Airwell YAV112 User manual

INSTALLATION MANUAL
INSTALLATION MANUAL
“MVi”Series
DC-inverter air-conditioners
ENGLISH
Outdoor unit
●YAV112
●YAV140
●YAV160
Before installing your air-conditioner,
please read this installation instruction
carefully and keep it for future reference.

CONTENT
1 Check of Density Limit..................................................................................................................................1
2 Space requirement .......................................................................................................................................2
3 Precaution ....................................................................................................................................................3
4 Installation tools required..............................................................................................................................4
4.1 New Refrigerant Air Conditioner Installation ..........................................................................................4
4.2 Changes in the product and components ..............................................................................................4
5 Introduction...................................................................................................................................................5
5.1 Combination ...........................................................................................................................................5
5.2 Standard attached ttings ......................................................................................................................5
5.3 Optional accessories..............................................................................................................................5
6 Selection location .........................................................................................................................................6
7 TRANSFER AND FIXUP OUTDOOR UNIT .................................................................................................7
7.2 How to prevent overturn.........................................................................................................................7
7.3 Unit dimension .......................................................................................................................................7
7.4 Fixup outdoor unit ..................................................................................................................................8
8 REFRIGERANT PIPING...............................................................................................................................9
8.1 Installation synopsis ...............................................................................................................................9
8.2 How to braze? ........................................................................................................................................11
8.3 How to connect are? ............................................................................................................................12
8.4 How to handle stop valve? .....................................................................................................................13
8.5 How to handle the valve cover? .............................................................................................................13
8.6 Pipe selection and how to calculate ......................................................................................................14
8.6 Pipe selection and how to calculate ......................................................................................................16
8.7 Additional refrigerant charge calculation ................................................................................................17
8.8 Leakage test...........................................................................................................................................18
8.9 Vacuum process ....................................................................................................................................19
8.10 Addition refrigerant charge...................................................................................................................20
8.11 Installation of drain pipe .......................................................................................................................20
9 eld wiring.....................................................................................................................................................21
9.1 Requirement of the wiring ......................................................................................................................21
9.2 Power supply wiring ...............................................................................................................................22
9.3 Main communication wiring....................................................................................................................23
9.4 R/C communication wiring ....................................................................................................................24
9.5 Dry contact function introduction ...........................................................................................................25
10 Installation Setting Through HMI ...............................................................................................................26
10.1. Address Setting Procedure .................................................................................................................26
10.2 Outdoor Control Mode Setting: ...........................................................................................................27
10.3 Dip switch introduction .........................................................................................................................28
11 APPENDIX .................................................................................................................................................29
11.1 Letter VS HMI display ........................................................................................................................29
11.2 HMI display content explanation ..........................................................................................................30
11.3 Protection Code ...................................................................................................................................31

1
1 CHECK OF DENSITY LIMIT
The room in which the air conditioner is to be
installed requires a design that in the event of
refrigerant gas leaking out, its density will not
exceed a set limit.
The refrigerant (R410A), which is used in the air condi-
tioner, is safe, without the toxicity or combustibility of
ammonia, and is not restricted by laws imposed to pro-
tect the ozone layer. However, since it contains more
than air, it poses the risk of suffocation if its density
should rise excessively. Suffocation from leakage
of refrigerant is almost non-existent. With the recent
increase in the number of high density buildings, how-
ever, the installation of multi air conditioner systems is
on the increase because of the need for effective use
of floor space, individual control, energy conservation
by curtailing heat and carrying power, etc.
Most importantly, the multi air conditioner system is
able to replenish a large amount of refrigerant com-
pared to conventional individual air conditioners. If a
single unit of the multi air conditioner system is to be
installed in a small room, select a suitable model and
installation procedure so that if the refrigerant acci-
dentally leaks out, its density does not reach the limit
(and in the event of an emergency, measures can be
made before injury can occur).
In a room where the density may exceed the limit,
create an opening with adjacent rooms, or install
mechanical ventilation combined with a gas leak
detection device. The density is as given below.
Total amount of refrigerant (kg)
Min. volume of the indoor unit installed room (m3)
≤Density limit (kg/m3)
The density limit of refrigerant which is used in multi
air conditioners is 0.44 kg/m3 (ISO 5149).
NOTE
2. The minimum indoor oor space compared with the
amount of refrigerant is roughly as follows (when the
ceiling is 2.7 m high):
1 Denition for minmum room volume
(1) No partition (shaded portion)
(2) When there is an effective opening with the adja-
cent room for ventilation of leaking refrigerant gas
( an opening 0.15% or larger than the respective
oor spaces at the top or bottom of the door).
(3) If an indoor unit is installed in each partitioned
room and the refrigerant tubing is interconnected,
the smallest room of course becomes the object.
But when mechanical ventilation is installed inter-
locked with a gas leakage detector in the smallest
room where the density limit is exceeded, the
volume of the next smallest room becomes the
object.
of 0.44 kg/m3
of 0.44 kg/m3

2
2 SPACE REQUIREMENT
Chart 1 Chart 2
Chart 5
Chart 7
Chart 10
Chart 12
Chart 11
Chart 8 Chart 9
Chart 6
Chart 3 Chart 4

3
3 PRECAUTION
CAUTION If the warning is not observed, it may cause injure or damage to the equipment.
WARNING If the warning is not observed, it may cause serious casualties.
CAUTION
● Install drain piping according to this installation manual to ensure favoring drainage, and insulate the
pipe to prevent condensation.
● Make sure all welding rods should contain 7% silver.
● Installation in the following places may cause trouble. If it is unavoidable, please consult with the dealer.
(1)A place full of machine oil;
(2)A saline place such as coast;
(3)Hot-spring resort;
(4)A place full of sulfide gas;
(5)A place where there is high frequency machines such as wireless installation, welding machine, medical
facilities.
(6)A place of special environmental conditions.
● Using a torque wrench, tighten the flare nuts to the specified torque setting.
● The appliance shall be installed in accordance with national wiring regulations.
● This appliance is not intended for use by persons (including children) with reduced physical, sensory,
or mental capacities, or lack of experience and knowledge, unless they have been given supervision or
instruction concerning use of the appliance by a person responsible for their safety.
● Children should be supervised to ensure that they do not play with the appliance.
● If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly
qualified persons in order to avoid a hazard.
● The appliance shall be installed in accordance with national wiring regulations, and shall be provided
to ensure all-pole disconnection from the supply mains, and distance between the poles shall be more
than 3 mm.
● Only qualified technician is allowed to perform the maintenance.
WARNING
● Ensure an electrical leakage breaker is fitted. This is to prevent the risk of electric shock.
● Installation and servicing of air conditioning equipment can be hazardous due to system pressure and
electric components. Ask the trained and qualified service personnel to install, repair or service your
equipment.
● Before performing service or maintenance operations on system, turn off main power switch of the unit.
Otherwise electrical shock could cause personal injury.
● According to this manual, do not install this unit by yourself. Because improper installation may lead to
water leakage, electric shocks or fire.
● When one unit is installed in a small room, it is necessary to measure the system refrigerant quantity, so
that the leaked refrigerant amount does not exceed the limit. If the leak amount exceeds the limit, it may
cause an oxygen deficiency accident.
● Be sure to use only the specified accessories and parts for installation. Failure using may result in water
leakage, electric shocks, fire, or the unit falling.
● If refrigerant leaks during the installation work,don't touch them! Or it will frostbite you! And ventilate the
room immediately.
● Electrical work must be performed by qualified personnel according to local laws and regulations and
this installation manual. Ensure the air conditioner uses a designated power supply.
● When connecting the installation wiring, be sure that all fixing terminals are securely fixed.

4
4 INSTALLATION TOOLS REQUIRED
4.1 New Refrigerant Air Conditioner Installation
● This air conditioner adopts the new HFC refrigerant (R410A) which doesn't destroy ozone layer.
R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the
working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the adoption of
the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be
sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant
R410A air conditioner circuit.
● To prevent mixing of refrigerant of refrigerating machine oil, the sizes of connecting sections of charging port on
main unit and installation tools are different from those used for the conventional refrigerant units. Accordingly,
special tools are requited for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping
materials with high pressure fittings made for R410A only, so that water and dust does not enter. Moreover, do
not use the existing piping because there are some problems with pressure fittings and possible impurities in
existing piping.
4.2 Changes in the product and components
● In air conditioners using R410A, in order to prevent any other refrigerant from being accidentally charged, the
service port diameter size of the outdoor unit control valve (3 way valve) has been changed.
● In order to increase the pressure resisting strength of the refrigerant piping, flare processing diameter and
opposing flare nuts sizes have been changed.
New tools for R410A Applicable to R410A New tools for R410A Applicable to R410A
Gauge manifold Flare tool (clutch type)
Charge hose Vacuum pump adapter
Electronic balance for
Refrigerant charging Gas leakage detector
Torque wrench
● Incidentally, the “refrigerant cylinder” comes with the refrigerant designation (R410A) and protector coating in
the U.S's ARI specified rose color (ARI color code: PMS 507).
● The charge port size of refrigerant cylinder should be as same a the charge hose's port size.
Table 1

5
5 INTRODUCTION
5.1 Combination
The Indoor units can be installed in the following range, To learn which models of indoor units are compatible
with MVi unit, refer to the product catalogs.
Total capacity/quantity of indoor units table:
Combination table:
5.2 Standard attached ttings
Please check whether the follow ttings are of full scope. If there are some attached tting free for use
immediately, please restore them carefully.
5.3 Optional accessories
To install the above outdoor units, the following optional parts are also required.
1.Indoor unit
2.Remote controller
3.Distribution joint
Outdoor unit Capacity match ratio Total quantity of indoor
unis (max)
112
50%-130%
6
140 8
160 9
No. Accessories part Qty. No. Accessories part Qty.
1
Drain connector
1 4
Connector tube
2
2 Drainage plug 25
Installation
manual 1
3
Mounting pads
4
Table 2
Table 3
Capacity match ratio=Total nominal capacity of indoor unit/nominal capacity of outdoor unit

6
6 SELECTION LOCATION
Place selection
MVi system is suitable for installation in a commercial and light industrial environment.
●Obtain permission from the customer to install the unit in a site that satisfies the following conditions:
1)A place that compliance with the requirement mentioned in the second page.
2)A place that permits level installation of the unit.
3)A place that provides enough space for servicing safely.
4)A place that the drainage from the unit will not pose a problem.
5)A place that the unit does not bother next door neighbors.
6)A place where the indoor unit and outdoor units’ piping and wiring lengths come with in the allowable ranges.
●Avoid installing in following places:
1)A place exposed to air with high salt content (ex. Seaside area)
2)A place exposed to large quantities of sulfide gas (ex. Hot spring).
3)A place where organic solvent is used nearby.
4)A place close to a machine generation high frequency.
5)A place with poor ventilation.
CAUTION
The installation of the air conditioning unit must be positioned in a location that can sufficiently support its
weight and give protection against adverse environmental conditions. Failure to do so may result in unit
damage and possible human injury.
WARNING
Ensure that the unit is placed where there is no risk of flammable gases.
Ensure the outdoor unit is fixed to the base, to prevent movement of the unit.
CAUTION
●When the outdoor unit is installed in a place where always exposed to strong wind like a coast or on the
roof of a high building, please apply the windproof measures referring to the following examples:
Install the unit so that its discharge port faces to the obstacle, keeps a distance as 500mm or more
between the unit and the obstacle. Ensure the air out-let direction is vertical to the wind direction of the
operation season of air conditioner.
●In regions with significant snowfall, the outdoor unit
should be provided with a platform and snow-proof
duct.
≥500mm
Seasonwind
Chart 13

7
7 TRANSFER AND FIXUP OUTDOOR UNIT
CAUTION
● Please carry the unit to installation place with its initial packaging as best as possible.
● Be careful when hang the unit with sling (for example), because the center of gravity is not the
epicenter of this unit, and some methods should be taken for its overturn.
● The gradient shouldn't exceed 45°when transit the unit. Don't store the unit in decumbent.
● Bring the unit slowly by grabbing the left and right grips.
● Place your hands on the corner instead of holding the suction inlet in the side of the case, otherwise
the case could be deformed.
● Take care not to let hands or other objects come in and contact with the rear fins. Or it will hurt your
hands and damage the unit.
7.2 How to prevent overturn
If it is necessary to prevent the unit from falling over, the following method can be for your information:
● Prepare all 4 wires as indicated in the drawing.
● Unscrew the top plate at the 4 locations indicated A and B.
● Put the screws through the nooses and screw them back tight.
7.3 Unit dimension
A Location of the 2 fixation holes on thefront side
B Location of the 2 fixation holes on the back side
C Wires: field supply
Chart 14
YAV 112/140 YAV 160
Chart 15

8
7.4 Fixup outdoor unit
● Before installation, check strength and horizon of the base for preventing abnormal vibration and noise.
● According to the following diagram, x the base rmly with the anchor bolts. (Anchor bolt, nut: M10,4pairs)
● Base create:
1) Use concrete or a similar material to create the base,and ensure good drainage.
Ordinarily, ensure a base height of 5 cm or more. If a drain pipe is used, or for use in cold-weather
regions,ensure a height of 15 cm or more at the feet on both sides of the unit.
(In this case, leave clearance below the unit for the drain pipe, and to prevent freezing of drainage water in
cold-weather regions.)
2) Refer to chart 16 for the anchor bolt dimensions.
3) Set the out margin of the anchor bolt to 25mm or less.
7 TRANSFER AND FIXUP OUTDOOR UNIT
25 or less
Chart 15

9
8 REFRIGERANT PIPING
8.1 Installation synopsis
Field pipes can be installed in three directions, this character increases the exible of installation.
Chart 17
Chart 18
1 Connecting liquid pipe (field supply) A the front
2 Connecting gas pipe B the rear
3 Front plate C the side
● Please knock out the hole as shown in the figure. Do not remove the pipe cover from the cabinet so that the
knockout hole can be easily punched. To knock out, it is easily taken off by hands by punching a position at the
lower side of 3 connected parts with screwdriver along the guide line.
● After marking the knockout hole, remove the burr and mount the attached protective bush and guard material
for pass-through part in order to protect pipes and wires.
knockout for
Power supply wiring
knockout for
refrigerantpiping
12
3

10
WARNING
● It is forbidden to discharge refrigerant into the atmosphere. Collect the refrigerant in accordance with the
Freon collection and destruction law.
● If the refrigerant gas leaks during installation work, ventilate the room immediately.
● Do not use flux when brazing the refrigerant piping. For brazing, use phosphor copper brazing filler metal
(BCuP) which does not require a flux.
CAUTION
● If being put aside for ling period after end caps being removed, breakdown may happen to tubes
because of invasion of dust, water and foreign matter into pipe, so please proceed connection
operation as following rapidly.
● Before tightening flare nuts, a layer of attached cooling engine oil should be thinly applied on the sealed
pad surface between tubes and connectors.
● Please proceed tubing connections with two wrenches and refer to table 4 for tightening torque.
● Please apply attached refrigerant lines thermal insulation materials for insulation on indoor lateral flare
connection areas.
Attentions on application of flexible couplings:
1)Please apply flexible coupling at indoor lateral interconnecting areas.
2)Bending angle cannot exceed 90°, and bending cannot be repeated more than 3 times.
3)To reach appropriate torque as per torque wrench:
Table 4
Piping procedure:
1)Keep stop valve on outdoor unit in “off” status (ex-factory specification) as original, dismantle end caps on
refrigerant lines and the unit, and proceed quickly flare connection.
2)Leakage test. For details,please refer to chapter 8.8 Leakage test.
3)Vacuum the system. For details, please refer to chapter 8.9 Vacuum process.
4)Addition refrigerant charge. For details,please refer to chapter 8.10 addition refrigerant charge.
5)After completion of above operation, keep stop valve (commonly used by liquid and gas) on the outdoor unit
totally open. By then, refrigerant cycle between indoor unit is all connected.
Tube diameter
(mm)
tightening torque,
approximate
Tube thickness
(mm)
Φ6.35 14-18 N.m
(140-180kgf.cm) 0.8
Φ9.52 34-42 N.m
(340-420kgf.cm) 0.8
Φ12.7 49-61 N.m
(490-610kgf.cm) 0.8
Φ15.88 68-82 N.m
(680-820kgf.cm) 1.0
Φ19.05 100-120 N.m
(1000-1200kgf.cm) 1.0
8 REFRIGERANT PIPING

11
CAUTION
8.2 How to braze?
● Do not allow anything other than the designated refrigerant to get mixed into the freezing cycle, such
as air, etc. If any refrigerant gas leaks while working on the unit, ventilate the room thoroughly right away.
● In order to prevent dirt, liquid or dust from entering the piping, cure the piping with a pinch or taping.
Great caution is needed when passing copper tubes through walls.
● Only use the flare nuts included with the unit. Using different flare nuts may cause the refrigerant leakage.
Ensure using a nitrogen blow when brazing. Brazing without carrying out nitrogen replacement or releasing
nitrogen into the piping will create large quantities of oxidized nitrogen into the piping, these would prevent normal
operation of valves and compressors. So, please braze tubes as followings:
Insert nitrogen into the tubing, and set the pressure to 0.02MPa with the reducing valve.
Chart 20
1 Refrigerant piping
2 Part to be brazed
3 Taping
4 Handsvalve
5 Reducing valve
6 Nitrogen
Chart 19
8 REFRIGERANT PIPING

12
8.3 How to connect are?
● See the following table for are part machining dimensions.
● When connecting the are nuts, apply refrigerant oil to the inside and outside of the ares and turn them three
or four times at rst. (Use only original oil from Airwell)
● When loosening a are nut, always use two wrenches in combination. When connecting the piping, always use
a spanner and torque wrench in combination to tighten the are nut.
● See the following table for tightening torque.
Applying too much torque may cause the ares to creak.
● After all the tubing has been connected, using nitrogen to perform a gas leak check.
● When without torqu e wrench, please take following method as standard when tightening are nut with wrench,
stop it and only rotate to angle stated as blow table when tightening torque increases quickly.
Chart 21
Table 5
Tube diameter
(mm)
Futher
tightening angle
Spanner length
(mm)
Φ6.35 60~90 About 150
Φ9.52 60~90 About 200
Φ12.7 30~60 About 250
Φ15.88 30~60 About 300
Φ19.05 20~35 About 450
Table 6
1 Piping union
2 Spanner
3 Flare nut
4 Torque wrench
Tube diameter
(mm)
Tightening
torque,
approximate
Tube thickness
(mm) Flare size A (mm) Flare Shape
Φ6.35 14-18 N.m
(140-180kgf.cm) 0.8 9.6~10.0
Φ9.52 34-42 N.m
(340-420kgf.cm) 0.8 12.8~13.2
Φ12.7 49-61 N.m
(490-610kgf.cm) 0.8 15.4~15.8
Φ15.88 68-82 N.m
(680-820kgf.cm) 1.0 19.3~19.7
Φ19.05
100-120 N.m
(1000-1200kgf.
cm)
1.0 22.9~23.3
8 REFRIGERANT PIPING

13
8.4 How to handle stop valve?
● The stop valves for indoor-outdoor connecting piping are
closed at shipment from the factory. Make sure to keep the
valve open during operation. The names of parts of the stop
valve are shown as following:
1 Service port
2 Shut-off valve
3 Field piping
connection
4 Valve cover
Chart 22
● Since the side boards may be deformed if only a torque
wrench is used when loosening or tightening flare nuts, so
always lock the shut-off valve with a wrench and then use a
torque wrench.
Do not place wrenches on the valve cover! This may result in
a refrigerant leak.
Chart 23 1 Spanner
2 Toerque wernch
● For cooling operation under low ambient temperature or
any other operation under low pressure, apply silicon pad or
similar to prevent freezing of the gas stop valve are nut.
Chart 24
Silioon sealign pad
(Make sure there is no gap)
8.5 How to handle the valve cover?
● The valve cover is sealed where indicated by the arrow:
● After operating the valve, be sure to tighten the valve cover properly.
● Check for refrigerant leakage after tightening the cap.
Chart 25
Tightening torque
Liqurd pipe 13.5~16.5N.m
Gas pipe 22.5~27.5N.m
Table 7
8 REFRIGERANT PIPING

14
8.6 Pipe selection and how to calculate
Main tube of unit
1stbranch
Unit distributiontube
LB
LA
L1
L2
LC LD ln
H1
H2
L3 l1l2l5ln1
Caution:Do not use commercially available distribution joint for the liquid tubing. Be sure to use special
R410A disribution joints which supplied by Airwell only.(Part No. 463750190)
Chart 26
■ Ranges that apply to refrigerant tubing lengths and differences in installation heights.
Items Marks Contents Length(m)
Allowable
tubing
length
L1 Max. tubing length
Actual tubing length ≤150
Equivalent tubing length ≤175
LA Max. tubing length ≤80
L(L2-L3) Difference between the max. length and the min.
length from the NO.1 distribution joint ≤40
l1,l2~ln Max. length of each distribution tube ≤30
l1+l2+~ln-1+L1 Total max. tubing length including length of each
distribution tube(only narrow tubing) ≤200
Allowable
elevation
difference
H1
When outdoor unit is installed higher than indoor unit ≤50
when outdoor unit is installed lower than indoor unit ≤40
H2 Max. difference between indoor units ≤15
Table 8
L1 – Maximum allowable tube length;
L2 – Maximum tubing length from the rst distribution;
L3 – Minimum tubing length from the rst distribution;
LA – Main tube of the unit between the ODU and the rst distribution;
8 REFRIGERANT PIPING

15
■ Main tubing size (LA):
Note:1 When only one indoor unit is connected to a 6HP unit, connect Φ19.05 gas tubing up to just before the
indoor unit, then use a socket or similar device (field supply) to change the tube diameter to Φ15.88 and
connect the gas tube to the indoor unit.
2 Siphon setting:If the outdoor unit is installed higher than indoor unit, a siphon is needed every 5 meters
in the passage of vertical gas tube. If the outdoor unit is installed lower than indoor unit, no need any
siphon.
Below
Capacity(kW) 14(5hp)
Over
Capacity(kW) 0
Main tubing
size(LA) <32 ≥32 ≥66
ODU model 11.2 14 16 11.2 14 16 11.2 14 16
Gas
tubing(mm) Φ15.88 Φ15.88 Φ19.05 Φ19.05 Φ19.05 Φ22.23 Φ19.05 Φ19.05 Φ22.23
Liquid
Tubing(mm) Φ9.52 Φ9.52 Φ12.70
Table 9 (1)
Below
Capacity(kW) 20.2(7.2hp)
Over
Capacity(kW) 14.0(5hp)
Main tubing
size(LA) <25 ≥25 ≥56
ODU model 11.2 14 16 11.2 14 16 11.2 14 16
Gas
tubing(mm) Φ15.88 Φ15.88 Φ19.05 Φ19.05 Φ19.05 Φ22.23 Φ19.05 Φ19.05 Φ22.23
Liquid
Tubing(mm) Φ9.52 Φ9.52 Φ12.70
Table 9 (2)
8 REFRIGERANT PIPING

16
8.6 Pipe selection and how to calculate
■ Main tubing size after distribution (LB,LC…)
■ Indoor unit tubing connection (l1, l2…ln-1)
■ Required Copper Tubing Dimensions (unit: mm/inch)
LB,LC...
Totalcapacityafterdistribution Below KW 6(2.2hp) 20.2(7.2hp)
Over KW 0 6(2.2hp)
Tubing size Gas tubing(mm/inch) Φ12. 7(1/2") Φ15. 88(5/8")
Liquid tubing(mm/inch) Φ9.52(3/8")
ln-1
Indoor unit type 22,28,36,45,56 63,71,90,110
Gas tubing(mm/inch) Φ12.7(1/2") Φ15.88(5/8")
Liquid tubing(mm/inch) Φ6.35(1/4"). Φ9.52(3/8").
Copper
tubing
Outer diameter(mm/
inch)Tube thickness 6.35(1/4") 9.25(3/8") 12.7(1/2") 15.88(5/8") 19.05(3/4")
Tube thickness 0.8 0.8 0.8 1.0 1.0
Table 10
Table 11
Table 12
8 REFRIGERANT PIPING
■ Installation sample: one project install a VRF system, following is the sketch map:
(1)Choose result of the indoor unit model:
Room number Indoor unit model Nominal capacity of
indoor unit (KW)
A SXV45 4.5
BCKV22 2.2
CCKV36 3.6
DPNV56 5.6
EPNV22 2.2
(2) Calculate the actual capacity match ratio：
Actual capacity match ratio=4.5+2.2+3.6+5.6+2.2X100%=129.3%
14
It meets the capacity match ratio requirement range [50%,130%].

17
8 REFRIGERANT PIPING
8.7 Additional refrigerant charge calculation
Additional refrigerant charge amount is calculated from the liquid tubing total length as follows.
Calculate the amount of refrigerant charge per meter according to liquid tubing size:
Liquid tubing size Amount of refrigerant charge(g/m)
Φ 6.35 25
Φ 9.52 55
Φ 12.7 120
*Always charge accurately using a scale of weighing ,so
The required additional refrigerant charge (kg)=(25Xa+55Xb+120Xc)X10-3
a: Total length of Φ6.35(mm) liquid tube
b: Total length of Φ9.52(mm) liquid tube
c: Total length of Φ12.7(mm) liquid tube
Following table offers the refrigerant charge amount at shipment (for outdoor unit):
Heat Pump Unit (kg) 112 140 160
4.5 5.5 6.5
Table 13
Table 14
Chose outdoor unit model as YAV140 (14KW）is the most economical.
(3)Pipe calculation and selection：
Pipe number Actual length（m）Sum of nominal capacity after
every branch (KW）
Pipe select result
Gas pipe/liquid pipe (mm）According as
LA 80 18.1 Φ19.05/Φ12.70 Table 9
LB 10 13.6 Φ15.88/Φ9.52 Table 10
LC 10 11.4 Φ15.88/Φ9.52 Table 10
LD 20 7.8 Φ15.88/Φ9.52 Table 10
l 1 30 -- Φ12.7/Φ6.35 Table 11
l 2 5 -- Φ12.7/Φ6.35 Table 11
l 3 5 -- Φ12.7/Φ6.35 Table 11
l 4 10 -- Φ12.7/Φ6.35 Table 11
l 5 30 -- Φ12.7/Φ6.35 Table 11
(3)Additional refrigerant charge calculation (Please refer to chapter 9.6)：
Liquid pipe size
(mm) Length（m）Unit charge (g/m) Total chage (kg)
Φ 6.35 80 25 2
Φ 9.52 40 55 2.2
Φ 12.7 80 120 9.6
Then the system need to add 13.8kg refrigerant R410A.

18
8.8 Leakage test
After the refrigerant piping has finished, execute a leakage test.
(1) Connect a nitrogen gas bomb as shown in the figure blow, and apply pressure.
(2) Please comply following steps to apply pressure:
STEP 1: Apply pressure 0.3Mpa (3.0kg/cm2G) for 3 minutes or more.
STEP 2: Apply pressure 1.5Mpa (15 kg/cm2G) for 3 minutes or more.
STEP3: Apply pressure 3.73Mpa (38kg/cm2G) for approx. 24 hours.
(3) Check the changment of pressure after 24 hours.
(4) Leaked position check: When a pressure down is detected in STEP1, STEP2, or STEP3,checking the
leakage at the connecting points. Check leakage with hearing sense, feeler, foaming agent, etc,and perform
re-brazing or re-tightening of flare if leakage is detected.
WARNING
1 Be sure to apply pressure to suction gas side, discharge gas side, and liquid side.
2 Never use “Oxygen”, “Flammable gas” and “Noxious gas” in an leakage test.
3 If there is no leakage,the pressure will not go down.Considering the change of ambient temp,
pressure drop by 0.01Mpa(0.1Kg/cm2G) per 10C is normal in 24 hours after pressure is
applied.
Chart 27
8 REFRIGERANT PIPING