Panasonic U-16GE2E5 User manual

Test Run Manual April 2012
Gas Heat Pump
Air Conditioner
Applicable Models
2WAY MULTI/W MULTI
U-16GE2E5
U-16GEP2E5
U-20GE2E5
U-20GEP2E5
U-25GE2E5
U-25GEP2E5
U-30GE2E5
Reference No. SM7110029-01
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I. Test run operations
1. Applicable models .......................................................................................................................I-1
2. Limitations on refrigerant tubing length .......................................................................................I-2
3. Tools and measuring equipment .................................................................................................I-6
II. Test Run Work (when Connecting Indoor Unit)
SAFETY PRECAUTIONS
Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer
operates the remote controller on the indoor unit. When working on internal parts of the outdoor unit, make
sure to cut the power to the outdoor unit at the circuit breaker before starting work. (However, if a centralized
control device such as an intelligent controller is used, a communications error may occur.) Otherwise,
perform a “Stop” operation on the outdoor unit.
●Test run flow ...................................................................................................................................II-1
1. Checking installation work
(1) Installation work check ..............................................................................................................II-2
(2) Outdoor unit check ....................................................................................................................II-2
(3) Safety check .............................................................................................................................II-3
(4) Indoor/outdoor control wire connection confirmation .................................................................II-3
(5) Indoor unit check .....................................................................................................................II-10
2. Preparations and checks before operation
(1) Preparations for operating the outdoor unit ............................................................................II-11
3. Setting the address
(1) Setting the indoor unit addresses automatically .....................................................................II-22
(2) Setting the indoor unit addresses manually ............................................................................II-25
(3) Checking the indoor unit addresses ........................................................................................II-27
(4) Changing the indoor unit addresses (when necessary) ..........................................................II-29
(5) Flow diagram for address setting ............................................................................................II-31
4. Checking the function
(1) Changing the function setting .................................................................................................II-32
(2) Checking the function of the outdoor unit ...............................................................................II-33
(3) Checking the indoor units and remote controller ....................................................................II-36
5. Checking performance
(1) Checking the basic performance of indoor and outdoor units .................................................II-38
(2) Completion of operations ........................................................................................................II-41
6. Operating instructions
(1) Remote controller switch (operation switch) operation and display ........................................II-42
(2) Daily inspection .......................................................................................................................II-45
(3) The necessity for maintenance ...............................................................................................II-45
7. Self-diagnosis function table (outdoor unit) ..................................................................................II-46
III.Reference Document
1. How to view of the outdoor main board......................................................................................III-1
2. Board switch and LED arrangement diagram ...........................................................................III-2
Appendix: GHP test run checklist (M2 Type W MULTI) ..................................................................... IV-1
CONTENTS
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I - 1
I. Test run operations
Get the customer to witness the test run.
1. Applicable models
cOutdoor units
Model Equivalent
horsepower
U-16GE2E5 16 HP
U-16GEP2E5
U-20GE2E5 20 HP
U-20GEP2E5
U-25GE2E5 25 HP
U-25GEP2E5
U-30GE2E5 30 HP
dIndoor units
Class 22 28 36 45 56 73 90 106 140 160 224 280
Capacity
Type kW 2.2/
2.5
2.8/
3.2
3.6/
4.2
4.5/
5.0
5.6/
6.3
7.3/
8.0
9.0/
10.0
10.6/
11.4
14.0/
16.0
16.0/
18.0
22.4/
25.0
28.0/
31.5
4-Way Air Discharge
Semi-Concealed ○○○○○○○○○○
4-Way Air Discharge
Semi-Concealed ○○○○○
2-Way Air Discharge
Semi-Concealed ○○○○○○
1-Way Air Discharge
Semi-Concealed Slim
Type
○○○○○
Silhouette Ducted ○○○○○○○○○○
Static Ducted ○○○○○
Ceiling-Mounted ○○○○ ○○
Wall-Mounted ○○○○○○ ○
Concealed
Floor Standing ○○○○○○
Floor Standing ○○○○○○
Concealed-Duct
High-Static Pressure ○○○○○
eWater heat exchanger units
Connected water heat exchanger unit type Cooling output Heating output
S-250WX2E5 25 kW 30 kW
S-500WX2E5 50 kW 60 kW
S-710WX2E5 71 kW 80 kW
Note: 1. When connecting a mixture of an outdoor air processing unit with direct-expansion coil and a
Multi indoor unit, or connecting multiple units and just an outdoor air processing unit with direct-
expansion coil, the indoor/outdoor unit capacity ratio is within 130%.
2. When connecting a mixture of an outdoor air processing unit with direct-expansion coil and a
Multi indoor unit, a gas tube valve kit is required for the outdoor air processing unit with direct-
expansion coil.
Furthermore, when connecting multiple units and just an outdoor air processing unit with direct-
expansion coil, a gas tube valve kit is required for the outdoor air processing unit with direct-
expansion coil. In either case, ensure the following conditions are satisfied.
At that time, ensure that the total capacity when no gas tube valve kit is connected (Multi indoor
units) is within that of the combined outdoor units, and becomes 50% of the outdoor unit that has
the maximum capacity.
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I - 2
2. Limitations on refrigerant tubing length
(1) System tubing
cLimitations on refrigerant tubing length
When T-tee branch tubing is
used (header branch method)
No. 1 branch
40 cm or less
40 cm or less
Used for
expansion
Symbols
Branch tube
(APR purchased separately)
Ball valve (purchased separately)
T-tee (provided by installer)
Closed (pinch) weld
Table 1-1 Ranges for Refrigerant Tubing Length and Installation Height Difference
450 560 710 850 450×2 450+560 560×2 450+710 560+710 710×2
Equivalent Horsepower 16 20 25 30 32 36 40 41 45 50
Ratio of capacity for indoor unit to
outdoor units 50 – 200%
50 –
170%
Min: Across the system, a minimum outdoor unit capacity of 50%
Max: Total capacity of 130% with 2 outdoor units
Minimum capacity of indoor units
that can be connected Type 22 or greater (equivalent to 0.8 horsepower)
Maximum number of indoor units
that can be connected (per system) 24 32 48 (A maximum of 24 indoor units can be connected per 1 outdoor unit)
* The number of indoor units that can be connected when a W-multi outdoor unit is installed by itself is 24 units or
fewer.
dRanges for Refrigerant Tubing Length and Installation Height Difference
Category Symbol Description Tubing length (m)
Allowable tubing
length
L1 Max. allowable tubing length ≤170
(equivalent length 200)
∆L=
(L2 – L4)
Difference between longest and shortest tubing lengths after
the No. 1 branch (first branching point) ≤70
LM Max. length for main tube (tube with widest diameter) 7≤LM≤120
ℓ1, ℓ2...ℓ48 Max. length for each tube branch ≤30
L5 Distance between outdoor units ≤7
Allowable height
difference
H1 Max. height difference between
indoor and outdoor units
If outdoor unit is above ≤50
If outdoor unit is below ≤35 (*1)
H2 Max. height difference between indoor units ≤α (*2)
H3 Max. height difference between outdoor units 1
Allowable length
for branched tubing
(header branch)
L3 Max. length between first T-tee branch (provided by installer)
and the closed tube end ≤2
(*1) If cooling mode is expected to be used when the external temperature is 10°C or below, the maximum length is
30 m.
(*2) The max/min permissible height between indoor units (α) is found by the difference (∆L) between the maximum
length and the minimum length from the first branch.
α=35- ∆L/2 (however, 0≤α≤15)
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I - 3
(2) Selecting system header and branch tubing sizes
Outdoor and indoor units are connected together by a pair of headers.
If the maximum tubing length exceeds 90 m (effective length), increase the size of the main tubing for both liquid
and gas by one size. Be careful when selecting tube sizes, as the wrong size may impair performance.
cOutdoor Tubing/Main Tube Size(*1) (*2)
Outdoor tubing Main tubing
Outdoor unit (gross) capacity (kW)
45 56 71 85 90 101 112 116 127 142
Gas tube (mm) φ28.58 (φ31.75) φ31.75 (φ38.1) φ38.1
Liquid tube
(mm)
φ12.7
(φ15.88) φ15.88 (φ19.05) φ19.05 (φ22.22)
(*1) If there are plans for future expansion, choose plumbing sizes according to the total capacity after such expan-
sion. However, if tube size is stepped up 3 levels, expansion is not possible.
(*2) If the maximum tube length exceeds 90 m (or equivalent length), use the figure in parentheses ( ) to size the
main tubing, along with those of the liquid and gas tubes.
However, size the gas tube only up to φ38.1. (A reducer has to be fitted on-site)
dSize of main tubing after branch (*1) (*2)
When indoor unit(s) are connected Main tube after branching
Post-branching indoor unit capacity (kW)*3
– 5.6 – 16.0 – 22.4 – 28.0 – 16.0 – 28.0 – 35.5 – 45.0 – 71.0 – 101.0 Over
101.0
Gas tube
(mm) φ12.7 φ15.88 φ19.05 φ22.22 φ15.88 (φ19.05)
φ22.22
(φ25.4)
φ25.4
(φ28.58) φ28.58 (φ31.75) φ31.75 (φ38.1) φ38.1
Liquid tube
(mm) φ9.52 φ9.52 (φ12.7) φ12.7 (φ15.88) φ15.88 (φ19.05) φ19.05 (φ22.22)
(*1) Select a diameter for the main tubing after a branch that is no larger than that of the header.
(In cases where the main tubing after a branch would have to be larger than the header tubing, select tubing of
the same size, and never exceed the header size.)
(*2) If the maximum tube length exceeds 90 m (or equivalent length), use the figure in parentheses ( ) to size the
main tube after branching, along with those of the liquid and gas tubes.
However, size the gas tube only up to φ38.1.
(*3) “–* *” in the table above means “** kW or less”.
eBranch/Header Tube Selection
Use the following branch tubing sets or tubing sets for branching the system’s main tube and indoor unit tubing.
Capacity after branch
Branch tube size (*1) Branch tube number
Gas tube (mm) Liquid tube (mm) Branch tubing
APR-P160BG APR-P680BG APR-P1350BG
Over 72.8 kW φ31.75 φ19.05 — — ●
Over 45.0 kW to 72.8 kW φ28.58 φ15.88 — ●●
Over 35.5 kW to 45.0 kW φ28.58 φ12.7 — ●●
Over 28.0 kW to 35.5 kW φ25.4 φ12.7 — ●●
Over 22.4 kW to 28.0 kW φ22.22 φ9.52 — ●●
Over 16.0 kW to 28.0 kW φ19.05 φ9.52 ●●●
Over 5.6 kW to 16.0 kW φ15.88 φ9.52 ●●
(*3) ●(*3)
5.6 kW or below φ12.7 (*2) φ9.52 ●●
(*3) ●(*3)
(*1) Make a selection so as not to exceed the main tubing size.
(*2) Even when 5.6 kW or below, make the gas tube diameter φ15.88 if 2 or more indoor units are connected after
branching.
(*3) As the tube diameter for the supplied reducer does not match, another reducer must be provided by the installer.
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I - 4
fSelecting ball valves
Valve connection tube diameter (mm)*1
Applicable outdoor
unit
Applicable indoor unit
Total indoor unit capacity through
valve
Model Type No. Gas Liquid Balance
SGP-BV710K φ31.75 φ19.05 - Type 710
(over 90 m) Over 72.8 kW to 101.0 kW
SGP-BV450K φ28.58 φ19.05 - - Over 35.5 kW to 72.8 kW
SGP-BV355K φ28.58 φ15.88 - Type 710 or 560 Over 45.0 kW to 72.8 kW
SGP-BV450M φ28.58 φ12.7 - Type 450 Over 35.5 kW to 45.0 kW
BV-RXP335AGB φ25.4 φ12.7 - Type 355 Over 28.0 kW to 35.5 kW
BV-RXP280AGB φ22.22 φ9.52 - - Over 22.4 kW to 28.0 kW
BV-RXP224AGB φ19.05 φ9.52 - - Over 16.0 kW to 22.4 kW
BV-RXP160AGB φ15.88 φ9.52 - - Over 5.6 kW to 16.0 kW
BU-RXP56AGB φ12.7 *2 φ6.35 - - 5.6 kW or less
BV-RP3GB φ9.52 For balance tube
Note 1. The ID of these valves is about the same as that of the connecting copper tube, so no correction for pressure
loss is necessary.
Note 2. Leakage pressure rating must be at least 4.15 MPa.
*1. Select a size that does not exceed header size.
*2. Even for 5.6 kW or less, if the indoor unit tubing branches, use 15.88 mm diameter gas tube.
(3) Selecting header tubing
[Anticipating additional indoor units]
1) Ball valve installation position: Install on main tubing after branching.
2) Installation guidelines
• Slope main tubes after branches so as to prevent oil buildup.
• Locate ball valves as close as possible to (within 40 cm) of their branch points.
• If the tube diameter at the ball valve is smaller than that of the main tube after branching, install reducers only at
the ball valve connections.
• Locate the equipment where it will be easy to operate and inspect in the future.
Caution
When installing indoor tubing (including that for future indoor expansion) along a main tube after a branch, be
sure to position service ports to face in the direction of their units (see dashed lines in the example above).
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I - 5
[Anticipating additional outdoor units]
1) Ball valve installation position: Install on main tubing after branching.
2) Installation guidelines
• Slope main tubes after branches so as to prevent oil buildup.
• Locate ball valves as close as possible to (within 40 cm) of their branch points.
• If the tube diameter at the ball valve is smaller than that of the main tube after branching, install reducers only at
the ball valve connections.
Caution
When installing outdoor tubing (including that for future indoor expansion), be sure to position the valve service
port to face in the direction of the outdoor unit (see dashed lines in the example above), and at least 50 cm from the
outdoor unit.
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I - 6
3. Tools and measuring equipment
Item Specification Q’ty Notes
Tools and equipment
Driver ( + ) S, M, L ( - ) M 1 each
Monkey wrench 150mm/200mm/250mm 1 each
Spanner 1 set
Leak detection liquid Appropriate
quantity
Step ladder 1
Socket wrench 1 set
Cloth Appropriate
quantity
For wiping the leak detection
liquid
Ordinary tools 1 set
Measurement
equipment
Insulation resistance meter DC 500 V 1
Gas leak detector 1
PC for monitoring 1 unit Including connecting cable
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II - 1
(1) Setting the indoor unit addresses automatically
When the indoor/outdoor control wire is not connected to several outdoor units
When the indoor/outdoor control wire is connected to several outdoor units
(2) Setting the indoor unit addresses manually
(3) Checking the indoor unit addresses
Checking the indoor unit address from the position of the main body of the indoor unit
Checking the position of the main body of the indoor unit from the address of the indoor unit
(4) Changing the indoor unit addresses (when necessary)
Changing the address of indoor unit under individual and group control
Changing the address of the indoor units for the whole system
(5) Address setting flow diagram
II. Test Run Work (when Connecting Indoor Unit)
Test run flow
Outdoor unit
1. Construction
checking
Indoor unit
2. Preparations and checks
before operation
3. Setting the addresses
4.
Checking the performance
5. Checking the
efficiency
6.Operating
instructions
(1) Checking the construction
(2) Checking the outdoor unit
Checking the gas type
External visual check
Checking accessory items
(3) Safety check
Insulation resistance check
Fuel gas connector leakage check
(4) Checking the indoor/outdoor control wire connection
(1) Changing the performance settings
(2) Checking the outdoor unit performance
Checks before start-up of the engine
Test run mode settings
Checking engine performance
Checking for abnormal noise or vibration
(3) Necessity of maintenance
(1) Self diagnosis function table (outdoor unit)
(5) Checking the indoor units
Remove fixing pad
(3) Checking the indoor unit and remote controller
Start/Stop checks
Checks in operate mode
Checks of air speed switching
Checking auto-flap operation
Checking the temperature setting
When the above checks are finished, stop all
remote controllers
(1) Remote controller switch (operation switch) opera-
tion and display
Operation
Display
(2) Daily inspection
7
(1) Preparing the outdoor unit for operation
Removing the panel
Crankcase heater 5-hour preparatory energization check
Outdoor unit main board
Checking and setting the fuel gas type
Checking and adjusting the time and date
Checking the initial values
Setting the number of indoor units connected
Set the indoor unit system address and whether there is termination resistance or not
Checking the coolant level
Opening the shutoff valve
Setting the total stop switch
(1) Checking the basic efficiency of the indoor and outdoor units
Reading the data
Judging the data
Mode change checks
Test run stop
Requests to investigate, take action, or improve
(2) Completion of operations
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II - 2
1. Checking installation work
(1) Installation work check
If there is a problem with the installation work, make a request through the sales representative that the problem be
remedied and measures be taken.
Write the necessary information in the “GHP Test Run Checklist (2WAY Multi/W Multi). (Refer to the appendix.)
(2) Outdoor unit check
Applicable Gas Type
Group P H L E
Gas composition
Standard gas
Calorific value
(MJ/m3N)
C3H8100%
G31
95.65
CH4100%
G20
37.78
CH486% N214%
G25
32.49
CH4100%
G20
37.78
Model
Name
45.0 kW Type
56.0 kW Type
71.0 kW Type
85.0 kW Type
Applicability : Standard setting when shipped from the factory
: Necessary to change the gas type setting on site
External appearance check
●Confirm visually that there is no external damage to the product caused during transport or subsequently.
●In particular, the heat exchanger fan is easily scratched, and some customers have pointed out scratches when
outdoor units were handed over. Be careful.
Accessory check
Required accessories Storage location Remarks
Instruction manual
These items are all stored in a plastic bag
which is attached to the inside of the face
panel with the display window for the
operation time.
Explain how to use the manual when you hand it
over to the customer.
Warranty Fill in the relevant items when you hand over the
warranty to the customer.
Labels
●Remote power switch label
●Refrigerant tube length and refrigerant charge
amount
●Label for a seal
●Warning label
After operation is finished, check that items such as the instruction manual and warranty have not been lost
when handing over the outdoor unit to the customer.
A list of all the accessories is included in “Procedures and Technical Points for System Installation,” but the ac-
cessories required after installation are those shown in the table above.
* In addition to the table above, the following are supplied with the outdoor unit at the time of shipment. Refer to
them together with this test run manual.
●Procedures and Technical Points for System Installation
●Procedures and Technical Points for Electrical Wiring Work
●Procedures and Technical Points for Test Run
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