Panasonic U-72me2u94 User manual

INSTALLATION INSTRUCTIONS

Air Conditioner

This air conditioner uses the refrigerant R410A.

NOTE External diameter of service port R410A: 5/16" (7.94mm)

Model No.

Outdoor Units

Type Outdoor Unit Type Nominal Capacity

ME2 2WAY VRF System

72 96 120 144

U-72ME2U9 U-96ME2U9 U-120ME2U9 U-144ME2U9

U-72ME2U94 U-96ME2U94 U-120ME2U94 U-144ME2U94

• To be connecting Indoor Unit

Indoor Units

Type Indoor Unit Type Nominal Capacity

7 9 12 15 18 24 36 48 54

U2 4-Way Cassette

36" × 36"

S-07MU2U6 S-09MU2U6 S-12MU2U6 S-24MU2U6 S-36MU2U6

Y2 4-Way Cassette

24" × 24"

S-07MY2U6 S-09MY2U6 S-12MY2U6 S-18MY2U6

D1 1-Way Cassette

S-07MD1U6 S-09MD1U6 S-12MD1U6

F2 Concealed Duct

- Medium Static

S-07MF2U6 S-09MF2U6 S-12MF2U6 S-15MF2U6 S-18MF2U6 S-24MF2U6 S-36MF2U6 S-48MF2U6 S-54MF2U6

M2 Concealed Duct

- Low Static

S-07MM2U6 S-09MM2U6 S-12MM2U6 S-15MM2U6 S-18MM2U6

E1 Concealed Duct

- High Static

S-36ME1U6 S-48ME1U6

T2 Ceiling

S-12MT2U6 S-18MT2U6 S-24MT2U6

K2 Wall Mounted

S-07MK2U6 S-09MK2U6 S-12MK2U6 S-18MK2U6 S-24MK2U6

P1 Floor Standing

S-07MP1U6 S-09MP1U6 S-12MP1U6 S-15MP1U6 S-18MP1U6 S-24MP1U6

R1 Concealed Floor

Standing

S-07MR1U6 S-09MR1U6 S-12MR1U6 S-15MR1U6 S-18MR1U6 S-24MR1U6

Read through the Installation Instructions before you proceed with the installation.

In particular, you will need to read under the “IMPORTANT!” section at the top of the page.

85464369760022

CV6231977845

ACXF60-18511

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IMPORTANT!

Please Read Before Starting

This air conditioning system meets strict safety and

operating standards. As the installer or service person, it is

an important part of your job to install or service the

system so it operates safely and efﬁciently.

For safe installation and trouble-free operation, you

must:

● Carefully read this instruction booklet before beginning.

● Follow each installation or repair step exactly as shown.

● This air conditioner shall be installed in accordance with

National Wiring Regulations.

● Pay close attention to all warning and caution notices

given in this manual.

WARNING

This symbol refers to a hazard or

unsafe practice which can result

in severe personal injury or death.

WARNING

CAUTION

This symbol refers to a hazard or

unsafe practice which can result

in personal injury or product or

property damage.

If Necessary, Get Help

These instructions are all you need for most installation

sites and maintenance conditions. If you require help for a

special problem, contact our sales/service outlet or your

certiﬁed dealer for additional instructions.

In Case of Improper Installation

The manufacturer shall in no way be responsible for

improper installation or maintenance service, including

failure to follow the instructions in this document.

SPECIAL PRECAUTIONS

WARNING

When Wiring

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH.

ONLY A QUALIFIED, EXPERIENCED

ELECTRICIAN SHOULD ATTEMPT TO

WIRE THIS SYSTEM.

• Do not supply power to the unit until all wiring and tubing

are completed or reconnected and checked.

• Highly dangerous electrical voltages are used in this system.

Carefully refer to the wiring diagram and these instructions

when wiring. Improper connections and inadequate

grounding can cause accidental injury or death.

• Ground the unit following local electrical codes.

• Connect all wiring tightly. Loose wiring may cause over-

heating at connection points and a possible re hazard.

• To prevent possible hazards from insulation failure,

the unit must be grounded.

• This equipment is strongly recommended to be installed

with Earth Leakage Circuit Breaker (ELCB) or Residual

Current Device (RCD). Otherwise, it may cause electrical

shock and re in case of equipment breakdown or

insulation breakdown.

When Transporting

Be careful when picking up and moving the indoor and

outdoor units. Get a partner to help, and bend your knees

when lifting to reduce strain on your back. Sharp edges or

thin aluminum ﬁns on the air conditioner can cut your

ﬁngers.

When Installing…

Select an installation location which is rigid and strong

enough to support or hold the unit, and select a location for

easy maintenance.

…In a Room

Properly insulate any tubing run inside a room to prevent

“sweating” that can cause dripping and water damage to

walls and ﬂoors.

WARNING

CAUTION

Keep the ﬁre alarm and the air

outlet at least 5 ft. (1.5 m) away

from the unit.

…In Moist or Uneven Locations

Use a raised concrete pad or concrete blocks to provide a

solid, level foundation for the outdoor unit. This prevents

water damage and abnormal vibration.

…In an Area with High Winds

Securely anchor the outdoor unit down with bolts and a

metal frame. Provide a suitable air bafe.

…In a Snowy Area (for Heat Pump-type Systems)

Install the outdoor unit on a raised platform that is higher

than drifting snow. Provide snow vents.

When Connecting Refrigerant Tubing

• Pay particular attention to refrigerant leakages.

• Ventilate the room immediately, in the event that is

refrigerant gas leaks during the installation. Be careful not

to allow contact of the refrigerant gas with a ﬂame as this

will cause the generation of toxic gas.

• Keep all tubing runs as short as possible.

• Apply refrigerant lubricant to the matching surfaces of the

are and union tubes before connecting them, then tighten

the nut with a torque wrench for a leak-free connection.

• Check carefully for leaks before starting the test run.

WARNING

• When performing piping work, do not mix air

except for speciﬁed refrigerant (R410A) in

refrigeration cycle. It causes capacity down, and

risk of explosion and injury due to high tension

inside the refrigerant cycle.

• If the refrigerant comes in contact with a ame,

it produces a toxic gas.

• Do not add or replace refrigerant other than

specied type. It may cause product damage,

burst and injury, etc.

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• Do not leak refrigerant while piping work for an

installation or re-installation, and while repairing

refrigeration parts.

Handle liquid refrigerant carefully as it may cause

frostbite.

When Servicing

• Turn the power OFF at the main power box (mains)

before opening the unit to check or repair electrical

parts and wiring.

• Keep your ﬁngers and clothing away from any moving

parts.

• Clean up the site after you nish, remembering to

check that no metal scraps or bits of wiring have been

left inside the unit .

WARNING

• This product must not be modied or

disassembled under any circumstances.

Modied or disassembled unit may cause re,

electric shock or injury.

• Do not clean inside the indoor and outdoor

units by users. Engage authorized dealer or

specialist for cleaning.

• In case of malfunction of this appliance, do

not repair by yourself. Contact to the sales

dealer or service dealer for a repair.

WARNING

CAUTION

• Do not touch the air inlet or the sharp

aluminum ﬁns of the outdoor unit.You

may get injured.

• Ventilate any enclosed areas when installing or

testing the refrigeration system. Leaked

refrigerant gas, on contact with re or heat, can

produce dangerously toxic gas.

• Conrm after installation that no refrigerant gas

is leaking. If the gas comes in contact with a

burning stove, gas water heater, electric room

heater or other heat source, it can cause the

generation of toxic gas.

Others

WARNING

CAUTION

• Do not sit or step on the unit, you may

fall down accidentally.

• Do not touch the air inlet or the sharp

aluminum ﬁns of the outdoor unit.

You may get injured.

• Do not stick any object into the FAN

CASE.

You may be injured and the unit may

be damaged.

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

conditioner, is safe, without the toxicity or combustibility of

ammonia, and is not restricted by laws imposed to protect

the ozone layer. However, since it contains more than air,

it poses the risk of suffocation if its density should rise

excessively. Suffocation from leakage of refrigerant is

almost non-existent. With the recent increase in the

number of high density buildings, however, the installation

of multi air conditioner systems is on the increase

because of the need for effective use of oor 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 compared to

conventional individual air conditioners.

If a single unit of the multi air conditioner system is to be

installed in a small room, select a suitable model and

installation procedure so that if the refrigerant

accidentally leaks out, its density does not reach the limit

(and in the event of an emergency, measures can be

made before injury can occur).

ASHRAE and the International Mechanical Code of the

ICC as well as CSA provide guidance and dene

safeguards related to the use of refrigerants, all of which

dene a Refrigerant Concentration Level (RCL) of 400 oz

(11.3 kg) per 1,000 ft3(28.3 m3) for R410A refrigerant.

For additional guidance and precautions related to

refrigerant safety, please refer to the following documents:

International Mechanical Code 2012 (IMC-2012)

(or more recently revised)

ASHRAE 15

ASHRAE 34

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Precautions for Installation Using New Refrigerant

1. Care regarding tubing

1-1. Process tubing

●Material: Use seamless phosphorous deoxidized copper tube for refrigeration. Wall thickness shall comply with the

applicable legislation. The minimal wall thickness must be in accordance with the table below.

●Tubing size: Be sure to use the sizes indicated in the table below.

●Use a tube cutter when cutting the tubing, and be sure to remove any flash. This also applies to distribution joints

(optional).

●When bending tubing, use a bending radius that is 4 times the outer diameter of the tubing or larger.

CAUTION

Use sufficient care in handling the tubing. Seal the tubing ends with caps or tape to

prevent dirt, moisture, or other foreign substances from entering.

These substances can result in system malfunction.

Material: O Material: O

Outer diameter Wall thickness Outer diameter Wall thickness

1/4" (6.35) 0.025 (0.635) 7/8" (22.22) 0.045 (1.143)

3/8" (9.52) 0.030 (0.762) 1-1/8" (28.58) 0.050 (1.27)

1/2" (12.7) 0.035 (0.889) 1-3/8" (34.92) 0.055 (1.397)

5/8" (15.88) 0.040 (1.016) 1-5/8" (41.28) 0.060 (1.524)

3/4" (19.05) 0.042 (1.0668) Unit: in. (mm)

1-2. Prevent impurities including water, dust and oxide from entering the tubing. Impurities can cause R410A

refrigerant deterioration and compressor defects. Due to the features of the refrigerant and refrigerating machine

oil, the prevention of water and other impurities becomes more important than ever.

2. Be sure to recharge the refrigerant only in liquid form.

2-1. Since R410A is a non-azeotrope, recharging the refrigerant in gas form can lower performance and cause defects

in the unit.

2-2. Since refrigerant composition changes and performance decreases when gas leaks, collect the remaining

refrigerant and recharge the required total amount of new refrigerant after fixing the leak.

3. Different tools required

3-1. Tool specifications have been changed due to the characteristics of R410A.

Some tools for R22- and R407C-type refrigerant systems cannot be used.

Item New

tools?

R407C tools

compatible

with R410A?

Remarks

Manifold gauge Yes No Types of refrigerant, refrigerating machine oil, and

pressure gauge are different.

Charge hose Yes No To resist higher pressure, material must be changed.

Vacuum pump Yes Yes

Use a conventional vacuum pump if it is equipped with

a check valve. If it has no check valve, purchase and

attach a vacuum pump adapter.

Leak detector Yes No

Leak detectors for CFC and HCFC that react to chlorine

do not function because R410A contains no chlorine.

Leak detector for HFC134a can be used for R410A.

Flaring oil Yes No

For systems that use R22, apply mineral oil (Suniso

oil) to the flare nuts on the tubing to prevent refrigerant

leakage. For machines that use R407C or R410A, apply

synthetic oil (ether oil) to the flare nuts.

* Using tools for R22 and R407C and new tools for R410A together can cause defects.

Manifold gauge

Vacuum pump

Outlet

Inlet

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3-2. Use R410A exclusive cylinder only.

Single-outlet valve

(with siphon tube)

Liquid refrigerant should be recharged

with the cylinder standing on end as

shown.

New refrigerant R410A cannot be used for

earlier models

1. Compressor specifications are different.

If recharging a R22 or R407C compressor with

R410A, durability will significantly decrease since

some of the materials used for compressor parts are

different.

2. Existing tubing cannot be used (especially R22).

Completely cleaning out residual refrigerating

machine oil is impossible, even by flushing.

3. Refrigerating machine oil differs (R22).

Since R22 refrigerating machine oil is mineral oil, it

does not dissolve in R410A. Therefore, refrigerating

machine oil discharged from the compressor can

cause compressor damage.

R22 refrigerating machine oil Mineral oil (Suniso oil)

R407C refrigerating machine oil Synthetic fluid (ether oil)

R410A refrigerating machine oil Synthetic fluid (ether oil)

Valve

Liquid

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IMPORTANT! ............................. 2

Please Read Before Starting

Check of Density Limit

Precautions for Installation Using New Refrigerant

New refrigerant R410A cannot be used for earlier models

1. GENERAL............................. 7

1-1. Tools Required for Installation (not supplied)

1-2. Accessories Supplied

1-3. Type of Copper Tube and Insulation Material

1-4. Additional Materials Required for Installation

1-5. Tubing Length

1-6. Tubing Size

1-7. Straight Equivalent Length of Joints

1-8. Additional Refrigerant Charge

1-9. System Limitations

1-10. Check of Limit Density

1-11. Installing Distribution Joint

1-12. Optional Distribution Joint Kits

1-13. Example of Tubing Size Selection and

Refrigerant Charge Amount

2. SELECTING THE INSTALLATION SITE . . . . . 17

2-1. Outdoor Unit

2-2. Shield for Horizontal Exhaust Discharge

2-3. Installing the Outdoor Unit in Heavy Snow

Areas

2-4. Precautions When Installing in Heavy Snow

Areas

2-5. Dimensions of Wind Ducting

2-6. Dimensions of Snow Ducting

3. HOW TO INSTALL THE OUTDOOR UNIT. . . . 23

3-1. Transporting

3-2. Installing the Outdoor Unit

3-3. Routing the Tubing

3-4. Prepare the Tubing

3-5. Connect the Tubing

4. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 28

4-1. General Precautions on Wiring

4-2. Recommended Wire Length and Wire

Diameter for Power Supply System

4-3. Wiring System Diagram

5. HOW TO PROCESS TUBING . . . . . . . . . . . . . 34

5-1. Connecting the Refrigerant Tubing

5-2. Connecting Tubing Between Indoor and

Outdoor Units

5-3. Insulating the Refrigerant Tubing

5-4. Taping the Tubes

5-5. Finishing the Installation

6. AIRPURGING......................... 37

nAir Purging with a Vacuum Pump (for Test Run)

Preparation

7. TESTRUN............................ 40

7-1. Preparing for Test Run

7-2. Test Run Procedure

7-3. Main Outdoor Unit PCB Setting

7-4. Function Switches on P.C. Board

7-5. Auto Address Setting

7-6. Setting Test Run Remote Controller

7-7. Caution for Pump Down

7-8. Self-Diagnosis Function Table and Contents of

Alarm Display

CONTENTS

Page Page

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1-1. Tools Required for Installation (not supplied)

1. Flathead screwdriver

2. Phillips head screwdriver

3. Knife or wire stripper

4. Tape measure

5. Level gauge

6. Sabre saw or keyhole saw

7. Hacksaw

8. Core bits

9. Hammer

10. Drill

11. Tube cutter

12. Tube flaring tool

13. Torque wrench

14. Adjustable wrench

15. Reamer (for deburring)

1-2. Accessories Supplied

See Table 1.

1-3. Type of Copper Tube and Insulation Material

If you wish to purchase these materials separately from a local

source, you will need:

1. Deoxidized annealed copper tube for refrigerant tubing.

2. Foamed polyethylene insulation for copper tubes as

required to precise length of tubing. Wall thickness of the

insulation should be not less than 5/16" (7.94mm).

3. Use insulated copper wire for field wiring. Wire size varies

with the total length of wiring.

See the section

“

4. ELECTRICAL WIRING” for details.

CAUTION

Check local electrical codes and

regulations before obtaining

wire. Also, check any specified

instructions or limitations.

1-4. Additional Materials Required for Installation

1. Refrigeration (armored) tape

2. Insulated staples or clamps for connecting wire

(See your local codes.)

3. Putty

4. Refrigeration tubing lubricant

5. Clamps or saddles to secure refrigerant tubing

6. Scale for weighing

1. GENERAL

This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for

the outdoor unit and make sure all accessory parts listed are with the system before beginning.

Table 1 Outdoor Unit

Part name Figure

Q’ty

U-72ME2U9

U-72ME2U94

(6 ton)

U-96ME2U9

U-96ME2U94

(8 ton)

U-120ME2U9

U-120ME2U94

(10 ton)

U-144ME2U9

U-144ME2U94

(12 ton)

Connection

tubing

Outer

diameter

ø1-1/8"(ø28.58)

Inner

diameter

ø1"(ø25.4)

0011

Operating

Instructions paper 1111

Installation

Instructions paper 1111

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1-5. Tubing Length

Select the installation location so that the length and size of refrigerant tubing are within the allowable range show in the figure below.

NOTE

* Be sure to use special R410A distribution joints (CZ: optional parts) for outdoor unit connections and tubing branches.

Table 1-2 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights

unit: ft. (m)

Item Mark Contents Length

Allowable tubing

length

L1 Max. tubing length Actual length 656 (200)*2

Equivalent length 689 (210)*2

L (L2 – L4) Difference between max. length and min.

length from the No.1 distribution joint 164 (50)*4

LM Max. length of main tubing (at maximum size)

1, 2~ 64 Max. length of each distribution tube 164 (50)*6

L1 + 1 + 2~ 63 + A

+ B + LF + LG + LH

Total max. tubing length including length of each distribution

tube (only liquid tubing) 3280 (1000)

A, B + LO, C + LO Maximum tubing length from outdoor’s 1st distribution

joint to each outdoor unit 33 (10)

Allowable elevation

difference

H1 When outdoor unit is installed higher than indoor unit 164 (50)

When outdoor unit is installed lower than indoor unit 131 (40)

H2 Max. difference between indoor units 49 (15)*5

H3 Max. difference between outdoor units 13 (4)

Allowable length of

joint tubing L3 T-joint tubing (field-supply); Max. tubing length between the

first T-joint and solidly welded-shut end point 6.6 (2) L = Length

H = Height

NOTE

1: The outdoor connection main tubing (LO portion) is determined by the total capacity of the outdoor units that are connected to

the tube ends.

2: If the longest tubing length (L1) exceeds 295 ft. (90m) (equivalent length), increase the sizes of the main tubes (LM) by 1 rank for

gas tubes and liquid tubes. (Use a field supply reducer.) (Select the tube size from the table of main tube sizes (Table 1-3) on the

following page (LA table), and from the table of refrigerant tubing sizes (Table 1-9) on the second following page.)

3: If the longest main tubing length (LM) exceeds 164 ft. (50m), increase the main tube size at the portion before 164 ft. (50m) by 1

rank for the gas tubes. (Use a field supply reducer.)

(For the portion that exceeds 164 ft. (50m), set based on the main tube sizes (LA) listed in the table on the following page.)

4: If the tubing length marked "L" (L2 - L4) exceeds 131 ft. (40m), increase the liquid tube and gas tube by 1 rank.

5: If the total distribution tubing length exceeds 1,640ft. (500m), maximum allowable elevation difference (H2) between the indoor

units is calculated by the following formula. Make sure the indoor unit’s actual elevation difference should fall within the figure

calculated as follows.

Unit of account (feet): 49 x (2 - total tubing length(ft.) ÷ 1,640) or Unit of account (meter): 15 x (2 - total tubing length(m) ÷ 500)

6: If any of the tubing length exceeds 98ft. (30m), increase the size of the liquid and gas tubes by 1 rank.

R410A optional distribution joint

CZ-P680PJ1U (for outdoor unit)

CZ-P1350PJ1U (for outdoor unit)

CZ-P160BK1U (for indoor unit)

CZ-P680BK1U (for indoor unit)

CZ-P1350BK1U (for indoor unit)

LO LA

62 63 64

Balance tubing

(ø1/4" (6.35mm))

Explanation of symbols

No.1 distribution joint for outdoor unit

No.1 distribution joint (for indoor unit)

Distribution joint

(CZ: optional parts)

For

extension

For

extension

Max.1.3 ft (40cm)

Solidly welded shut

(pinch weld)

Ball valve (field supply)

T-joint (field supply)

1. Main tubing length (maximum tubing size) LM = LA + LB …

2. Main distribution tubes LC – LH are selected according to the capacity after the distribution joint.

3. The outdoor connection main tubing (LO portion) is determined by the total capacity of the outdoor units that are

connected to the tube ends.

4. Sizes of indoor unit connection tubing 1 – 64 are determined by the connection tubing sizes on the indoor units.

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1-6. Tubing Size

Table 1-3 Main Tubing Size (LA)

Between No.1 distribution joint for outdoor unit and No.1 distribution joint (for indoor unit) Unit: in. (mm)

BTU/h

(kW)

72,000

(21.1)

96,000

(28.1)

120,000

(35.2)

144,000

(42.2)

168,000

(49.2)

192,000

(56.3)

216,000

(63.3)

240,000

(70.3)

264,000

(77.4)

288,000

(84.4)

312,000

(91.4)

336,000

(98.4)

360,000

(105.5)

Total system

tonnage 6 8 10 12 14 16 18 20 22 24 26 28 30

Gas tubing ø3/4"

(ø19.05)

ø7/8"

(ø22.22)

ø1-1/8"

(ø28.58)

ø1-3/8"

(ø34.92)

ø1-5/8"

(ø41.28)

Liquid tubing ø3/8"

(ø9.52)

ø1/2"

(ø12.7)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

*1: If future extension is planned, select the tubing diameter based on the total tonnage after extension.

However, extension is not possible if the resulting tubing size is three ranks higher.

*2: The balance tube (outdoor unit tube) diameter is ø1/4" (6.35mm).

*3: Type 1 tubing should be used for the refrigerant tubes.

nSize of tubing (LO) between outdoor units

Select the size of tubing between outdoor units based on the main tubing size (LA) as given in the table above.

Table 1-4 Main Tubing Size After Distribution (LB, LC...) Unit: in. (mm)

Total capacity

after distribution

Below BTU/h (kW) 24,200

(7.09)

54,600

(16.0)

76,800

(22.5)

102,400

(30.0)

143,300

(42.0)

178,800

(52.4)

238,900

(70.0)

340,000

(99.6) –

Over BTU/h (kW) –24,200

(7.09)

54,600

(16.0)

76,800

(22.5)

102,400

(30.0)

143,300

(42.0)

178,800

(52.4)

238,900

(70.0)

340,000

(99.6)

Tubing size

Gas tubing ø1/2"

(ø12.7)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

ø7/8"

(ø22.22)

ø1-1/8"

(ø28.58)

ø1-1/8"

(ø28.58)

ø1-1/8"

(ø28.58)

ø1-3/8"

(ø34.92)

ø1-5/8"

(ø41.28)

Liquid tubing ø3/8"

(ø9.52)

ø3/8"

(ø9.52)

ø3/8"

(ø9.52)

ø3/8"

(ø9.52)

ø1/2"

(ø12.7)

ø1/2"

(ø12.7)

ø5/8"

(ø15.88)

ø3/4"

(ø19.05)

ø3/4"

(ø19.05)

Note: In case the total capacity of connected indoor units exceeds the total capacity of the outdoor units, select the main tubing size

for the total capacity of the outdoor units.

Table 1-5 Outdoor Unit Tubing Connection Size ( A –C) Unit: in. (mm)

BTU/h

(kW)

72,000

(21.1)

96,000

(28.1)

120,000

(35.2)

144,000

(42.2)

Gas tubing

ø3/4"

(ø19.05)

ø7/8"

(ø22.22)

ø1-1/8"

(ø28.58)

Brazing connection

Liquid tubing ø3/8" (ø9.52) ø3/8" (ø9.52) ø1/2" (ø12.7)

Flare connection

Balance tubing ø1/4" (ø6.35)

Flare connection

Table 1-6 Refrigerant Charge Amount at Shipment (for outdoor unit)

BTU/h (kW) 72,000 (21.1) 96,000 (28.1) 120,000 (35.2) 144,000 (42.2)

Initial amount oz (g)321 (9,100) 363 (10,300) 300 (8,500) 416 (11,800)

Table 1-7 Indoor Unit Tubing Connection Size Unit: in. (mm)

Indoor unit type 7 9 12 15 18 24 36 48 54

Gas tubing ø1/2" (ø12.7) ø5/8" (ø15.88)

Liquid tubing ø1/4" (ø6.35) ø3/8" (ø9.52)

ex.) type72

Balance

tube

Liquid tube Gas tube

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1-7. Straight Equivalent Length of Joints

Design the tubing system by referring to the following table for the straight equivalent length of joints.

Table 1-8 Straight Equivalent Length of Joints Unit: ft. (m)

Gas tubing size (in. (mm)) 1/2"

(12.7)

5/8"

(15.88)

3/4"

(19.05)

7/8"

(22.22)

1-1/8"

(28.58)

1-3/8"

(34.92)

1-5/8"

(41.28)

90° elbow 1

(0.30)

1.1

(0.35)

1.4

(0.42)

1.6

(0.48)

1.9

(0.57)

2.5

(0.76)

2.8

(0.85)

45° elbow 0.8

(0.23)

0.9

(0.26)

(0.32)

1.2

(0.36)

1.4

(0.43)

1.8

(0.55)

2.0

(0.61)

U-shape tube bent (R2-3/8" – 4" (60 – 100mm)) 3

(0.90)

3.4

(1.05)

4.1

(1.26)

4.7

(1.44)

5.6

(1.71)

7.4

(2.26)

8.4

(2.56)

Trap bend 7.5

(2.30)

9.2

(2.80)

10.5

(3.20)

12.5

(3.80)

15.4

(4.70)

19.2

(5.85)

22.3

(6.80)

Y-branch distribution joint Equivalent length conversion not needed.

Ball valve for service Equivalent length conversion not needed.

Table 1-9 Refrigerant tubing (Existing tubing can be used.)

Tubing size (in. (mm)) * When bending the tubes, use a

bending radius that is at least 4 times

the outer diameter of the tubes.

In addition, take sufficient care to

avoid crushing or damaging the tubes

when bending them.

Material: O Material: O Material: O

Outer diameter Wall thickness Outer diameter Wall thickness Outer diameter Wall thickness

1/4" (6.35) 0.025 (0.635) 5/8" (15.88) 0.040 (1.016) 1-1/8" (28.58) 0.050 (1.27)

3/8" (9.52) 0.030 (0.762) 3/4" (19.05) 0.042 (1.0668) 1-3/8" (34.92) 0.055 (1.397)

1/2" (12.7) 0.035 (0.889) 7/8" (22.22) 0.045 (1.143) 1-5/8" (41.28) 0.060 (1.524)

1-8. Additional Refrigerant Charge

Additional refrigerant charge amount is calculated from the liquid tubing total length, combination number of outdoor unit and

refrigerant amount according to all indoor unit cooling capacity.

Required amount of additional refrigerant charge

= [(Necessary amount of additional refrigerant charge per ft. (m) of each size of liquid tube x its tube length) + (...) + (...)]

+ [Necessary amount of additional refrigerant charge per outdoor unit]

+ [Necessary amount of additional refrigerant charge for all indoor unit cooling capacity]

* Always charge accurately using a scale for weighing.

Table 1-10-1 Necessary Amount of Additional Refrigerant Charge Per ft. (or per meter), According to Liquid Tubing Size

Liquid tubing size inch ø1/4" ø3/8" ø1/2" ø5/8" ø3/4" ø7/8"

(mm) (ø6.35) (ø9.52) (ø12.7) (ø15.88) (ø19.05) (ø22.22)

Additional amount oz/ft. 0.279 0.602 1.38 1.99 2.78 3.93

(g/m) (26) (56) (128) (185) (259) (366)

Table 1-10-2 Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit

Further charge a certain amount listed below in addition to the amount of refrigerant charge.

Combination number of outdoor unit 123

Additional amount oz (g)70.5 (2,000) 141.0 (4,000) 212 (6,000)

Necessary Amount of Additional Refrigerant Charge for All Indoor Unit Cooling Capacity

Charge a refrigerant amount calculated in the following formula according to the total amount of indoor unit cooling capacity.

Additional refrigerant amount when cooling capacity is BTU/h = Cooling capacity (BTU/h) x 1.034 x 0.001 + 10.6 (oz)

or Additional refrigerant amount when cooling capacity is kW = Cooling capacity (kW) x 1000 x 0.1 + 300 (g)

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1-9. System Limitations

Table 1-11 System Limitations

Max. No. allowable connected outdoor units 3 *2

Max. capacity allowable connected outdoor

units

360,000 BTU/h

(30 ton, 105.5 kW)

Max. connectable indoor units 64 *1

Max. allowable indoor/outdoor capacity ratio 50 – 200 % *3

*1: In the case of 18 ton (63.3kW) or smaller units, the number is

limited by the total capacity of the connected indoor units.

*2: Up to 3 units can be connected if the system has been extended.

*3: It is strongly recommended that you choose the unit so the load

can become between 50 and 130%.

Table 1-12 System Limitations of Total Refrigerant Amount

Combination number of outdoor unit 123

Upper limit oz (g)1,763 (50,000) 2,821 (80,000) 3,703 (105,000)

Make sure the values calculated using the following formula should not exceed the maximum allowable values (Table 1-12).

Total refrigerant amount = Refrigerant charge amount at shipment (for outdoor unit)

+ Necessary amount of additional refrigerant charge per ft. (or per meter) according to liquid tubing size

+ Necessary amount of additional refrigerant charge per outdoor unit

+ Necessary amount of additional refrigerant charge for all indoor unit cooling capacity

WARNING

CAUTION

Always check the gas density limit for the room in which the unit is installed.

1-10. Check of Limit Density

When installing an air conditioner in a room, it is necessary to ensure that even if the refrigerant gas accidentally leaks out, its

density does not exceed the limit level for that room.

Maximum number of connectable indoor units

when connected with minimum capacity

Total system

tonnage

Number of

indoor units

Total system

tonnage

Number of

indoor units

6 20 14 45

8 25 16 50

10 32 18 55

12 39 20~30 64

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1-11. Installing Distribution Joint

CAUTION

Pay special attention to any location, such as a basement, etc., where leaking refrigerant can

accumulate, since refrigerant gas is heavier than air.

(1) Refer to “HOW TO ATTACH DISTRIBUTION JOINT” enclosed with the optional distribution joint kit (CZ-P680PJ1U,

CZ-P1350PJ1U, CZ-P160BK1U, CZ-P680BK1U, CZ-P1350BK1U).

●When connecting a branch tubing to the indoor unit directly, it is necessary for each branch tubing to install at a positive angle

with respect to horizontal in order to prevent accumulation of refrigerant oil in stopped units. (See the below chart.)

Branch tubing system Restricted Not restricted

How to install

branch tubing

When connecting branch tubing to indoor unit directly

When not connecting

branch tubing to indoor

unit directly

Suction tube

* In case of common use solenoid valve kit Liquid tube / Discharge tube

Suction tube /

Discharge tube /

Liquid tube

When connecting to A When connecting to B

Horizontal

15〜90°

Straight tubing

length over

8 in. (200mm)

Arrow view D

15〜90°

15〜30°

15〜90°

15〜30°

Straight tubing

length over

8 in. (200mm)

(Branch tubing

angle)

Horizontal

Straight tubing length

over 8 in. (200mm)

0〜30°

(Branch tubing

angle)

Horizontal

Vertical

Upward

Vertical Vertical Vertical Vertical

Downward

15〜90°

Vertical

Straight tubing

length over

8 in. (200mm)

15〜90°

Straight tubing

length over

8 in. (200mm)

Vertical

Vertical Vertical

● Be sure to solidly weld shut the T-joint end (marked by X in

the figure). In addition, pay attention to the insertion depth

of each connected tube so that the flow of refrigerant within

the T-joint is not impeded.

Be sure to use a commercial available T-joint.

●When using the header joint system, do not make further

branches in the tubing.

●Do not use the header joint system on the outdoor unit

side.

Header branch system (Main tubing is horizontal.)

Outdoor

Indoor

(From 1st branch to tip

of solidly welded part)

Horizontal line

Install at a positive angle

(15~30°)

Install at a positive angle

(15~30°)

Solidly welded shut (X)

6.5 ft. (2m)

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1-12. Optional Distribution Joint Kits

See the installation instructions packaged with the distribution joint kit for the installation procedure.

Table 1-12

Model name Cooling capacity after distribution Remarks

1. CZ-P680PJ1U 232,000 BTU/h (68.0 kW) or less For outdoor unit

2. CZ-P1350PJ1U more than 232,000 BTU/h (68.0 kW) For outdoor unit

3. CZ-P160BK1U 76,400 BTU/h (22.4 kW) or less* For indoor unit

4. CZ-P680BK1U 232,000 BTU/h (68.0 kW) or less* For indoor unit

5. CZ-P1350BK1U more than 232,000 BTU/h (68.0 kW)* For indoor unit

nTubing size (with thermal insulation)

1. CZ-P680PJ1U

For outdoor unit (Capacity after distribution joint is 232,000 BTU/h (68.0 kW) or less.)

FEDC

6-59/64

(175)

5-5/16

(135)

4-21/64

(110)

(97)

3-13/16

4-31/64

(114)

2-53/64

(72)

Example: Gas tubing Liquid tubing

Distribution

Joint

Distribution

Joint

Reducing

Joints

Reducing

Joints

Unit: in. (mm)

Insulation

Table 1-13 Size of connection point on each part (Shown are inside diameters of tubing)

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm) ø1-3/8"

(ø34.92)

ø1-1/4"

(ø31.75)

ø1-1/8"

(ø28.58)

ø1"

(ø25.4)

ø7/8"

(ø22.22)

ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

2. CZ-P1350PJ1U

For outdoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW).)

(175)

(135)

(110)

(97)

4-31/64

(114)

2-53/64

(72)

H I

6-57/64

5-5/16

4-21/64

3-13/16

C C

D D

Example: Gas tubing Liquid tubing

Distribution

Joint Distribution

Joint

Insulation

: Outside dimension

Reducing

Joints

Reducing

Joints

Unit: in. (mm)

With regard to the diameter of the tube without description in Table 1-14, use a reducer (field supply) to adjust the tube diameter.

Table 1-14 Size of connection point on each part (Shown are inside diameters of tubing)

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I

in. (mm) ø1-3/8"

(ø34.92)

ø1-1/4"

(ø31.75)

ø1-1/8"

(ø28.58)

ø1"

(ø25.4)

ø7/8"

(ø22.22)

ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

* In case the total capacity of indoor

units connected after distribution

exceeds the total capacity of the

outdoor units, select the distribution

tube size for the total capacity of the

outdoor units.

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3. CZ-P160BK1U Use: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.)*

4-21/64

(110)

4-21/64

(110)

(97)

3-13/16 3-13/16

(97)

2-53/64

(72)

2-53/64

(72)

A D

B C

C D E

Example: Gas tubing Liquid tubing

Distribution

Joint

Distribution

Joint

Insulation Insulation

Unit: in. (mm)

Table 1-15 Size of connection point on each part (Shown are inside diameters of tubing)

Size Part A Part B Part C Part D Part E

in. (mm) ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

ø1/4"

(ø6.35)

4. CZ-P680BK1U Use: For indoor unit (Capacity after distribution joint is greater than 76,400 BTU/h (22.4 kW) and no more

than 232,000 BTU/h (68.0 kW).)*

6-57/64

(175)

5-5/16

(135)

4-21/64

(110)

(97)

3-13/16

B C D F GH

D C B EF

4-31/64

(114)

2-53/64

(72)

Example: Gas tubing Liquid tubing

Distribution

Joint

Distribution

Joint

Insulation

Reducing

Joints

Reducing

Joints

Unit: in. (mm)

Table 1-16 Size of connection point on each part (Shown are inside diameters of tubing)

Size Part A Part B Part C Part D Part E Part F Part G Part H

in. (mm) ø1-1/8"

(ø28.58)

ø1"

(ø25.4)

ø7/8"

(ø22.22)

ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

ø1/4"

(ø6.35)

5. CZ-P1350BK1U Use: For indoor unit (Capacity after distribution joint is greater than 232,000 BTU/h (68.0 kW).)*

(175)

(135)

4-21/64

(110)

(97)

3-13/16

4-31/64

(114)

2-53/64

(72)

6-57/64

5-5/16

F F

C D

Unit: in. (mm)

Gas tubing Liquid tubing

Example:

Distribution

Joint

Distribution

Joint

Insulation

Reducing

Joints

Reducing

Joints : Outside dimension

With regard to the diameter of the tube without description in Table 1-17, use a reducer (field supply) to adjust the tube diameter.

Table 1-17 Size of connection point on each part (Shown are inside diameters of tubing)

Size Part A Part B Part C Part D Part E Part F Part G Part H Part I Part J

in. (mm) ø1-3/8"

(ø34.92)

ø1-1/4"

(ø31.75)

ø1-1/8"

(ø28.58)

ø1"

(ø25.4)

ø7/8"

(ø22.22)

ø3/4"

(ø19.05)

ø5/8"

(ø15.88)

ø1/2"

(ø12.7)

ø3/8"

(ø9.52)

ø1/4"

(ø6.35)

In case the total capacity of indoor units connected after distribution exceeds the total capacity of the outdoor units, select the

distribution tube size for the total capacity of the outdoor units.

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1-13. Example of Tubing Size Selection and Refrigerant Charge Amount

Additional refrigerant charging

Based on the values in Tables 1-3, 4, 5, 7, 10-1 and 10-2, use the liquid tubing size and length, and calculate the amount of

additional refrigerant charge using the formula below.

Unit of account (oz)

Required additional

refrigerant charge (oz) =

Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit

+ 3.93 × (a) + 2.78 × (b) + 1.99 × (c) + 1.38 × (d) + 0.602 × (e) + 0.279 × (f)

+ Necessary amount of additional refrigerant charge for all indoor unit cooling capacity

Unit of account (g)

Required additional

refrigerant charge (g)=

Necessary Amount of Additional Refrigerant Charge Per Outdoor Unit

+ 366 × (a) + 259 × (b) + 185 × (c) + 128 × (d) + 56 × (e) + 26 × (f)

+ Necessary amount of additional refrigerant charge for all indoor unit cooling capacity

(a) : Liquid tubing Total length of ø7/8" (ft.) or (m) (d) : Liquid tubing Total length of ø1/2" (ft.) or (m)

(b) : Liquid tubing Total length of ø3/4" (ft.) or (m) (e) : Liquid tubing Total length of ø3/8" (ft.) or (m)

● Charging procedure

Be sure to charge with R410A refrigerant in liquid form.

1. After performing a vacuum, charge with refrigerant from the liquid tubing side.

At this time, all valves must be in the “fully closed” position.

2. If it was not possible to charge the designated amount, operate the system in Cooling mode while charging with refrigerant

from the gas tubing side. (This is performed at the time of the test run. For this, all valves must be in the “fully open” position.

However, if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valves fully closed.)

Charge with R410A refrigerant in liquid form.

With R410A refrigerant, charge while adjusting the amount being fed a little at a time in order to prevent liquid refrigerant from

backing up.

● After charging is completed, turn all valves to the “fully open” position.

● Replace the tubing covers as they were before.

CAUTION

1. R410A additional charging absolutely must be done through liquid charging.

2. The R410A refrigerant cylinder has a gray base color, and the top part is pink.

3. The R410A refrigerant cylinder includes a siphon tube. Check that the siphon tube is present.

(This is indicated on the label at the top of the cylinder.)

4. Due to differences in the refrigerant, pressure, and refrigerant oil involved in installation, it is

not possible in some cases to use the same tools for R22 and for R410A.

For type 72 For type 96 For type 120/144

Balance tube

Use a flathead screwdriver and

open by turning the part with the