Sanyo Mini ECO-i SPW-ASR74GXH56(A/B) User manual

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RC
WT
85464359780000 ©SANYO 2005 SANYO Electric Co., Ltd.
Gunma, Japan
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– Mini ECO-i System Air Conditioner –
INSTALLATION INSTRUCTIONS
■R410A Models
Indoor Units
Outdoor Units
Indoor Unit Type 7 9 12 16 18 25 36 48
AS 1-Way Air Discharge SPW- SPW- SPW-
Semi-Concealed ASR74GXH56(A/B) ASR94GXH56(A/B) ASR124GXH56(A/B)
LD 1-Way Air Discharge SPW- SPW- SPW- SPW-
Semi-Concealed Slim LDR94GXH56(A/B) LDR124GXH56(A/B) LDR184GXH56(A/B) LDR254GXH56(A/B)
S 2-Way Air Discharge SPW- SPW- SPW- SPW- SPW- SPW-
Semi-Concealed SR74GXH56(A/B) SR94GXH56(A/B) SR124GXH56(A/B) SR164GXH56(A/B) SR184GXH56(A/B) SR254GXH56(A/B)
X 4-Way Air Discharge SPW- SPW- SPW- SPW- SPW- SPW- SPW- SPW-
Semi-Concealed* XDR74GXH56(A/B) XDR94GXH56(A/B) XDR124GXH56(A/B) XDR164GXH56(A/B) XDR184GXH56(A/B) XDR254GXH56(A/B) XDR364GXH56(A/B) XDR484GXH56(A/B)
K Wall-Mounted SPW- SPW- SPW- SPW- SPW- SPW-
KR74GXH56(A/B) KR94GXH56(A/B) KR124GXH56(A/B) KR164GXH56(A/B) KR184GXH56(A/B) KR254GXH56(A/B)
T Ceiling-Mounted SPW- SPW- SPW- SPW- SPW- SPW-
TDR124GXH56(A/B) TDR164GXH56(A/B) TDR184GXH56(A/B) TDR254GXH56(A/B) TDR364GXH56(A/B) TDR484GXH56(A/B)
U Concealed-Duct SPW- SPW- SPW- SPW- SPW- SPW- SPW- SPW-
UR74GXH56(A/B) UR94GXH56(A/B) UR124GXH56(A/B) UR164GXH56(A/B) UR184GXH56(A/B) UR254GXH56(A/B) UR364GXH56(A/B) UR484GXH56(A/B)
D Concealed-Duct SPW- SPW- SPW-
High Static Pressure* DR254GXH56(A/B) DR364GXH56(A/B) DR484GXH56(A/B)
F Floor-Standing SPW- SPW- SPW- SPW- SPW- SPW-
FR74GXH56(A/B) FR94GXH56(A/B) FR124GXH56(A/B) FR164GXH56(A/B) FR184GXH56(A/B) FR254GXH56(A/B)
FM Concealed-Floor- SPW- SPW- SPW- SPW- SPW- SPW-
Standing FMR74GXH56(A/B) FMR94GXH56(A/B) FMR124GXH56(A/B) FMR164GXH56(A/B) FMR184GXH56(A/B) FMR254GXH56(A/B)
* SPW-XDR604GXH56(A/B) is also available.
* SPW-DR764GXH56(A/B) and DR964GXH56(A/B) are also available.
* Refrigerant R410A is used in the outdoor units.
C
Heat Pump Unit SPW-CR365GXH56, SPW-CR485GXH56, SPW-CR605GXH56
Cooling Unit SPW-CR365GX56, SPW-CR485GX56, SPW-CR605GX56
Optional Controllers
Remote Controller RCS-SH80AG
Wireless Remote Controller (For X type) RCS-SH80AG.WL
Wireless Remote Controller (For S, LD type) RCS-TH80AG.WL
Wireless Remote Controller (For T type) RCS-TRP80ANG.WL
RC Wireless Remote Controller (For AS, U, D, F, FM type) RCS-BH80AG.WL
Wireless Remote Controller (For K type) RCS-SH1AG
Simplified Remote Controller RCS-KR1AG
Remote Sensor ART-K45AG
System Controller SHA-KC64AG
Schedule Timer SHA-TM64AG
for Refrigerant R410A
05-194 5/27/05 5:06 PM Page a

2
IMPORTANT!
Please Read Before Starting
This air conditioning system meets strict safety and operat-
ing 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.
●Observe all local, state, and national electrical codes.
●This product is intended for professional use.
Permission from the power supplier is required when
installing an outdoor unit that is connected to a 16 A
distribution network.
●Pay close attention to all warning and caution notices
given in this manual.
This symbol refers to a hazard or
unsafe practice which can result
in severe personal injury or death.
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 fail-
ure to follow the instructions in this document.
SPECIAL PRECAUTIONS
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 sys-
tem. Carefully refer to the wiring diagram and these
instructions when wiring. Improper connections and inad-
equate 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 fire hazard.
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…
…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.
…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 baffle.
…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
• Ventilate the room well, 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 poisonous gas.
• Keep all tubing runs as short as possible.
• Use the flare method for connecting tubing.
• Apply refrigerant lubricant to the matching surfaces of
the flare and union tubes before connecting them, then
tighten the nut with a torque wrench for a leak-free con-
nection.
• Check carefully for leaks before starting the test run.
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 finish, remembering to check
that no metal scraps or bits of wiring have been left
inside the unit being serviced.
Ventilate any enclosed areas when installing or testing
the refrigeration system. Escaped refrigerant gas, on
contact with fire or heat, can produce dangerously toxic
gas.
• Confirm after installation that no refrigerant gas is leak-
ing. 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 poisonous gas.
WARNING
WARNING
CAUTION
CAUTION
05-194 5/27/05 5:06 PM Page 2

3
2. The standards for minimum room volume are as
follows.
(1) No partition (shaded portion)
(2) When there is an effective opening with the adja-
cent room for ventilation of leaking refrigerant gas
(opening without a door, or an opening 0.15% or
larger than the respective floor 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 vol-
ume of the next smallest room becomes the object.
3. The minimum indoor floor space compared with the
amount of refrigerant is roughly as follows (when
the ceiling is 2.7 m high):
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 con-
ditioners is 0.3 kg/m3(ISO 5149).
1. If there are 2 or more refrigerating systems in a sin-
gle refrigerating device, the amount of refrigerant
should be as charged in each independent device.
For the amount of charge in this example:
The possible amount of leaked refrigerant gas in rooms
A, B and C is 10 kg.
The possible amount of leaked refrigerant gas in rooms
D, E and F is 15 kg.
NOTE
Outdoor unit
Refrigerant tubing
Indoor unit
e.g., charged
amount (10 kg)
Outdoor unit
Indoor unit
Room A Room B Room C Room D Room E Room F
e.g., charged
amount (15 kg)
Refrigerant tubing
Outdoor unit
Very
small
room Indoor unit
Small
room Medium room Large room
Mechanical ventilation device –Gas leak detector
40
35
30
25
20
15
10
5
010 20 30
Total amount of refrigerant
Min. indoor floor space
m
2
kg
Range below the
density limit
of 0.3 kg/m
3
(countermeasures
not needed)
Range above
the density limit
of 0.3 kg/m
3
(countermeasures
needed)
05-194 5/27/05 5:06 PM Page 3

New
tool?
4
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 of 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.
Unit: mm
Material O
Copper tube Outer diameter 6.35 9.52 12.7 15.88 19.05
Wall thickness 0.8 0.8 0.8 1.0 1.0
R407C tools
Item compatible Remarks
with R410A?
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.
Precautions for Installation Using New Refrigerant
1. Care regarding tubing
1-1. Process tubing
●Material: Use C1220 phosphorous deoxidized copper specified in JIS H3300 “Copper and Copper Alloy Seam-
less Pipes and Tubes.”
●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.
* Using tools for R22 and R407C and new tools for R410A together can cause defects.
Manifold gauge
Vacuum pump
Outlet
Inlet
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.
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5
Valve
Liquid
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.
05-194 5/27/05 5:06 PM Page 5

6. AIR PURGING . . . . . . . . . . . . . . . . . . . . . . . . .34
■Air Purging with a Vacuum Pump (for Test Run)
Preparation
7. TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
7-1. Preparing for Test Run
7-2. Test Run Procedure
7-3. Main Outdoor Unit PCB Setting
7-4. Auto Address Setting
7-5. Caution for Pump Down
7-6. Meaning of Alarm Messages
Page
6
IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Please Read Before Starting
Check of Density Limit
Precautions for Installation Using New Refrigerant
1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1-1. Tools Required for Installation (not supplied)
1-2. Accessories Supplied with Unit
1-3. Type of Copper Tube and Insulation Material
1-4. Additional Materials Required for Installation
1-5. Tubing Size
1-6. Straight Equivalent Length of Joints
1-7. Additional Refrigerant Charge
1-8. System Limitations
1-9. Tubing Length
1-10. Check of Limit Density
1-11. Installing Distribution Joint
1-12. Optional Distribution Joint Kit
1-13. Optional Ball Valve Kit
1-14. Recommended Location of Ball Valves
1-15. Example of Tubing Size Selection and
Refrigerant Charge Amount
2. SELECTING THE INSTALLATION SITE . . . . .17
2-1. Indoor Unit
2-2. Outdoor Unit
2-3. Air-Discharge Chamber for Top Discharge
2-4. Installing the Unit in Heavy Snow Areas
2-5. Precautions for Installation in Heavy Snow
Areas
2-6. Dimensions of Air-Discharge Chamber
2-7. Dimensions of Outdoor Unit with
Air-Discharge Chamber (field supply)
2-8. Dimensions of Snow Ducting
2-9. Dimensions of Outdoor Unit with Snow-Proof
Vents (field supply)
3. HOW TO INSTALL THE OUTDOOR UNIT . . .25
3-1. Installing the Outdoor Unit
3-2. Drainage Work
3-3. Routing the Tubing and Wiring
4. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . .26
4-1. General Precautions on Wiring
4-2. Recommended Wire Length and Wire
Diameter for Power Supply System
4-3. Wiring System Diagrams
5. HOW TO PROCESS TUBING . . . . . . . . . . . . .30
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
CONTENTS
Page
05-194 5/27/05 5:06 PM Page 6

7
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.
1-1. Tools Required for Installation (not supplied)
1. Standard screwdriver
2. Phillips head screwdriver
3. Knife or wire stripper
4. Tape measure
5. Carpenter’s level
6. Sabre saw or key hole 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 with Outdoor Unit
See Table 1-1.
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 8 mm.
3. Use insulated copper wire for field wiring. Wire
size varies with the total length of wiring. Refer to
5. ELECTRICAL WIRING for details.
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
CAUTION
Check local electrical codes
and regulations before
obtaining wire. Also, check
any specified instructions
or limitations.
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8
Table 1-4 Indoor Unit Tubing Connection ( 1, 2... n–1)
(mm) ø15.88
ø9.52 Unit: mm ø6.35
ø12.7
Gas tubing
(mm)
Liquid tubing
Indoor unit type 791216
18 25 36 48 60
ø9.52
ø15.88
ø9.52
ø12.7
(mm)
(mm)
–
7.1
(2.5 hp)
7.1
( 2.5 hp)
11.2
(4 hp)
14.0
(5 hp)
ø19.05
15.5
(6 hp)
Below kW
Over kW
Total capacity
after distribution
Tubing size Gas tubing
Liquid tubing hp = horsepower
Unit: mm
1-5. Tubing Size
Table 1-2 Main Tubing Size (LA)
ø19.05
6
Unit: mm
15.5
14.0
5
ø9.52
ø15.88
4
11.2
kW
System
horsepower
Gas tubing
(mm)
Liquid tubing
(mm)
Table 1-3 Main Tubing Size After Distribution (LB, LC...)
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 1-1 (Outdoor Unit)
Figure
Qty
Tube Discharge
Assy
1
Part name
0
1
0
1
1
Instruction manual paper
hp = horsepower
365 Model
(4 hp)
485 Model
(5 hp)
605 Model
(6 hp)
05-194 5/27/05 5:06 PM Page 8

9
1-7. Additional Refrigerant Charge
Additional refrigerant charge amount is calculated from the liquid tubing total length as follows.
Table 1-7 Amount of Refrigerant Charge Per Meter, According to Liquid Tubing Size
Material O
Copper tubing Outer diameter 6.35 9.52 12.7 15.88
Wall thickness 0.8 0.8 0.8 1.0 1.0
19.05
Narrow tubing size Amount of refrigerant
charge/m (g/m)
φ6.35 26
φ9.52 56
Required amount of charge = (Amount of refrigerant
charge per meter of each size of liquid tube ×its tube
length) + (...) + (...)
*Always charge accurately using a scale for weighing.
Table 1-6 Required Copper Tubing Dimensions Unit: mm
Table 1-8 Refrigerant Charge Amount at Shipment (for outdoor unit)
1-8. System Limitations
Table 1-9 System Limitations
Number of max. connectable indoor units
Outdoor units (Type) 365
6
485
8
605
9
Max. allowable indoor/outdoor capacity ratio 50 130%
Heat pump unit SPW-CR365GXH56
3.5
SPW-CR365GX56
3.5
SPW-CR485GXH56
3.5
SPW-CR485GX56
3.5
SPW-CR605GXH56
3.5
SPW-CR605GX56
3.5
(kg)
(kg)
Cooling only unit
Gas tubing size (mm)
90°elbow
45°elbow
U-shape tube bend (R60 100 mm)
Trap bend
12.7
0.30
0.23
0.90
2.30
15.88
0.35
0.26
1.05
2.80
19.05
0.42
0.32
1.26
3.20
Y-branch distribution joint Equivalent length conversion not needed.
Ball valve for service Equivalent length conversion not needed.
1-6. Straight Equivalent Length of Joints
Design the tubing system by referring to the following table for the straight equivalent length of joints.
Table 1-5 Straight Equivalent Length of Joints
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10
1-9. Tubing Length
Table 1-10 Ranges that Apply to Refrigerant Tubing Lengths and to Differences in Installation Heights
R410A distribution joint
APR-RP160AG (for indoor unit)
Note: Do not use commercially available T-joints for the liquid tubing.
H2
LD
L1
L2
LCLB
LA
* Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor
unit connections and tubing branches.
Main tube of unit
1st branch
Unit distribution tube
12 3 n-1
n
L3
H1
Items Marks Contents Length (m)
L1 Max. tubing length Actual length 150
Equivalent length 175
L (L2 –L3) Difference between max. length and min. 40
length from the No.1 distribution joint
1, 2~ nMax. length of each distribution tube 30
1+2+~ n–1
Total max. tubing length including length of 200
each distribution tube (only narrow tubing)
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
L = Length, H = Height
Allowable tubing
length
>
>
Allowable elevation
difference
>
>
>
>
>
>
+L1
Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown
in the figure below.
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11
WARNING
Always check the gas den-
sity 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 neces-
sary to ensure that even if the refrigerant gas acciden-
tally leaks out, its density does not exceed the limit
level for that room.
If the density could exceed the limit level, it is neces-
sary to provide an opening between the unit and the
adjacent room, or to install mechanical ventilation
which is interlocked with the leak detector.
(Total refrigerant charged amount: kg)
(Min. indoor volume where the indoor unit is installed: m3)
≤Limit density 0.3 (kg/m3)
The limit density of refrigerant which is used in this unit
is 0.3 kg/m3(ISO 5149).
The shipped outdoor unit comes charged with the
amount of refrigerant fixed for each type, so add it to
the amount that is charged in the field. (For the refriger-
ant charge amount at shipment, refer to the unit’s
nameplate.)
1-11. Installing Distribution Joint
(1) Refer to “HOW TO ATTACH DISTRIBUTION
JOINT”enclosed with the optional distribution joint
kit (APR-RP160AG).
(2) In order to prevent accumulation of refrigerant oil in
stopped units, if the main tubing is horizontal then
each branch tubing length should be at an angle that
is greater than horizontal. If the main tubing is verti-
cal, provide a raised starting portion for each branch.
(3) If there are height differences between indoor units
or if branch tubing that follows a distribution joint is
connected to only 1 unit, a trap or ball valve must be
added to that distribution joint. (When adding the ball
valve, locate it within 40 cm of the distribution joint.)
(Consult with SANYO separately concerning the
ball valve.)
If a trap or ball valve is not added, do not operate
the system before repairs to a malfunctioning
unit are completed. (The refrigerant oil sent
through the tubing to the malfunctioning unit will
accumulate and may damage the compressor.)
Minimum indoor volume & floor area as against the
amount of refrigerant is roughly as given in the follow-
ing table.
40.5
54.0
20 30 40 50 60 70 80 kg
67.5
81.0
94.5
108.0
121.5
135.0
148.5
162.0
175.5
189.0
202.5
216.0
229.5
243.0
256.5
270.0
m
2
m
3
Total amount of refrigerant
Min. indoor floor area (when the ceiling is 2.7 m high)
Min. indoor volume
Range below the
density limit of
0.3 kg/m
3
(Countermeasures
not needed)
Range above the
density limit of
0.3 kg/m
3
(Countermeasures
needed)
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
15 to 30°
B
A
BA
Tube branching methods (horizontal use)
Arrow view
Horizontal
line View as seen
from arrow
Ball valve
(BV: purchased
separately)
Main tubing
Types of vertical trap specifications
(If only 1 unit is connected, a ball
valve is also needed on this side.)
Indoor unit (1)
(When not using ball valve)
(When using ball valve)
Branch tubing is
directed upward.
(Each unit is
connected to tubing
that is either level or
is directed
downward.)
Main tubing
Indoor unit
More than
20 cm
Indoor unit (more than 2 units)
Horizontal
Indoor unit is directed downward
CAUTION
Pay special attention to any
location, such as a basement,
etc., where leaking refrigerant
can accumulate, since refrig-
erant gas is heavier than air.
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12
APR-RP160AG
Use: For indoor unit (Capacity after distribution joint is 22.4 kW or less.)
Table 1-12 Dimension for Connections of Each Part Unit: mm
210 55
145 135
185
83
103
F
HG F
FG
H
GH JJ
J
F
F
Insulator Insulator
Gas tube Liquid tube
Example: (F below indicates inner diameter. below indicates outer diameter.)
FFH
H
H
50
I
I
I
•When creating a tube of diameter G,
use a tube cutter and cut between F
and H. Cut at a point as close to H
as possible.
Position A B C D E F G H I J
Dimension –– – – –
φ19.05 φ15.88 φ12.7 φ9.52 φ6.35
1-12. Optional Distribution Joint Kit
See the installation instructions packaged with the distribution joint kit for the installation procedure.
Table 1-11
Model name Cooling capacity after distribution Remarks
APR-RP160AG 22.4 kW or less For indoor unit
1-13. Optional Ball Valve Kit
Table 1-13
1. Because the diameter of this ball valve is approximately the same as the inner diameter of the connecting cop-
per tube, correction for pressure loss is not necessary.
2. Airtightness must be 3.6 MPa or more.
It is recommended that the ball valve is installed at each outdoor unit (gas tube and liquid tube), in order to
prevent refrigerant from being released into the atmosphere if the outdoor unit is eventually replaced.
NOTE
Model No. Gas tube Liquid tube
BV-RXP160AG 15.88
BV-RXP56AG 12.7
9.52
6.35
Valve connecting tube size (mm) Indoor unit where used
16.0 kW or less
5.6 kW or less
Total capacity of indoor units
after the valve
A
E
D
C
Service port
30˚
Insulator
(divided in 2)
ø6.35 (1/4")
ø9.52 (3/8")
ø12.7 (1/2")
ø15.88 (5/8")
ABCDE
72
76
89
108
42
42
42
51
54
54
58
68
16
16
20
22
44
44
51
56
Type with flare nut at each end
Dimensions
Size
Figure
Dimensions Unit: mm
Note: Install the service port so that it faces the extension side.
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13
Ball Valve Installation (for refrigerant R410A only)
Check the size of the ball valve set you separately purchased.
1. Installing the ball valve
(1) If the ball valve is to be installed for indoor unit
extension, or near an indoor unit, install it so that
the service port faces the indoor unit side.
(This facilitates indoor unit leak testing and vacu-
um procedures.)
Install the ball valve as close as possible to the
distribution joint.
CAUTION
This ball valve is for use
only in systems that utilize
refrigerant R410A. The ser-
vice port connection size is
φφ7.94. The face-to-face dis-
tance between the φφ12.7 or
φφ15.88 flare nuts is 26 mm
or 29 mm, respectively.
Be sure to use only the
supplied flare nuts. Be
careful to use the correct
tools and materials.
2. Flare nut tightening
The flare nut on the service port side is fully tight-
ened. Recommended tightening torque is
(8~10 N·m).
If the valve is used for extension, it can be used
as-is. In all other cases, use 2 monkey wrenches
in combination to loosen the flare nut.
Outdoor unit
Indoor
Indoor unit
Service
port
Ball valve Outdoor
Indoor unit extension
Model name Size
BV-RXP56AG φ6.35 •φ12.7
BV-RXP160AG φ9.52 •φ15.88
Service port
Fully tightened (this side only)
Plug
(this side only)
Cool with damp shopcloth or other
means when heating brazed plug
with torch.
Service port
Tightening torque (8~10 N•m)
Valve cap
Tightening torque (19~21 N•m)
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14
1-14. Recommended Location of Ball Valves
●Select a valve location that allows service to be easily provided for each unit or each refrigerant system.
(1) When adding ball valve for indoor unit
1. Location: Install the ball valve at the distribution tube (not main tube).
2. Installation requirements
•Be sure to install the ball valve up-grade to prevent the inadvertent flow of oil.
•Install the ball valve at the shortest distance (within 40 cm) from the main tube. If the diameter of the ball valve
is smaller than that of the main tube, use a reducer or the like to reduce the size of the tubing at that location.
•Select a place where it is easy to operate, using careful consideration of the location in advance.
Outdoor unit
Distribution tube
Distribution joint
Main tube
Ball valve (for extension)
Less than 40 cm
Indoor unit for extension
Distribution tube
Main tube
Ball valve (for extension)
Indoor unit for extension
3. Opening and closing the valve
This valve is open at the time of shipment from the
factory. If the valve is used for extension, be sure
to close it.
4. Installing thermal insulation
The thermal insulation used for a flare-nut type
valve is in the form of a bag. When the valve is
used for extension, it can be used as-is. If the
valve is used for any other purpose, use a box
cutter or similar tool to cut away the part shown in
the figure at right.
The insulation is divided into 2 parts. After per-
forming the leak test, use vinyl tape or other
means to temporarily fasten the 2 parts together.
Then carry out final finishing.
Valve opened Spindle Valve closed Spindle
Notch
Insulator
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15
1-15. Example of Tubing Size Selection and Refrigerant Charge Amount
Additional refrigerant charging
Based on the values in Tables 1-2, 1-3, 1-4 and 1-7, use the liquid tubing size and length, and calculate the
amount of additional refrigerant charge using the formula below.
= [56 ×(a) + 26 ×(b)] ×10–3
(a): Liquid tubing Total length of φ9.52 (m) (b): Liquid tubing Total length of φ6.35 (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.)
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.
Required additional
refrigerant charge (kg)
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.
1
3
4
2
Tightening torque for valve stem cap: 19~21 N·m
Tightening torque for valve stem cap: 28~32 N·m
Tightening torque: 34~42 N·m
Tightening torque: 68~82 N·m
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16
Checking of limit density
Density limit is determined on the basis of the size of a
room using an indoor unit of minimum capacity. For
instance, when an indoor unit is used in a room (floor
area 7.43 m2×ceiling height 2.7 m = room volume
20.06 m3), the graph at right shows that the minimum
room volume should be 14.1 m3(floor area 5.2 m2) for
refrigerant of 4.238 kg. Accordingly, openings such as
louvers are required for this room.
<Determination by calculation>
Overall refrigerant charge amount for the air conditioner: kg
(Minimum room volume for indoor unit: m3)
= 4.238 (kg) + 3.5 (kg) = 0.39 (kg/m3) ≥0.3 (kg/m3)
20.06 (m3)
Therefore, openings such as louvers are required for
this room.
●Obtain charge amount for each tubing size
Note that the charge amounts per 1 meter are different for each liquid tubing size.
φ9.52 →LA + LB + LC + LD : 65 m ×0.056 kg/m = 3.64 kg
φ6.35 →1 + 2 + 3 + 4 + 5 : 23 m ×0.026 kg/m = 0.598 kg
Total 4.238 kg
Additional refrigerant charge amount is 4.238 kg.
Be sure to check the limit densi-
ty for the room in which the
indoor unit is installed.
CAUTION
●Example of each tubing length
Main tubing Distribution joint tubing
LA = 40 m Indoor side
LB = 5 m 1 = 5 m 4 = 6 m
LC = 5 m 2 = 5 m 5 = 5 m
LD = 15 m 3 = 2 m
LN
L1
L2
LCLB
LA
Main tube of unit
1st branch
model 74 model 94 model 124 model 164
model 184
Unit distribution tube 12 3 n–1
n
Example:
40
35
30
25
20
15
10
5
0
108.0
94.5
81.0
67.5
54.0
40.5
27.0
13.5
010 20 30
Total amount of refrigerant
Min. indoor floor area
(when the ceiling is 2.7 m high)
m
2
kg
Range below the
density limit
of 0.3 kg/m
3
(countermeasures
not needed)
Range above
the density limit
of 0.3 kg/m
3
(countermeasures
needed)
m
3
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17
2. SELECTING THE INSTALLATION SITE
2-1. Indoor Unit
AVOID:
●areas where leakage of flammable gas may be
expected.
●places where large amounts of oil mist exist.
●direct sunlight.
●locations near heat sources which may affect the
performance of the unit.
●locations where external air may enter the room
directly. This may cause “sweating”on the air dis-
charge ports, causing them to spray or drip.
●locations where the remote controller will be splashed
with water or affected by dampness or humidity.
●installing the remote controller behind curtains or fur-
niture.
●locations where high-frequency emissions are gener-
ated.
DO:
●select an appropriate position from which every cor-
ner of the room can be uniformly cooled.
●select a location where the ceiling is strong enough
to support the weight of the unit.
●select a location where tubing and drain pipe have
the shortest run to the outdoor unit.
●allow room for operation and maintenance as well as
unrestricted air flow around the unit.
●install the unit within the maximum elevation differ-
ence above or below the outdoor unit and within a
total tubing length (L) from the outdoor unit as
detailed in Table 1-10.
●allow room for mounting the remote controller about
1m off the floor, in an area that is not in direct sun-
light nor in the flow of cool air from the indoor unit.
Air delivery will be degraded if the distance from the
floor to the ceiling is greater than 3 m (for SL type,
greater than 3.5 m).
NOTE
Concealed-Duct Type
4-Way Semi-Concealed Type
1m
1m 1m
1m
1m
2-Way,
Wall-Mounted Type
min.15 cm
Front View
min.
15 cm
min.
15 cm
Floor-Standing, Concealed Floor-Standing Type
min.
10 cm
min. 100 cm
min.
10 cm min. 100 cm
Horizontal view Vertical view
Ceiling-Mounted Type
Side view
min. 25 cm
The rear of the indoor unit can be installed flush
against the wall.
min. 50 cm Air intake
Air
discharge
min. 25 cm
Ceiling
Wall
NOTE
Front view
Max. 25 cm
Obstacle
Fig. 2-1
Fig. 2-2
20cm
20cm
100
cm
20cm
100cm
min. 5 cm
min. 5 cm
min. 1 m
Air
intake
Air
discharge
Obstacle
Ceiling
Wall
Wall
Side view
Semi-Concealed Type Semi-Concealed Slim Type
1-Way Semi-Concealed & Slim Type
Fig. 2-3
Fig. 2-5
Fig. 2-4
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18
2-2. Outdoor Unit
AVOID:
●heat sources, exhaust fans, etc. (Fig. 2-6)
●damp, humid or uneven locations
DO:
●choose a place as cool as possible.
●choose a place that is well ventilated and outside
air temperature does not exceed maximum 45°C
constantly.
●allow enough room around the unit for air intake/
exhaust and possible maintenance. (Fig. 2-7)
●use lug bolts or equal to bolt down unit, reducing
vibration and noise.
Installation space
Distance between obstructions and the unit air inlet
and outlet must be as shown below.
Fig. 2-6
Fig. 2-8
Fig. 2-9
Out-
door
unit
Heat source
Hot air
Exhaust fan
Anchor bolts
(4 pieces)
In case of multiple installations
●provide a solid base (concrete block, 10 ×40 cm
beams or equal), a minimum of 15 cm above
ground level to reduce humidity and protect the unit
against possible water damage and decreased ser-
vice life. (Fig. 2-9)
●use lug bolts or equal to bolt down unit, reducing
vibration and noise.
*4
*1
*2
*3
*1
More than 1 cm
More than
100 cm
More than 1 cm
Inlet side C
Inlet side
More than 20 cm
Outlet side
(field supply)
AB
(Ground)
Air direction chamber
(Obstruction above unit)
(Obstruction on
inlet side)
CAUTION
●Concerning inlet-side distance “C”(Fig. 2-7)
The minimum for distance “C”is 15 cm if there are no obstructions on the outlet side
(wall *1 side) and *2 or *4 is not present. In all other cases, the minimum for distance
“C”is 20 cm.
●If the unit is installed with the outlet side facing wall *1, then there must be no obstruc-
tions on 2 of the remaining 3 sides: *2, *3, *4.
●If wall *1 is on the outlet side (Fig. 2-7), or if obstructions are present on all 3 sides *2,
*3, and *4 (Fig. 2-7), then the minimum distance for “A”and “B”is 2 m (Fig. 2-9). Even
if there is no wall on the outlet side, a minimum of 100 cm is required.
Fig. 2-7
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19
Fig. 2-10
Fig. 2-11
Fig. 2-12
2-3. Air Discharge Chamber for Top Discharge
Be sure to install an air discharge chamber in the
field when:
●it is difficult to keep a space of min. 50 cm between
the air discharge outlet and an obstacle.
●the air discharge outlet is facing a sidewalk and
discharged hot air may annoy passers-by.
Refer to Fig. 2-10.
2-4. Installing the Unit in Heavy Snow Areas
In locations with strong wind, snow-proof ducting
should be fitted and direct exposure to the wind
should be avoided as much as possible.
■Countermeasures against snow and wind
In regions with snow and strong wind, the following
problems may occur when the outdoor unit is not pro-
vided with a platform and snow-proof ducting:
a) The outdoor fan may not run and damage to the
unit may occur.
b) There may be no air flow.
c) The tubing may freeze and burst.
d) The condenser pressure may drop because of
strong wind, and the indoor unit may freeze.
2-5. Precautions for Installation in Heavy Snow
Areas
(1) The platform should be higher than the max. snow
depth. (Fig. 2-11)
(2) The 2 anchoring feet of the outdoor unit should be
used for the platform, and the platform should be
installed beneath the air intake side of outdoor
unit.
(3) The platform foundation must be firm and the unit
must be secured with anchor bolts.
(4) In case of installation on a roof subject to strong
wind, countermeasures must be taken to prevent
the unit from being blown over.
Air discharge
In regions with significant snowfall, the outdoor unit should
be provided with a platform and snow-proof duct.
Without snow-
proof ducting
(Low platform)
With snow-
proof ducting
(High platform)
Outdoor
Duct
Air
Unit
Intake
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20
2-6. Dimensions of Air-Discharge Chamber
Reference diagram for air-discharge chamber (field supply)
STK-DRE140A for SPW-CR365/485/605GX(H)56
24029.5
29.5
35537317 70
Rectangular
hole Rectangular hole
Rectangular
hole Rectangular hole
300
2
143
240
35317537 70
54425 25
569
1090
997
250
250
310250
Unit: mm
1 Unit front, air discharge chamber
2 Unit left side, air discharge chamber
3 Unit light side, air discharge chamber
4 Reinforcement brackets, 4 locations
110660170
13 13
340
405
380 1015
2020
13
68 544
300
Wind
direction
Wind direction
940
18
1230
Wind
direction
Wind
direction
Wind
direction
Wind
direction
300
108997
Wind direction
Wind direction
Unit: mm
2-7. Dimensions of Outdoor Unit with Air-Discharge Chamber (field supply)
SPW-CR365/485/605GX(H)56 with STK-DRE140A
05-194 5/27/05 5:06 PM Page 20