steam, or sulfuric gas. Do not install in location that is hot or humid for long periods of time. 2.3. Installing the unit (Fig. 2.3.1, 2.3.2, 2.3.3, 2.3.4) 1. Remove 2 screws (A Screw) from unit and remove the cover. (See Fig. 2.3.1) 2. Install the 4 screws (locally supplied) in the 4 holes (C Hole). * To prevent the unit from falling off the wall, select the appropriate screws (locally supplied) and secure the base horizontally to the appropriate wall location. (See Fig. 2.3.2) A Screw B Cover C Hole for installation Weight 2.4 kg + ACCESSORIES 0.8 kg Allowable ambient temperature 0 to 35 C Allowable ambient humidity 80% RH or less 30 mm or more Unit:mm Cover C 11.5 336 313 [12 [5 (11.5) C 22 69 200 278 10 Base Wall TB143 TB142 TB141 TB6 <Fig. 2.3.2> Service space C 3-ELECTRIC WIRE INLET When installed on a wall: Lower side <Fig. 2.3.3> C Remove the 2 screws A (control box cover screws). Base Cover Slide the control box cover until the bottom of the cover comes into contact with the bottom of the control box. Pull the cover to the front and remove it. Front Bottom Top Bottom Top Bottom Top 1 2 3 <Fig. 2.3.4> 3
3. System The is designed for use with a number of heat pump systems. Please refer to the following table to find the relevant installation information for your system. 3.1. First step (Electrical work) Mode select Temp. setting System diagram Power supplies Operation mode input Remote controller Remote controller Outdoor unit only Remote controller only Outdoor unit 4.1 4.2 Remote controller Local controller (External input: Contact signal) Remote controller Outdoor unit Outdoor unit only 4.1 Remote controller and external input 4.2 4.4 4.4.1 Local controller (/,MODE) Remote controller Local controller (External input: Contact signal) Local controller (External input: Analog signal) Outdoor unit Outdoor unit only 4.1 External input and analog input 4.4 4.4.1 4.4.2 Local controller (/,MODE,Temp.) 4
3. System 3.2. Second step (Thermistor setting) Outdoor unit type (Split type / Packaged type) Domestic hot water tank (DHW tank) Outdoor unit type DHW tank System diagram Thermistor Split type (Present) Outdoor unit DHW tank TH2: Liquid refrigerant temp. : Flow water temp. : Return water temp. : Tank water temp. 4.3 TH2 Heat emitter Heat exchanger (Absent) Outdoor unit TH2: Liquid refrigerant temp. : Flow water temp. : Return water temp. 4.3 Heat emitter TH2 Heat exchanger Packaged type (Present) DHW tank : Flow water temp. : Return water temp. : Tank water temp. Outdoor unit 4.3 Heat emitter Heat exchanger (Absent) : Flow water temp. : Return water temp. Outdoor unit 4.3 Heat emitter Heat exchanger 5
3. System 3.3. Third step (Heater setting) Immersion heater Booster heater position Immersion heater Booster heater position System diagram Output signal (Absent) both DHW DHW tank Booster heater only and Heating 4.4 4.4.3 4.5 Booster heater * Heat emitter (Present) both DHW and Heating DHW tank Immersion heater Booster heater and Immersion heater 4.4 4.4.3 4.5 Booster heater * Heat emitter (Absent) Heating only DHW tank Booster heater only 4.4 4.4.3 4.5 Booster heater Heat emitter * (Present) Heating only DHW tank Immersion heater Booster heater and Immersion heater 4.4 4.4.3 4.5 Booster heater Heat emitter * Note(*): When the booster heater is positioned for heating only, flow water temp. thermistor () is not able to detect the outlet water temperature of circulation water during DHW or legionella prevention mode. To determine more accurately if the heater is with DHW or legionella prevention mode, must be placed where it is able to detect the outlet water temperature of circulation water. Therefore the recommended booster heater position is for both DHW and heating. Although the booster heater is positioned for both DHW and heating, switching Dip SW 2-9 deactivates the booster heater during DHW or legionella prevention mode. 6
3. System 3.4. Fourth step (Water circuit parts installation) * Make sure to check the followings for your safety when designing a system. These are the minimum requirement for the safe use of unit. Parts name Requirement Booster heater General * Consider necessity and capacity of booster heater to meet the following points. (1) Heating capacity and flow water temperature should always be sufficient. (2) System can increase the temperature of the stored water in tank to inhibit legionella bacterium growth. Control Power for Contactor Separate power for Heater Current: 0.5A Max., 10mA Min., Power supply: 230V AC * Use a relay. Connect the surge absorber according to the load at site. Install an earth leakage circuit breaker for heater, separate from control power. * When using two booster heaters, booster heater 1 capacity must be less than that of booster heater 2. When using a single booster heater, use booster heater 1. Heater capacity/breaker/wiring (recommended) <1 Phase> <3 Phase> Description Power supply Total capacity (BH1 + BH2) Breaker Wiring Booster heater ~/N 230V 2 kw (2 kw + 0 kw) 16 A 2.5 mm² (Primary circuit) 50Hz 6 kw (2 kw + 4 kw) 32 A 6.0 mm² * When installing a booster heater with the capacity of bigger than shown above, select an appropriate size breaker and cable (diameter) based on the maximum possible electric current. Safety device (1) Use an overheat protection thermostat (manual reset type) (to detect unusual temperature increase/heating up without water). Protection device operating temperature must be above 80 C. Protection device should not operate quickly, but water circuit must not boil even when heater(s) overshoot. (Reference value) Thermostat operation temperature used in our Cylinder unit and Hydrobox : 90 C ± 4 C (2) Connect a pressure relief valve on the primary circuit side. Immersion heater General * Consider necessity and capacity of immersion heater to meet the following points. (1) Heating capacity and flow water temperature should always be sufficient. (2) System can increase the temperature of the stored water in tank to inhibit legionella bacterium growth. Water circulation pump Control Power for Contactor Separate power for heater Safety device Current: 0.5A Max., 10mA Min., Power supply: 230V AC * Use a relay. Connect the surge absorber according to the load at site. Description Power supply Booster heater 3~ 400V (Primary circuit) 50Hz Total capacity (BH1 + BH2) Install an earth leakage circuit breaker for heater, separate from control power. Heater capacity/breaker/wiring (recommended) Description Power supply Capacity Breaker Wiring Immersion heater (DHW tank) ~/N 230V 50Hz 3 kw 16 A 2.5 mm² * When installing an immersion heater with the capacity of bigger than shown above, select an appropriate size breaker and cable (diameter) based on the maximum possible electric current. (1) Install the enclosed thermistor on the DHW tank. (Microcomputer detecting temperature for protection: 80 C) (2) Use a built-in direct cut-off thermostat (manual reset type). Protection device operating temperature must be above 80 C. Protection device should not operate quickly, but water circuit must not boil even when a heater overshoots. (Reference value) Thermostat operation temperature used in our Cylinder unit : 85 C ± 5 C (3) Connect a pressure relief valve on the sanitary water side. Connect a pump via relay. Current: 0.5A Max., 10mA Min. Power supply: 230V AC Connect the surge absorber according to the load at site. Adjust the pump speed so that the flow rate in the primary circuit is appropriate for the outdoor unit installed see the table and figures below. Outdoor heat pump unit Water flow rate range [L/min] Packaged PUHZ-W50 6.5-14.3 PUHZ-W85 10.8-25.8 PUHZ-W112 14.4-32.1 PUHZ-HW112 14.4-32.1 PUHZ-HW140 17.9-40.1 Split PUHZ-RP35 5.0-11.8 PUHZ-RP50 7.0-17.2 PUHZ-RP60 8.6-20.1 PUHZ-(H)RP71 10.2-22.9 PUHZ-(H)RP100 14.4-32.1 PUHZ-(H)RP125 17.9-40.1 PUHZ-RP140 20.1-45.9 PUHZ-RP200 27.3-64.2 PUHZ-HRP200 28.7-68.9 PUHZ-RP250 32.1-80.3 PUHZ-SW40 7.1-11.8 PUHZ-SW50 7.1-17.2 PUHZ-SW75 9.5-22.9 PUHZ-SW100 13.0-32.1 PUHZ-SW120 17.9-45.9 PUHZ-SW160 23.0-63.1 PUHZ-SW200 28.7-71.7 PUHZ-SHW80 10.2-22.9 PUHZ-SHW112 14.4-32.1 PUHZ-SHW140 17.9-40.1 PUHZ-SHW230 28.7-65.9 * The water velocity in pipes should be kept within certain limits of material to avoid erosion corrosion and excessive noise generation. (e.g. Copper pipe: 1.5m/s) Breaker Wiring 9 kw (3 kw + 6 kw) 16 A 2.5 mm² 7
3. System From the previous page. Parts name Water circulation pump (1) Packaged-type units Heating PUHZ-W50 Requirement PUHZ-W85 Return water temp. [:] 19.0 17.0 15.0 13.0 11.0 9.0 7.0 Available range Return water temp. [:] 19.0 17.0 15.0 13.0 11.0 9.0 7.0 Available range 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0 14.0 Water flow rate [L/min] 5.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 Water flow rate [L/min] (2) Split-type units Heating PUHZ-RP60/71 *2 PUHZ-HRP71 *3 PUHZ-RP35/50 *1 PUHZ-SW40/50 PUHZ-SW75 *2 PUHZ-SHW80 *2 Return water temp. [:] PUHZ-W112 Return water temp. [:] PUHZ-HW112/140 25.0 23.0 21.0 Available range 19.0 17.0 15.0 13.0 11.0 9.0 7.0 5.0 14.0 19.0 24.0 29.0 34.0 39.0 Water flow rate [L/min] 19.0 17.0 Available range 15.0 13.0 11.0 9.0 7.0 5.0 5.0 7.0 9.0 11.0 13.0 15.0 17.0 19.0 Water flow rate [L/min] Return water temp. [:] 19.0 17.0 15.0 13.0 11.0 9.0 7.0 5.0 8.0 10.0 12.0 Available range 14.0 16.0 18.0 20.0 22.0 24.0 Water flow rate [L/min] PUHZ-RP100/125/140 *3 PUHZ-HRP100/125 *3 PUHZ-RP200/250 *4 PUHZ-HRP200 *4 PUHZ-SW100/120 *3 PUHZ-SHW112/140 *3 PUHZ-SHW230 *4 Return water temp. [:] 19.0 19.0 17.0 Available range 17.0 Available range 15.0 15.0 13.0 13.0 11.0 11.0 9.0 9.0 7.0 7.0 5.0 5.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 40.0 44.0 48.0 25.0 35.0 45.0 55.0 65.0 75.0 85.0 Water flow rate [L/min] Water flow rate [L/min] Return water temp. [:] PUHZ-SW160 *4 PUHZ-SW200 *4 Return water temp. [ C] 19.0 17.0 15.0 13.0 11.0 9.0 7.0 5.0 25.0 35.0 45.0 55.0 65.0 75.0 85.0 Water flow rate [L/min] Available range *1 When the connected plate heat exchanger is ACH 30-30 made by ALFA LAVAL. *2 When the connected plate heat exchanger is ACH 70-30 made by ALFA LAVAL. *3 When the connected plate heat exchanger is ACH 70-40 made by ALFA LAVAL. *4 When two ACH 70-40 plate heat exchangers made by ALFA LAVAL are parallel-connected. 8
3. System Parts name 3-way valve Flow switch Connect a 3-way valve via relay. Current: 0.5A Max., 10mA Min. Power supply: 230V AC Connect the surge absorber according to the load at site. It is required to protect system from the effects of insufficient flow. Requirement Strainer /Magnetic filter (water circuit) Pressure relief valve (Primary circuit side) (Sanitary water side) Expansion Vessel (Primary circuit side) Expansion Vessel (Sanitary water side) Limits of TOTAL electric current when connecting field supply parts Provide it as required to protect parts from damages caused by iron particles/water/contamination (e.g. the position before pump and return part from emitters). It is required to protect system from reaching high pressure. Select the operating pressure depending on water pressure in the circuit in normal use. * Follow the national regulations. When the water circuit is closed, select the expansion vessel according to water quantity of the water circuit. * Follow the national regulations. (Power supply from outdoor unit) TOTAL current requirement MUST be 3A (otherwise, the fuse on the outdoor unit PCB will blow). 4. Electrical work 4.1. Electrical connection All electrical work should be carried out by a suitably qualified technician. Failure to comply with this could lead to electrocution, fire, and death. It will also invalidate product warranty. All wiring should be according to national wiring regulations. Connections should be made to the terminals indicated in the following figures depending on the phase. When the wires are wired to adjacent terminals use ring terminals and insulate the wires. INPUT Remote controller Thermistor OUTPUT <Fig. 4.1.1> Wiring for Power cables Notes: 1. Do not run the low voltage cables through a slot that the high voltage cables go through. 2. Do not bundle power cables together with other cables. 3. Bundle cables as Fig. 4.1.1 by using clamps. <1 phase> Power supply ~/N 230V 50Hz Earth leakage circuit breaker Wiring circuit breaker or Isolating switch Outdoor unit L S1 N S2 S3 L N S1 S2 S3 TB6 To control board powered via outdoor unit *1 If the installed earth leakage circuit breaker does not have an over-current protection function, install a breaker with that function along the same power line. *2 Affix label A that is included with the manuals near each wiring diagram for and outdoor units. Note: In accordance with IEE regulations the circuit breaker/isolating switch located on the outdoor unit should be installed with lockable devices (health and safety). <3 phase> Outdoor unit L Power supply 3N~ 400V 50Hz Earth leakage circuit breaker Wiring circuit breaker or Isolating switch L1 L2 L3 N S1 S2 S3 N S1 S2 S3 To control board Wiring Wiring No. size (mm²) Circuit rating <Fig. 4.1.2> Electrical connections 1 phase/3 phase TB6 - Outdoor unit *2 3 1.5 (polar) - Outdoor unit earth *2 1 Min. 1.5 - Outdoor unit S1 - S2 *3 230V AC - Outdoor unit S2 - S3 *3 24V DC *1. A breaker with at least 3.0 mm contact separation in each pole shall be provided. Use earth leakage breaker (NV). The breaker shall be provided to ensure disconnection of all active phase conductors of the supply. *2. Max. 45 m If 2.5 mm² used, Max. 50 m If 2.5 mm² used and S3 separated, Max. 80 m *3. The values given in the table above are not always measured against the ground value. Notes: 1. Wiring size must comply with the applicable local and national codes. 2. /outdoor unit connecting cords shall not be lighter than polychloroprene sheathed flexible cord. (Design 60245 IEC 57) 3. Install an earth longer than other cables. 9
120 30 4. Electrical work TB.143 RC 4.2. Connecting the remote controller 4.2.1. Connect the remote controller cable to Connect the remote controller cable to 13 and 14 on the terminal block (TB143) on the controller. <Fig. 4.2.1> Wiring wire No. size (mm²): 2 0.3 (non polar) The 5 m wire is attached as an accessory. Max. 500 m Wiring size must comply with the applicable local and national codes. Circuit rating: 12V DC Circuit rating is NOT always against the ground. <Fig. 4.2.1> Notes: Wiring for remote controller cable shall be (5 cm or more) apart from power source wiring so that it is not influenced by electric noise from power source wiring. (Do not insert remote controller cable and power source wiring in the same conduit.) (Refer to Fig. 4.1.1) When wiring to TB143, use the ring type terminals and insulate them from the cables of adjoining terminals. Remote controller profile Installation pitch 30 83.5 46 30 Required clearances surrounding the remote controller 4.2.2. Installing the remote controller 1. The remote controller can be installed either in the switch box or directly on the wall. Perform the installation properly according to the method. (1) Secure clearances shown in <Fig. 4.2.2> regardless of whether installing the remote controller either directly on the wall or in the switch box. (2) Prepare the following items in the field. Double switch box Thin metal conduit Locknut and bushing Cable cover Wall plug <Fig. 4.2.2> 2. Drill an installation hole in the wall. Installation using a switch box Drill a hole in the wall for the switch box, and install the switch box in the hole. Fit the conduit tube into the switch box. Bushing Wall Conduit tube Locknut Switch box Direct wall installation Drill a cable access hole and thread the remote controller cable through it. Caution: To prevent entry of dew, water, and insects, seal the gap between the cable and the hole through which the cable is threaded with putty. Otherwise, electric shock, fire, or failure may result. Seal the gap with putty. Remote controller cable <Fig. 4.2.3> 3. Have the remote controller ready. Remove the back cover from the remote controller. 4. Connect the remote controller cable to the terminal block on the back cover. Modify the remote controller cable as shown in <Fig. 4.2.5>, and thread the cable from behind the back cover. Completely thread the cable to the front so that the unsheathed part of the cable cannot be seen behind the back cover. Connect the remote controller cable to the terminal block on the back cover. Cosmetic cover and front cover <Fig. 4.2.4> Back cover Direct wall installation Seal the gap between the cable and the hole through which the cable is threaded. Caution To prevent electric shock or failure, keep the sheath ends or any other foreign objects out of the terminal block. Do not use ring terminals to connect the wires to the terminal block on the back cover. The terminals will come in contact with the control board and the cosmetic cover, which will result in failure. Completely thread the unsheathed portion to the front. Sheath The 2 inner wires must not be seen on the back. Remote controller cable Seal the gap with putty. 10mm Front Back 6mm Thread the cable. Connect the 2 inner wires to the terminal block (non polarized). Thread the cable from behind the remote controller. 10 <Fig. 4.2.5>
4. Electrical work Roundhead cross slot screws Double switch box Completely seal the gap around the cable access hole. See Step 2. Remote controller cable See Step 5. 5. Install the back cover. Installation using a switch box When installing the back cover in the switch box, secure at least two corners of the switch box with screws. Wood screw Remote controller cable See Step 5. Thread the cable through the slot. Direct wall installation Thread the cable through the slot provided. When mounting the back cover on the wall, secure at least two corners of the remote controller with screws. To prevent the back cover from lifting, use top-left bottom-right corners of the remote controller (viewed from the front) to secure the back cover to the wall with wall plugs or the like. Caution: To avoid causing deformation or cracks to the remote controller, do not overtighten the screws and make an additional installation hole(s). <Fig. 4.2.6> <Fig. 4.2.7> 6. Cut out the cable access hole. Direct wall installation Cut out the knockout hole (indicated with grey in <Fig. 4.2.7>) in the cosmetic cover by knife or nipper. Thread the remote controller cable from the slot behind the back cover through this access hole. Securely plug the connector into the jack. 7. Plug the lead wire cable into the front cover. Plug the lead wire cable coming from the back cover into the front cover. Caution: To avoid failures, do not remove the controller board protective sheet and the controller board from the front cover. After the cable is plugged into the front cover, do not hang the front cover as shown in <Fig. 4.2.8>. Otherwise, the remote controller cable could sever, which could cause malfunction to the remote controller. <Fig. 4.2.8> 8. Fit the lead wires into the clamps. Clamps Caution: Hold the wires in place with clamps to prevent excessive strain from being applied on the terminal block and causing cable breakage. Hold the wires in place with clamps. <Fig. 4.2.9> 11
4. Electrical work 9. Fit the front cover and the cosmetic cover onto the back cover. The front cover assembly (fitted with the cosmetic cover at factory shipment) has two tabs on top. Hook the tabs onto the back cover and snap the front cover onto the back cover into place. Check that the cover is securely installed. Caution: When the front cover is correctly attached to the back cover a click is heard. If the cover is not clicked into place it may fall off. <Fig. 4.2.10> Seal the gap between the cable and the access hole with putty. Check that the cover is securely installed and not lifted. Use a cable cover. Direct wall installation (when routing the remote controller cable along the wall surface) Thread the remote controller cable through the cable access hole at the top of the remote controller. Seal the gap between the cable and the access hole with putty. Use a cable cover. Thread the remote controller cable through the cable access hole at the top of the remote controller. <Fig. 4.2.11> Disassembling the front cover and the cosmetic cover (1) Remove the cosmetic cover. Insert a flat head screwdriver into either of two open slots at the bottom of the remote controller and move the screwdriver handle downward as shown. The engagement of the tabs will be released. Then pull the cosmetic cover toward the front to remove the cosmetic cover. (2) Remove the front cover. Insert a flat head screwdriver into either of two open slots at the bottom of the remote controller. The subsequent procedure is the same as that of the cosmetic cover. Caution: Use a 5 mm- flat head screwdriver. Do not turn the screwdriver forcibly while placing the blade in the slots. Doing so could break the covers. <Fig. 4.2.12> 12
4. Electrical work 4.3. Connecting the thermistor cables Connect the thermistor for the controller. TB.143 TB.143 TB.143 TH2 TB.143 CNW12 CN21 CNW5 4.3.1. Connecting the refrigerant pipe temp. thermistor (TH2) cable Connect the TH2 cable to the CN21 connector on. For split Outdoor unit : Connect TH2. For packaged Outdoor unit : It is NOT necessary to connect TH2. When the TH2 cable is too long, connect to TH2 terminal (TB143.5-6) after cut them to the appropriate length or bundle the excess cable outside the unit. Do not bind the wires in the unit. <Thermistor position> Place TH2 on refrigerant piping ( liquid side). It is recommended to protect the thermistor with heat insulating materials so as not to be affected by ambient temperature. Note: Be sure to place TH2 where it correctly detects refrigerant piping temp. (liquid side). Because; (1) TH2 is required to detect heating subcool correctly. (2) Refrigerant temperature of water-to-refrigerant heat exchanger also needs to be detected for protection purpose. <Fig. 4.3.1> 4.3.2. Connecting the flow water temp. thermistor () cable and the return water temp. thermistor () cable The and the cables share a connector, and the connector connects to CNW12 connector on. When the and cable are too long, connect to and terminal (TB143.1-2 and 3-4) after cut them to the appropriate length or bundle the excess cable outside the unit. Do not bind the wires in the unit. <Thermistor position> Place on water piping (water outlet side) after booster heater, and on the water inlet side. It is recommended to protect the thermistor with heat insulating materials so as not to be affected by ambient temperature. Note: Be sure to attach where it correctly detects Flow temp. (water oulet side). 4.3.3. Connecting the actual DHW tank thermistor () cable Connect the cable to the CNW5 connector on if the DHW tank is available. When the cable is too long, connect to terminal (TB143.7-8) after cut them to the appropriate length or bundle the excess cable outside the unit. Do not bind the wires in the unit. <Thermistor position> Place on the position where tank water temperature can be detected correctly. It is recommended to position the thermistor at the mid height of the DHW tank (to control DHW heating with this sensor). It is recommended to protect the thermistor with heat insulating materials so as not to be affected by ambient temperature. Especially for double (insulated) tank, thermistor should be attached to the inner side (to detect the water temperature). Note: Connect the terminals by using the ring terminals and also insulate the cables of adjoining terminals when wiring to TB143. Caution: Do not route the thermistor cables together with power cables. The sensor part of the thermistor should be installed where user can not access. (It should be separated, by supplementary insulation, from areas the user can access.) 13
4. Electrical work 4.3.4. Thermistor position and necessity <Thermistor position and necessity> Outdoor unit type DHW tank TH2 Split Packaged Present Absent Present Absent : Necessary. Connect the thermistor. : Not necessary. The thermistor is not required, do not connect. SPLIT type outdoor unit with DHW tank and booster heater DHW tank temperature PACKAGED type outdoor unit with DHW tank and booster heater DHW tank temperature Refrigerant LIQUID side Water OUTLET side after booster heater Water OUTLET side after booster heater Outdoor unit Outdoor unit TH2 *1 Water INLET side *1 Water INLET side Not necessary Refrigerant piping SPLIT type (without a refrigerant-water HEX inside) Water piping *1 Refrigerant-water HEX Water piping PACKAGED type (with a refrigerant-water HEX inside) TH2 *1 Refrigerant-water HEX SPLIT type outdoor unit with booster heater Not necessary PACKAGED type outdoor unit with booster heater Not necessary Refrigerant LIQUID side Water OUTLET after booster heater Water OUTLET side after booster heater Outdoor unit Outdoor unit Not necessary TH2 TH2 *1 Water INLET side *1 Water INLET side Refrigerant piping SPLIT type (without a refrigerant-water HEX inside) Water piping *1 Refrigerant-water HEX Water piping PACKAGED type (with a refrigerant-water HEX inside) *1 Refrigerant-water HEX <Fig. 4.3.2> 14
4. Electrical work 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CNW12 1 4 (RED) CN21 1 3 (YLW) 2 1 2 1 CNW5 SW6 (WHT) LED2 LED3 LED5 LED4 SW3 10 10 SW1 1 10 SW2 LED1 4.4. Connecting external inputs/outputs can be operated by following external input. When the wires are wired to adjacent terminals use ring terminals and insulate the wires. TB143 2 4 6 8 10 12 14 1 3 5 7 9 11 13 TB142 1 5 CN105 (RED) 8 1 CN100 (WHT) FTC 2B 2 4 6 8 10 12 14 1 3 5 7 9 11 13 TB141 <Fig. 4.4.1> 1 1 S1 S2 S3 L N TB6 TB142 1 3 CNS2 (RED) 4.4.1. External inputs (Contact signal) Name Terminal block Item (Open) (Short) IN1 TB142 1-2 IN2 TB142 3-4 Emergency operation input Legionella prevention mode input *1 Srandard operation Emergency operation Legionella prevention mode IN3 TB142 5-6 Flow switch input Refer to SW3-6 in <5.1. Dip switch function> IN4 TB142 7-8 Cooling mode input Cooling mode IN5 TB142 10-11 Heating mode input Heating mode IN6 Heating ECO mode TB142 10-12 input *2 Heating ECO mode IN7 TB142 10-13 DHW mode input *3 DHW mode IN8 TB142 10-14 Holiday mode input Holiday mode Room thermostat Ana.IN1 TB143 9-10 input *1 Input signal: Pulse Pulse specifications: (short) Refer to SW3-4 in <5.1. Dip switch function> Emergency Legionella prevention Flow switch Cooling Heating HeatingECO DHW Holiday 1 2 3 4 5 6 7 8 9 10 11 12 13 14 (open) 200ms or more *2 Heating ECO mode sets the set temperature depending on the outdoor temperature. *3 When SW1-1 and SW1-2 are, the mode is switched into auto DHW mode. Input signal: Pulse Pulse specifications: (short) (open) 200ms or more When SW1-1 or SW1-2, or both are, the mode is switched into DHW mode. TB143 TH2 Thermostat 4-20mA/1-5V/0-10V Remote controller 4-20mA / 1-5V / 0-10V setting Flow temp. ( ( ( ( ( ( ( 1 2 3 4 5 6 7 8 9 10 11 + 12 13 14 4.4.2. External inputs ( Analog signal ) 4-20mA / 1-5V / 0-10V Connect the transmission cables to No.11 and 12 on the terminal block (TB143). No.11 on the terminal block (TB143) : Plus side No.12 on the terminal block (TB143) : Minus side (Reference side) Wiring specification and field supply parts Item Name Model and specifications External inputs function External inputs wire Switch Use sheathed vinyl coated cord or cable. Max. 10 m Wire type: CV, CVS or equivalent Wire size: Stranded wire 0.5 mm² to 1.25 mm² Solid wire: ø0.65 mm to ø1.2 mm Non-voltage a contact signals Remote switch: minimum applicable load 12V DC, 1mA No.2 Temp. No.1 Temp. Stop 4-20mA 0mA -- 4mA --------------- 20mA Analog signal 1-5V 0V-------1V------------------- 5V 0-10V 0V------------------10V 15
4. Electrical work 4.4.3. Outputs Name Terminal block Item Signal / Current Max. total current OUT1 TB141 1-2 Water circulation pump output 230V AC 0.5A Max. 10mA Min. (Relay) OUT2 TB141 3-4 Booster heater 1 output 230V AC 0.5A Max. 10mA Min. (Relay) OUT3 TB141 5-6 Booster heater 2 output 230V AC 0.5A Max. 10mA Min. (Relay) OUT4 TB141 7-8 Immersion heater output 230V AC 0.5A Max. 10mA Min. (Relay) 3 A OUT5 TB141 9-10 3-way valve output Heating DHW 230V AC 0.5A Max. 10mA Min. (Relay) OUT6 TB141 11-12 Defrost output Normal Defrost 230V AC 0.5A Max. 10mA Min. OUT7 TB141 13-14 Error output Normal Error 230V AC 0.5A Max. 10mA Min. N L N L N L N L N L N L N L Wiring specification and field supply parts Item Name Model and specifications TB141 1 2 OUT1 3 4 5 OUT2 OUT3 6 7 8 OUT4 9 10 11 12 13 14 OUT5 OUT6 OUT7 External outputs function External outputs wire Use sheathed vinyl coated cord or cable. Max. 50 m Wire type: CV, CVS or equivalent Wire size: Stranded wire 0.5 mm² to 1.25 mm² Solid wire: ø0.65 mm to ø1.2 mm Note: 1. Do not drive the pump directly, heater and valve by these output signals. 2. Connect the surge absorber according to the load at site. <Wiring for booster heater with a built-in direct cut-off thermostat> Earth leakage circuit breaker for booster heater 4.5. Wiring for heater <Care to be taken when connecting a booster heater(s)> When the connected booster heater(s) has a built-in direct cut-off thermostat, perform wiring according to Fig. 4.5.1. OUT3 (TB141 5-6) When the connected booster heater(s) has a built-in indirect cut-off thermostat, perform wiring according to Fig. 4.5.2. Contactor or relay for booster heater Contactor or relay for booster heater 2 OUT2 (TB141 3-4) OUT3 (TB141 5-6) <Care to be taken when connecting an immersion heater> The initial setting assumes that the connected immersion heater has a built-in direct cut-off thermostat. <Fig. 4.5.3> Direct cut-off thermostat Booster heater1 Booster heater2 <Fig. 4.5.1> <Wiring for booster heater with a built-in indirect cut-off thermostat> <Wiring for immersion heater with a built-in direct cut-off thermostat> Earth leakage circuit breaker for booster heater Earth leakage circuit breaker for immersion heater Contactor or relay for protecting booster heater Contactor or relay for booster heater 1 Booster heater1 Contactor or relay for booster heater 2 OUT2 (TB141 3-4) Cut-off thermostat OUT3 (TB141 5-6) Contactor or relay for immersion heater Direct cut-off thermostat Immersion heater <Fig. 4.5.3> OUT4 (TB141 7-8) Indirect cut-off thermostat 16 Booster heater2 Contactor or relay for protecting <Fig. 4.5.2>
5. Dip switch setting 5.1. Dip switch functions Located on the printed circuit board are 4 sets of small white switches known as Dip switches. The Dip switch number is printed on the circuit board next to the relevant switches. The word is printed on the circuit board and on the Dip switch block itself. To move the switch you will need to use a pin or the corner of a thin metal ruler or similar. Dip switch settings are listed below. Make sure to turn off both indoor unit and outdoor unit power supplies before changing the switch settings. SW1 SW6 SW2 SW3 Dip switch Function SW1 SW1-1 System setting SW1-2 SW1-1 SW1-2 / input Change mode input Change temp. input Remote controller Remote controller Remote controller External input Remote controller Analog input (4-20mA/1-5V) External input External input Analog input (4-20mA/1-5V) Analog input (0-10V) Default setting SW1-3 DHW tank WITH DHW tank WITHOUT DHW tank SW1-4 Immersion heater WITHOUT Immersion heater WITH Immersion heater SW1-5 Booster heater function For Heating and DHW For Heating only or WITHOUT Booster heater SW1-6 Outdoor unit type Split type Packaged type SW1-7 Cooling mode function Inactive Active SW1-8 Automatic change over mode function Active Inactive (Heating mode DHW mode) SW1-9 Automatic change over mode function Active Inactive (Cooling mode DHW mode) SW1-10 Heat pump maximum outlet water temp. 55 C 60 C *1 SW2 SW2-1 DHW temparature drop 10deg 20deg SW2-2 Operation in DHW mode Eco Nomal SW2-3 Economy setting for water circulation pump Inactive Active SW2-4 SW2-5 Legionella prevention mode setting SW2-4 SW2-5 Operation Activate every "1 times" DHW operations. Activate every "15 times" DHW operations. Activate every "150 times" DHW operations. Activate by IN2. SW2-6 Legionella prevention hot water temp. 60 C 65 C SW2-7 Immersion heater usage in DHW mode Used Not used SW2-8 Booster heater usage in Heating mode Used Not used SW2-9 Booster heater usage in DHW mode Used Not used SW2-10 Heater delay timer in DHW mode 15min 30min SW3 SW3-1 3-way valve control during defrost in Heating mode (Heating circuit) (DHW circuit) SW3-2 Water circulation pump manual operation SW3-3 3-way valve manual operation SW3-4 Room thermostat input (Ana,IN1) logic change Operation stop at thermostat short Operation stop at thermostat open SW3-5 Comp. for mode change (DHW Heating) Inactive Active SW3-6 Flow switch input (IN3) logic change Failure detection at flow switch short Failure detection at flow switch open SW3-7 Emergency mode (Heater only operation) Normal Emergency mode (Heater only operation) (To be activated only when powered ) SW3-8 Freeze protection function Active Inactive SW3-9 Thermo differential during comp. cycling (/) prevention operation Target temp. ±3deg Target temp. ±5deg SW3-10 SW6 SW6-1 Analog input setting SW6-1 SW6-2 Operation 0-10V or Not used SW6-2 1-5V 4-20mA Note: 1. When the is connected with a PUHZ-RP outdoor unit of which maximum outlet water temperature is 55ºC, Dip SW1-10 must be changed to. 2. If emergency mode is no longer required, return the switch to position. *2 17
5. Dip switch setting 5.2. Outdoor unit type Set Dip SW 1-6 to set the outdoor unit type. Dip SW 1-6 Setting Note Split type Necessary to connect TH2 Packaged type Not necessary to connect TH2 Set Dip SW 1-10 to set the heat pump maximum outlet water temperature. Dip SW 1-10 55 C 60 C Setting When the outdoor unit is a PUHZ-RP series set the Dip SW 1-10 to, other than that, set the Dip SW 1-10 to. 5.3. Functions setting Set Dip SW 1-3 to set whether the system has a DHW tank. Dip SW 1-3 Setting Note WITH DHW tank Necessary to connect WITHOUT DHW tank Not necessary to connect When Dip SW 1-3 is, DHW and legionella prevention mode is not available. Set Dip SW 1-4 to set whether the system has an immersion heater. Dip SW 1-4 Setting WITHOUT immersion heater WITH immersion heater Set Dip SW 1-5 to set the booster heater function. Dip SW 1-5 Setting For heating and DHW For heating only or WITHOUT booster heater <Summary of Function setting> Dip SW 1-3 (DHW tank) Dip SW 1-4 (Immersion heater) Dip SW 1-5 (BH function) System diagram (WITH DHW tank) (WITHOUT immersion heater) (For heating and DHW) DHW tank 3-way valve Booster heater Heat emitter (WITH DHW tank) (WITH immersion heater) (For heating and DHW) 3-way valve DHW tank Immersion heater Booster heater Heat emitter (WITH DHW tank) (WITHOUT immersion heater) (For heating only) DHW tank 3-way valve Booster heater Heat emitter (WITH DHW tank) (WITH immersion heater) (For heating only) 3-way valve DHW tank Immersion heater Booster heater Heat emitter (WITHOUT DHW tank) Booster heater Heat emitter 18
5. Dip switch setting 5.4. Operation setting 5.4.1. Operation mode setting Operation mode Heating mode Heating ECO mode Cooling mode DHW mode Legionella prevention mode Holiday mode Description Space heating through heat emitters Space heating incorporating outdoor temperature compensation through heat emitters Space cooling through heat emitters Domestic hot water heating mode for showers, sinks, etc A function on systems with tanks to prevent the growth of legionella bacterium Space heating for unused time (Different target temperature from above-mentioned heating mode is settable.) Set Dip-SW1-1/1-2/6-1/6-2 to set switching /, changing over operation mode and target temperature setting. / input Change mode input Change temp. input SW1-1 SW1-2 SW6-1 SW6-2 Remote controller Remote controller or External input (non-voltage contact) Remote controller External input (non-voltage contact) Analog input (1-5V) *1 Analog input (4-20mA) *2 External input (non-voltage contact) *1 1-5V : 0-0.5V *2 4-20mA : 0-2mA External input (non-voltage contact) External input (non-voltage contact) External input (non-voltage contact) External input (non-voltage contact) Remote controller Analog input (1-5V) Analog input (4-20mA) Analog input (0-10V) Set Dip SW 1-7 to set activate or deactivate cooing mode. Dip SW 1-7 Setting Inactive Active When Dip SW 1-7 is, cooling mode is not available. Set Dip SW 1-8 to set activate or deactivate automatic change over mode (DHW Heating). Dip SW 1-8 Active Inactive Setting Set Dip SW 1-9 to set activate or deactivate automatic change over mode (DHW Cooling). Dip SW 1-9 Active Inactive Setting Automatic change over mode <SW1-1 /SW1-2 > Mode System operation Heating SW1-8 Heating and DHW mode (Automatic change over mode) SW1-8 Heating mode only Heating ECO SW1-8 Heating ECO and DHW mode (Automatic change over mode) SW1-8 Heating ECO mode only Cooling SW1-9 Cooling and DHW mode (Automatic change over mode) SW1-9 Cooling mode only DHW DHW (Domestic hot water) mode only Holiday Holiday mode only <SW1-1 /SW1-2 or SW1-1 /SW1-2 or SW1-1 /SW1-2 > Mode System operation Heating SW1-8 Heating mode only *1 SW1-8 Heating mode only Heating ECO SW1-8 Heating ECO mode only *1 SW1-8 Heating ECO mode only Cooling SW1-9 Cooling mode only *1 SW1-9 Cooling mode only DHW DHW (Domestic hot water) mode only *1 Holiday Holiday mode only *1 Automatic change over mode is available only when SW1-1/1-2 is set / and the receives external signals for Heating (or Heating ECO or Cooling) and DHW at the same time from the local controller. Automatic change over mode is NOT available when SW1-1/1-2 are set / or /. 19
5. Dip switch setting The priority order of external signals is DHW>Heating>Heating ECO>Holiday>Cooling. However, the priority order might be changed if you put DHW, Heating or Heating ECO or Holiday and Cooling signals at the same time. When automatic change over mode is selected DHW always has priority over space heating. System example Example 1: Only our remote controller is used for system control. No local system controller exists. Target temperature for each mode and Heating or Heating ECO or Cooling mode are set with remote controller. Automatic change over mode is selected (SW1-8 or SW1-9 must be switched to ). The system will automatically change from Heating or Heating ECO or Cooling to DHW mode and back dependent on the DHW tank temperature. SW1-1 /SW1-2 /SW1-8 /SW1-9 or SW1-1 /SW1-2 /SW1-8 /SW1-9 or SW1-1 /SW1-2 /SW1-8 /SW1-9 Flow switch TH2 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 Emergency Legionella Flow Cooling Heating Heating DHW Holiday prevention switch ECO TH2 Ana.IN1 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 Room thermostat Water circulation Booster heater 2 3-port valve pump Booster heater 1 Immersion heater Defrost Error Remote controller Example 2: A local timer and our remote controller are used for system control. Target temperature for each mode and Heating or Heating ECO or Cooling mode are set with remote controller. A local timer is used rather than automatic change over mode (SW1-8 and SW1-9 must be switched to ). The system runs in Heating or Heating ECO or Cooling until a signal is received from the local timer (the signal received from local timer must be longer than 200 ms). The system then switches to DHW mode. Once DHW mode is satisfied the system automatically reverts to Heating or Heating ECO or Cooling. SW1-1 /SW1-2 /SW1-8 /SW1-9 Flow switch TH2 Local timer External input IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 Emergency Legionella Flow Cooling Heating Heating DHW Holiday prevention switch ECO TH2 Ana.IN1 OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 Room thermostat Water circulation Booster heater 2 3-port valve pump Booster heater 1 Immersion heater Defrost Error Remote controller Example 3: A Local controller and our remote controller are used for system control. Target temperatures for each mode are set with remote controller. A local controller is used to select the running mode. Automatic change over mode is available when SW1-8 and SW1-9 is and the receives external signals for Heating or Heating ECO or Cooling, and DHW at the same time from the local controller. Automatic change over mode is not available when SW1-8 and SW1-9 is. SW1-1 /SW1-2 /SW1-8 /SW1-9 or SW1-1 /SW1-2 /SW1-8 /SW1-9 Flow switch Local system controller External input <IMPORTANT NOTE> In this system, the operation mode must be switched by a local controller which can output separate signals for each operation mode. (This can be realised by using a schedule timer and relays.) TH2 IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 Emergency Legionella Flow Cooling Heating Heating DHW Holiday prevention switch ECO TH2 Ana.IN1 Room thermostat OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 Water circulation Booster heater 2 3-port valve pump Booster heater 1 Immersion heater Defrost Error Remote controller Example 4: Only a Local controller is used for system control. The system operates in the same way as Example 3 except that the target temperatures for each mode must also be inputted via the analogue signal from the local controller. (SW1-8 and SW1-9 must be switched to ) SW1-1 /SW1-2 /SW1-8 /SW1-9 or SW1-1 /SW1-2 /SW1-8 /SW1-9 Local system controller <IMPORTANT NOTE> In this system, the operation mode must be switched by a local controller which can output separate signals for each operation mode. In addition, the target temperature in each operation mode must be sent by analog signal from the local controller. Flow switch TH2 External input IN1 IN2 IN3 IN4 IN5 IN6 IN7 IN8 Emergency Legionella Flow Cooling Heating Heating DHW Holiday prevention switch ECO TH2 Ana.IN2 Analog input OUT1 OUT2 OUT3 OUT4 OUT5 OUT6 OUT7 Water circulation Booster heater 2 3-port valve pump Booster heater 1 Immersion heater Defrost Error 20