Bell Sports Air Conditioner PQRY P72 96TGMU A User Manual

Air-Conditioners For Building Application

HEAT SOURCE UNIT

PQRY-P72·96TGMU-A

For use with R410A

INSTALLATION MANUAL

For safe and correct use, please read this installation manual thoroughly before installing the air-conditioner unit.

MANUEL D’INSTALLATION

Veuillez lire le manuel d’installation en entier avant d’installer ce climatiseur pour éviter tout accident et vous assurer d’une utilisation correcte.

8.2

[Fig. 8.2.1]

No.7

A : BC controller (standard)

B : BC controller (main)

C : BC controller (sub)

D : indoor unit (06 ~ 54)

E : indoor unit (72, 96)

No.1

No.2

No.3 No.4

No.5

No.6

(Unit: mm [in])

C, D

(Unit: mm [in])

Å Heat source model

ı High press. side

ø15.88 [5/8]

Ç Low press. side

ø19.05 [3/4]

Ì High press.

gas pipe

Ó Low press.

¬ Liquid pipe

P72

P96

gas pipe

ø19.05 [3/4]

ø22.2 [7/8]

ø19.05 [3/4]

ø22.2 [7/8]

~ 72

73 ~ 108

109 ~ 126

ø15.88 [5/8]

ø19.05 [3/4]

ø9.52 [3/8]

ø12.7 [1/2]

(Unit: mm [in])

Ï Gas line

ø28.58 [1-1/8]

Î Total capacity of indoor units

‰ Liquid line

ø9.52 [3/8]

a, b, c, d, e, f, g

Ô Model number

(Unit: mm [in])

Ï Gas line

~ 54

ø15.88 [5/8]

ø19.05 [3/4]

‰ Liquid line

55 ~ 72

06,08,12,15,18

ø6.35 [1/4]

ø9.52 [3/8]

ø12.7 [1/2]

24,27,30,36,48,54

ø15.88 [5/8]

ø19.05 [3/4]

ø22.2 [7/8]

9.2

[Fig. 9.2.1]

[Fig. 9.2.2]

<A> [Ball valve (Low press. side/flanged type)]

[Ball valve

(High press. side/flared type)]

<C> This figure shows the valve

in the fully open state.

A : Close-packed packing

B : Hollow packing

[Fig. 9.2.3]

A: Valve stem

B: Stopper pin

H: Flare nut

I: ø15.88 [5/8] (PQRY-P72)

ø19.05 [3/4] (PQRY-P96)

C: Packing (Accessory)

J: ø19.05 [3/4] (PQRY-P72)

D: Connecting pipe (Accessory)

E: Open (Operate slowly)

F: Cap

ø22.2 [7/8] (PQRY-P96)

K: Field piping

G: Service port

9.3

[Fig. 9.3.1]

[Fig. 9.3.2]

A : Nitrogen gas

B : To indoor unit

C : System analyzer

D : Lo knob

A : System analyzer

B : Lo knob

C : Hi knob

D : Ball valve

E : Hi knob

E : Low press. pipe

F : High press. pipe

G : Service port

H : Three-way joint

I : Valve

F : Ball valve

G : Low press. pipe

H : High press. pipe

I : Heat source unit

J : Service port

J : Valve

[Fig. 9.3.3]

K : R410A cylinder

L : Scale

M : Vacuum pump

N : To indoor unit

O : Heat source unit

A : Syphon pipe

In case of the cylinder having no syphon pipe.

9.4

[Fig. 9.4.1]

[Fig. 9.4.2]

[Fig. 9.4.3]

A : Steel wire

B : Piping

C : Asphaltic oily mastic or asphalt

D : Heat insulation material A

E : Outer covering B

A : High press. pipe

C : Electric wire

E : Insulator

B : Low press. pipe

D : Finishing tape

[Fig. 9.4.4]

<A> Inner wall (concealed)

Outer wall

<C> Outer wall (exposed) <D> Floor (waterproofing)

<E> Roof pipe shaft

<F> Penetrating portion on fire

limit and boundary wall

A B

[3.28 ft]

A : Sleeve

B : Heat insulating material

D : Caulking material

F : Waterproofing laye

H : Lagging material

C : Lagging

E : Band

G : Sleeve with edge

I : Mortar or other incombustible caulking

J : Incombustible heat insulation material

10.2

[Fig. 10.2.1]

A : Power source

B : Transmission line

C : Ground screw

L1 L2 L3

TB1

M1M2 M1M2 S

TB3

TB7

10.3

[Fig. 10.3.1]

<A> Change the jumper connector

from CN41 to CN40

CN40

(51)

(52)

M1M2S

(01)

TB5

M1M2S

(02)

TB5

M1M2S

(55)

M1M2S

(05)

TB5

M1M2S

(06)

TB5

M1M2S

SW2-1:ON

TB3

M1M2

M1M2S

TB7

(101)

(105)

(155)

<C> Keep the jumper connector on

CN41

^RCE

SW2-1:ON

(03)

(04)

(07)

CN40

(53)

(54)

TB3

M1M2S

TB5

M1M2S

TB5

M1M2S

TB5

M1M2S

M1M2

M1M2S

TB7

System

controller

M1M2S

(104)

[Fig. 10.3.2]

<A> Change the jumper connector

from CN41 to CN40

(01)

(02)

(05)

(06)

CN40

SW2-1:ON

(51)

(52)

(55)

M1M2S

TB3

TB5

M1M2S

TB15

TB5

M1M2S

TB15

TB5

M1M2S

TB15

TB5

M1M2S

TB15

M1M2

M1M2S

TB7

<C> Keep the jumper connector on

CN41

SW2-1:ON

^MAE

A : Group 1

(03)

(04)

(07)

CN40

(53)

B : Group 4

(54)

TB3

M1M2S

TB5

M1M2S

TB15

TB5

M1M2S

TB15

TB5

M1M2S

TB15

C : Group 5

M1M2

M1M2S

TB7

D : Shielded wire

E : Sub remote

System

controller

M1M2S

controller

( ): Address

10.4

[Fig. 10.4.1]

~208 - 230 V

A : Switch (breakers for wiring and cur-

rent leakage)

B : Heat source unit

C : BC controller (main)

: BC controller (sub)

~208 - 230 V

D : Pull box

E : Indoor unit

F : Breakers for current leakage

Contents

1. Safety precautions ...................................................................................... 6

1.1. Before installation and electric work .......................................... 6

1.2. Precautions for devices that use R410A refrigerant .................. 6

1.3. Before getting installed .............................................................. 7

1.4. Before installation electrical work .............................................. 7

1.5. Before starting the test run ........................................................ 7

2. About the product ....................................................................................... 7

3. Specifications .............................................................................................. 7

4. Confirmation of parts attached ................................................................... 8

5. Lifting method ............................................................................................. 8

6. Installation of unit and service space .......................................................... 8

6.1. Installation ................................................................................. 8

6.2. Service space ............................................................................ 8

7. Water pipe installation................................................................................. 8

7.1. Precautions during installation .................................................. 8

7.2. Insulation installation ................................................................. 8

7.3. Water processing and water quality control............................... 8

7.4. Pump interlock........................................................................... 9

8. Refrigerant piping installation ..................................................................... 9

8.1. Caution ...................................................................................... 9

8.2. Refrigerant piping system.......................................................... 9

9. Additional refrigerant charge ..................................................................... 10

9.1. Calculation of additional refrigerant charge ............................. 10

9.2. Precautions concerning piping connection and

valve operation ........................................................................ 10

9.3. Airtight test, evacuation, and refrigerant charging ................... 11

9.4. Thermal insulation of refrigerant piping ................................... 12

10. Wiring ........................................................................................................ 12

10.1. Caution .................................................................................... 12

10.2. Control box and connecting position of wiring ......................... 12

10.3. Wiring transmission cables...................................................... 12

10.4. Wiring of main power supply and equipment capacity ............ 14

11. Test run ..................................................................................................... 14

11.1. The following phenomena do not represent trouble

(emergency) ............................................................................ 14

12. Information on rating plate ........................................................................ 14

1. Safety precautions

•

Securely install the heat source unit terminal cover (panel).

- If the terminal cover (panel) is not installed properly, dust or water may enter

the heat source unit and fire or electric shock may result.

When installing and moving the air conditioner to another site, do not

charge it with a refrigerant different from the refrigerant (R410A) speci-

fied on the unit.

1.1. Before installation and electric work

s Before installing the unit, make sure you read all the “Safety

precautions”.

s The “Safety precautions” provide very important points re-

- If a different refrigerant or air is mixed with the original refrigerant, the refrig-

erant cycle may malfunction and the unit may be damaged.

If the air conditioner is installed in a small room, measures must be taken

to prevent the refrigerant concentration from exceeding the safety limit

even if the refrigerant should leak.

- Consult the dealer regarding the appropriate measures to prevent the safety

limit from being exceeded. Should the refrigerant leak and cause the safety

limit to be exceeded, hazards due to lack of oxygen in the room could result.

When moving and reinstalling the air conditioner, consult the dealer or

an authorized technician.

- If the air conditioner is installed improperly, water leakage, electric shock, or

fire may result.

After completing installation work, make sure that refrigerant gas is not

leaking.

- If the refrigerant gas leaks and is exposed to a fan heater, stove, oven, or

other heat source, it may generate noxious gases.

Do not reconstruct or change the settings of the protection devices.

- If the pressure switch, thermal switch, or other protection device is shorted

and operated forcibly, or parts other than those specified by Mitsubishi Elec-

tric are used, fire or explosion may result.

garding safety. Make sure you follow them.

•

Symbols used in the text

Warning:

Describes precautions that should be observed to prevent danger of injury

or death to the user.

•

Caution:

Describes precautions that should be observed to prevent damage to the

unit.

Symbols used in the illustrations

: Indicates an action that must be avoided.

: Indicates that important instructions must be followed.

: Indicates a part which must be grounded.

: Beware of electric shock. (This symbol is displayed on the main unit label.)

<Color: yellow>

•

To dispose of this product, consult your dealer.

The installer and system specialist shall secure safety against leakage

according to local regulation or standards.

- Following standards may be applicable if local regulation are not available.

Pay a special attention to the place, such as a basement, etc. where re-

frigeration gas can stay, since refrigeration is heavier than the air.

Warning:

Carefully read the labels affixed to the main unit.

•

Warning:

•

Ask the dealer or an authorized technician to install the air conditioner.

- Improper installation by the user may result in water leakage, electric shock,

or fire.

1.2. Precautions for devices that use R410A

refrigerant

•

Install the unit in a place that can withstand its weight.

- Inadequate strength may cause the unit to fall down, resulting in injuries.

Use the specified cables for wiring. Make the connections securely so

that the outside force of the cable is not applied to the terminals.

- Inadequate connection and fastening may generate heat and cause a fire.

Prepare for rain and other moisture and earthquakes and install the unit

at the specified place.

- Improper installation may cause the unit to topple over and result in injury.

Always use an filter and other accessories specified by Mitsubishi Electric.

- Ask an authorized technician to install the accessories. Improper installation

by the user may result in water leakage, electric shock, or fire.

Never repair the unit. If the air conditioner must be repaired, consult the

dealer.

- If the unit is repaired improperly, water leakage, electric shock, or fire may

result.

If refrigerant gas leaks during installation work, ventilate the room.

- If the refrigerant gas comes into contact with a flame, poisonous gases will

be released.

Install the air conditioner according to this Installation Manual.

- If the unit is installed improperly, water leakage, electric shock, or fire may

result.

Have all electric work done by a licensed electrician according to “Elec-

tric Facility Engineering Standard” and “Interior Wire Regulations”and

the instructions given in this manual and always use a special circuit.

- If the power source capacity is inadequate or electric work is performed im-

properly, electric shock and fire may result.

Caution:

Do not use the existing refrigerant piping.

•

- The old refrigerant and refrigerator oil in the existing piping contains a large

amount of chlorine which may cause the refrigerator oil of the new unit to

deteriorate.

- R410A is a high-pressure refrigerant and can cause the existing piping to

burst.

Use refrigerant piping made of phosphorus deoxidized copper and copper

alloy seamless pipes and tubes. In addition, be sure that the inner and

outer surfaces of the pipes are clean and free of hazardous sulphur, ox-

ides, dust/dirt, shaving particles, oils, moisture, or any other contaminant.

- Contaminants on the inside of the refrigerant piping may cause the refriger-

ant residual oil to deteriorate.

Store the piping to be used during installation indoors and keep both

ends of the piping sealed until just before brazing. (Store elbows and

other joints in a plastic bag.)

- If dust, dirt, or water enters the refrigerant cycle, deterioration of the oil and

compressor trouble may result.

Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerator

oil to coat flares and flange connections.

- The refrigerator oil will degrade if it is mixed with a large amount of mineral oil.

Use liquid refrigerant to fill the system.

- If gas refrigerant is used to seal the system, the composition of the refriger-

ant in the cylinder will change and performance may drop.

•

Do not use a refrigerant other than R410A.

- The some electric parts should be damaged when power is supplied under

the miss wiring.

Install the power cable so that tension is not applied to the cable.

- Tension may cause the cable to break and generate heat and cause a fire.

Install a leak circuit breaker, as required.

- If a leak circuit breaker is not installed, electric shock may result.

Use power line cables of sufficient current carrying capacity and rating.

- Cables that are too small may leak, generate heat, and cause a fire.

Use only a circuit breaker and fuse of the specified capacity.

- A fuse or circuit breaker of a larger capacity or a steel or copper wire may

result in a general unit failure or fire.

- If another refrigerant (R22, etc.) is mixed with R410A, the chlorine in the

refrigerant may cause the refrigerator oil to deteriorate.

Use a vacuum pump with a reverse flow check valve.

- The vacuum pump oil may flow back into the refrigerant cycle and cause the

refrigerator oil to deteriorate.

Do not use the following tools that are used with conventional refrigerants.

(Gauge manifold, charge hose, gas leak detector, reverse flow check valve,

refrigerant charge base, refrigerant recovery equipment)

- If the conventional refrigerant and refrigerator oil are mixed in the R410A,

the refrigerant may deteriorated.

•

- If water is mixed in the R410A, the refrigerator oil may deteriorate.

- Since R410A does not contain any chlorine, gas leak detectors for conven-

tional refrigerants will not react to it.

Do not use a charging cylinder.

- Using a charging cylinder may cause the refrigerant to deteriorate.

Be especially careful when managing the tools.

•

Do not wash the air conditioner units.

- Washing them may cause an electric shock.

Be careful that the installation base is not damaged by long use.

- If the damage is left uncorrected, the unit may fall and cause personal injury

or property damage.

Install the drain piping according to this Installation Manual to ensure

proper drainage. Wrap thermal insulation around the pipes to prevent

condensation.

- Improper drain piping may cause water leakage and damage to furniture

and other possessions.

Be very careful about product transportation.

- Only one person should not carry the product if it weighs more than 20 kg

[45 LBS].

- Some products use PP bands for packaging. Do not use any PP bands for a

means of transportation. It is dangerous.

•

- If dust, dirt, or water gets in the refrigerant cycle, the refrigerant may deteriorate.

1.3. Before getting installed

Caution:

•

Do not install the unit where combustible gas may leak.

- If the gas leaks and accumulates around the unit, an explosion may result.

Do not use the air conditioner where food, pets, plants, precision instru-

ments, or artwork are kept.

- The quality of the food, etc. may deteriorate.

- When transporting the heat source unit, support it at the specified positions

on the unit base. Also support the heat source unit at four points so that it

cannot slip side ways.

•

Do not use the air conditioner in special environments.

- Oil, steam, sulfuric smoke, etc. can significantly reduce the performance of

the air conditioner or damage its parts.

•

Safely dispose of the packing materials.

When installing the unit in a hospital, communication station, or similar

place, provide sufficient protection against noise.

- Packing materials, such as nails and other metal or wooden parts, may cause

stabs or other injuries.

- The inverter equipment, private power generator, high-frequency medical

equipment, or radio communication equipment may cause the air conditioner

to operate erroneously, or fail to operate. On the other hand, the air condi-

tioner may affect such equipment by creating noise that disturbs medical

treatment or image broadcasting.

Do not install the unit on a structure that may cause leakage.

- When the room humidity exceeds 80 % or when the drain pipe is clogged,

condensation may drip from the indoor unit.Perform collective drainage work

together with the heat source unit, as required.

- Tear apart and throw away plastic packaging bags so that children will not

play with them. If children play with a plastic bag which was not torn apart,

they face the risk of suffocation.

1.5. Before starting the test run

•

Caution:

•

Turn on the power at least 12 hours before starting operation.

- Starting operation immediately after turning on the main power switch can

result in severe damage to internal parts. Keep the power switch turned on

during the operational season.

1.4. Before installation electrical work

•

Do not touch the switches with wet fingers.

Warning

- Touching a switch with wet fingers can cause electric shock.

Do not touch the refrigerant pipes during and immediately after operation.

- During and immediately after operation, the refrigerant pipes are may be hot

and may be cold, depending on the condition of the refrigerant flowing through

the refrigerant piping, compressor, and other refrigerant cycle parts. Your

hands may suffer burns or frostbite if you touch the refrigerant pipes.

Do not operate the air conditioner with the panels and guards removed.

- Rotating, hot, or high-voltage parts can cause injuries.

Do not turn off the power immediately after stopping operation.

- Always wait at least five minutes before turning off the power. Otherwise,

water leakage and trouble may occur.

Do not touch the surface of the compressor during servicing.

- If unit is connected to the supply and not running, crank case heater at

compressor is operating.

When installing or relocating the unit, make sure that no substance other

than the specified refrigerant (R410A) enters the refrigerant circuit.

Any presence of foreign substance such as air can cause abnormal pres-

sure rise or explosion.

Caution:

Ground the unit.

•

- Do not connect the ground wire to gas or water pipes, lightning rods, or

telephone ground lines. Improper grounding may result in electric shock.

The reverse phase of L lines (L¹, L2, L3) can be detected (Error cord: 4103),

but the reverse phase of L lines and N line can be not be detected.

•

2. About the product

•

This unit uses R410A-type refrigerant

•

Do not use the existing piping, as it contains chlorine, which is found in con-

ventional refrigerating machine oil and refrigerant.This chlorine will deteriorate

the refrigerant machine oil in the new equipment.The existing piping must not

be used as the design pressure in systems using R410A is higher than that in

the systems using other types of refrigerant and the existing pipes may burst.

Piping for systems using R410A may be different from that for systems using

conventional refrigerant because the design pressure in systems using R410A

is higher. Refer to Data Book for more information.

•

Some of the tools and equipment used for installation with systems that use

other types of refrigerant cannot be used with the systems using R410A. Refer

to Data Book for more information.

3. Specifications

Model

PQRY-P72TGMU-A

46 dB <A>

257 kg [568 LBS]

PQRY-P96TGMU-A

47 dB <A>

260 kg [574 LBS]

Noise level

Net weight

Allowable pressure

Refrigerant

HP: 4.15 MPa [601 psi], LP: 2.21 MPa [320 psi]

R410A: 7.5 kg [16 LBS 9 oz] R410A: 8.5 kg [18 LBS 12 oz]

Total capacity

Model / Quantity

50 ~ 150 %

Indoor units

P06 ~ P96 / 1 ~ 15

P06 ~ P96 / 1 ~ 19

Operation temperature

Maximum water pressure

Rated water volume

Water temperature: 10˚C ~ 45˚C [50˚F ~ 113˚F] Note.1

1.0 MPa [145 psi]

4.56 m³/h [1204 G/h]

3.9 ~ 6.8 m³/h [1030 ~ 1795 G/h]

5.76 m³/h [1521 G/h]

Allowable water volume

4.5 ~ 7.2 m³/h [1188 ~ 1901 G/h]

Note 1. When the total capacity of indoor units exceeds 130% of heat source units capacity, the operating temperature range of circulating water is 15˚C ~ 45˚C [59˚F ~ 113˚F]

4. Confirmation of parts attached

Connecting pipe × 1 (Connecting pipe is fixed with the unit.)

Bushing × 2

Packing (inside ø23 [29/32 in], outside ø35 [1-13/32 in]) × 1

5. Lifting method

[Fig. 5.0.1] (P.2)

Caution:

Be very careful when carrying the product.

- Do not have only one person to carry product if it is more than 20 kg [46 LBS].

- PP bands are used to pack some products. Do not use them as a mean for transportation because they are dangerous.

- Tear plastic packaging bag and scrap it so that children cannot play with it. Otherwise plastic packaging bag may suffocate children to death.

- When carrying the heat source unit, be sure to support it at four points. Carrying with 3-point support may make the heat source unit unstable, resulting in it falling.

6. Installation of unit and service space

Warning:

6.1. Installation

•

Be sure to install unit in a place strong enough to withstand its weight.

Any lack of strength may cause unit to fall down, resulting in a personal

injury.

•

Using the anchoring holes shown below, firmly bolt the unit to the base.

[Fig. 6.1.1] (P.2)

Have installation work in order to protect against earthquake.

Any installation deficiency may cause unit to fall down, resulting in a

personal injury.

Heat source unit

(Top view)

4-ø14 [9/16] (Anchoring hole)

Bases and anti-vibration

•

Be sure to install unit in a place strong enough to withstand its weight. If the

base is unstable, reinforce with a concrete base.

6.2. Service space

•

Please allow for the following service spaces after installation.

(All servicing can be performed from the front of the unit)

•

The unit must be anchored on a level surface. Use a level to check after

installation.

[Fig. 6.2.1] (P.2)

•

Anti-vibration pads must be placed under the base of the unit.

Piping space (for side piping)

Service space (front side)

Heat source unit

(Top view)

If the unit is installed near a room where noise is a problem, using an anti-

vibration stand on the base of the unit is recommended.

[Fig. 6.1.2] (P.2)

[Fig. 6.2.2] (P.2)

Anti-vibration pad etc.

Concrete base

Piping space (for top piping)

Heat source unit

Piping space (for side piping)

(Front view)

7. Water pipe installation

•

City Multi WR2 Series pipes are similar to other air-conditioning pipes, how-

ever, please observe the following precautions during installation.

[Fig. 7.1.1] (P.2)

Water circulation pipe

Close valve

Water outlet

Y-type strainer

Drain pipe

Close valve

7.1. Precautions during installation

•

Refrigerant piping

Water inlet

Use the reverse-return method to insure proper pipe resistance to each unit.

•

To insure easy maintenance, inspection, and replacement of the unit, use a

proper joint, valve, etc. on the water intake and outlet port. In addition, be sure

to install a strainer on the water intake pipe. (In order to maintain the heat

source unit, a strainer on the circulating water inlet is necessary.)

* An example of the heat source unit installation is shown in the diagram be-

low.

7.2. Insulation installation

With City Multi WR2 Series piping, as long as the temperature range of the circu-

lating water is kept to average temperatures year-round (30 °C [86 °F] in the sum-

mer, 20 °C [68 °F] in the winter), there is no need to insulate or otherwise protect

indoor piping from exposure.You should use insulation in the following situations:

•

Install a suitable air vent on the water pipe. After sending water through the

pipe, be sure to vent the excess air.

•

Any heat source piping.

Indoor piping in cold-weather regions where frozen pipes are a problem.

When air coming from the outside causes condensation to form on piping.

Any drainage piping.

Compressed water may form in the low-temperature sections of heat source

unit. Use a drainage pipe connected to the drain valve at the base of the unit to

drain the water.

•

There is a water vent plug in the center of the heat exchanger water inlet head

at the middle of the unit. Use this for maintenance, etc.

In addition, do not allow any of the unit’s electrical parts (such as the solenoid

valve coil or compressor power supply) to become wet.

7.3. Water processing and water quality con-

trol

To preserve water quality, use the closed type of cooling tower for WR2. When the

circulating water quality is poor, the water heat exchanger can develop scales,

leading to a reduction in heat-exchange power and possible corrosion of the heat

exchanger.Please pay careful attention to water processing and water quality control

when installing the water circulation system.

•

Install a back flow-prevention valve on the pump and a flexible joint to prevent

excess vibration.

•

Use a sleeve to protect the pipes where they go through a wall.

Use metal fittings to secure the pipes, and install them so that they have maxi-

mum protection against breakage and bending.

•

Removal of foreign objects or impurities within the pipes.

During installation, be careful that foreign objects, such as welding fragments,

sealant particles, or rust, do not enter the pipes.

•

Do not confuse the water intake and outlet valves.

This unit doesn’t have any heater to prevent freezing within tubes. When the

water flow is stopped on low ambient, take out the water from tubes.

•

Water Quality Processing

Depending on the quality of the cold-temperature water used in the air-

conditioner, the copper piping of the heat exchanger may become corroded.

We recommend regular water quality processing.

•

The unused knockout holes should be closed and the opening of refrigerant

pipes, water pipes, power source and transmission wires should be filled with

putty and so on to prevent from rain. (field construction)

Cold water circulation systems using open heat storage tanks are

particularly prone to corrosion.

Example of heat source unit installation (using left piping)

When using an open-type heat storage tank, install a water-to-water heat

exchanger, and use a closed-loop circuit on the air conditioner side. If a

water supply tank is installed, keep contact with air to a minimum, and

keep the level of dissolved oxygen in the water no higher than 1mg/r.

Water quality standard

Please consult with a water quality control specialist about water quality

control methods and water quality calculations before using anti-corrosive

solutions for water quality management.

Lower mid-range

Tendency

Scale-

temperature water system

Recirculating

When replacing a previously installed air conditioning device (even when

only the heat exchanger is being replaced), first conduct a water quality

analysis and check for possible corrosion.

Corrosion can occur in cold-water systems even if there has been no prior

signs of corrosion.

Items

Make-up

water

Corrosive

[20<T<60°C]

forming

[68<T<140°F]

7.0 ~ 8.0

30 or less

[300 or less]

50 or less

pH (25°C) [77°F]

Electric conductivity (mS/m) (25°C) [77°F] 30 or less

(µ s/cm) (25°C) [77°F] [300 or less]

7.0 ~ 8.0

If the water quality level has dropped, please adjust water quality suffi-

ciently before replacing the unit.

Chloride ion

(mg Cl^-/r) 50 or less

(mg SO4^2-/r) 50 or less

Sulfate ion

7.4. Pump interlock

The heat source unit may become damaged if it is operated with no water circulat-

ing through the pipes.

Standard

Acid consumption (pH4.8)

(mg CaCO₃/r)

items

50 or less

70 or less

50 or less

30 or less

0.3 or less

0.1 or less

not to be

detected

0.1 or less

0.3 or less

4.0 or less

–

Total hardness

(mg CaCO₃/r) 70 or less

Be sure to interlock unit operation and the water-circuit pump. Use the terminal

blocks for interlocking (TB8-3, 4) that can be found on the unit.

In the case of a pump interlock circuit signal connection to the TB8-3, 4, remove

the short-circuit wire. Also, to prevent mistaken error detection, resulting from a

poor connection, in the pressure valve 63PW, use a low maintained current of 5mA

or less.

Calcium hardness (mg CaCO₃/r) 50 or less

Ionic silica

Iron

(mg SiO₂/r) 30 or less

(mg Fe/r) 1.0 or less

(mg Cu/r) 1.0 or less

Refer-

ence

Copper

items

not to be

(mg S^2-/r)

Sulfide ion

[Fig. 7.4.1] (P.2)

detected

(mg NH₄⁺/r) 0.3 or less

(mg Cl/r) 0.25 or less

Short-circuit wire (Connected before delivery from manufacturer)

Pump interlock circuit connection

Ammonium ion

Residual chlorine

Free carbon dioxide (mg CO₂/r) 0.4 or less

Ryzner stability index

–

Reference : Guideline of Water Quality for Refrigeration and Air Conditioning

Equipment. (JRA GL02E-1994)

8. Refrigerant piping installation

City Multi WR2 Series is constituted by an end branching system in which the

refrigerant piping from heat source unit is branched at BC controller and connected

to each indoor unit.

The connection method adapted is brazing connection for high pressure pipe and

low pressure pipe between heat source unit and BC controller, and flare connec-

tion between BC controller and indoor unit. Brazing connection is employed for

joint pipe set and branch pipe set.

Residues in commercially available antioxidants may have adverse effects on

the equipment. Braze only with non-oxide brazing material. The use of other

brazing material may result in compressor damage.

(Refer to item 9.2. for detailed information on pipe connections and valve op-

erations.)

Never perform heat source unit piping connection work when it is rain-

ing.

Warning:

Warning

Always use extreme care to prevent the refrigerant gas from leaking while

using fire or flame. If the refrigerant gas comes in contact with a flame from

any source, such as a gas stove, it breaks down and generates a poisonous

gas which can cause gas poisoning. Never weld in an unventilated room.

Always conduct an inspection for gas leakage after installation of the refrig-

erant piping has been completed.

When installing and moving the unit, do not charge it with refrigerant other

than the refrigerant specified on the unit.

- Mixing of a different refrigerant, air, etc. may cause the refrigerant cycle to mal-

function and result in severe damage.

Caution:

•

Use a vacuum pump with a reverse flow check valve.

- If the vacuum pump does not have a reverse flow check valve, the vacuum

pump oil may flow back into the refrigerant cycle and cause deterioration of

the refrigerator oil and other trouble.

Do not use the tools shown below used with conventional refrigerant.

(Gauge manifold, charge hose, gas leak detector, check valve, refrigerant

charge base, vacuum gauge, refrigerant recovery equipment)

- Mixing of conventional refrigerant and refrigerator oil may cause the refrig-

erator oil to deteriorate.

8.1. Caution

This unit uses refrigerant R410A. Follow the local regulations on materials and

pipe thickness when selecting pipes.

Use the following materials for refrigeration piping.

•

Material: Use refrigerant piping made of phosphorus deoxidized copper.

In addition, be sure that the inner and outer surfaces of the pipes are clean

and free of hazardous sulphur, oxides, dust/dirt, shaving particles, oils,

moisture, or any other contaminant.

- Mixing of water will cause the refrigerator oil to deteriorate.

- R410A refrigerant does not contain any chlorine.Therefore, gas leak detec-

tors for conventional refrigerants will not react to it.

Manage the tools more carefully than normal.

- If dust, dirt, or water gets in the refrigerant cycle, the refrigerator oil will dete-

riorate.

Commercially available piping often contains dust and other materials. Always

blow it clean with a dry inert gas.

Use care to prevent dust, water or other contaminants from entering the piping

during installation.

•

Reduce the number of bending portions as much as possible, and make bend-

ing radius as big as possible.

Never use existing refrigerant piping.

- The large amount of chlorine in conventional refrigerant and refrigerator oil

in the existing piping will cause the new refrigerant to deteriorate.

Store the piping to be used during installation indoors and keep both

ends of the piping sealed until just before brazing.

- If dust, dirt, or water gets into the refrigerant cycle, the oil will deteriorate and

the compressor may fail.

Do not use a charging cylinder.

- Using a charging cylinder may cause the refrigerant to deteriorate.

Do not use special detergents for washing piping.

Always observe the restrictions on the refrigerant piping (such as rated length,

the difference between high/low pressures, and piping diameter). Failure to do

so can result in equipment failure or a decline in heating/cooling performance.

Either a lack or an excess of refrigerant causes the unit to make an emergency

stop. Charge the system with an appropriate amount of refrigerant. At such a

time, always properly charge the unit. When servicing, always check the notes

concerning pipe length and amount of additional refrigerant at both locations,

the refrigerant volume calculation table on the back of the service panel and

the additional refrigerant section on the labels for the combined number of

indoor units.

•

8.2. Refrigerant piping system

Connection Example

Use liquid refrigerant to fill the system.

Never use refrigerant to perform an air purge. Always evacuate using a vacuum

pump.

[Fig. 8.2.1] (P.3)

‰

Heat source model

Low press. side

High press. side

Always insulate the piping properly. Insufficient insulation will result in a de-

cline in heating/cooling performance, water drops from condensation and other

such problems.

Total capacity of indoor units

Gas line

Liquid line

High press. gas pipe

Liquid pipe

Low press. gas pipe

Model number

When connecting the refrigerant piping, make sure the ball valve of the heat

source unit is completely closed (the factory setting) and do not operate it until

the refrigerant piping for the heat source and indoor units has been connected,

a refrigerant leakage test has been performed and the evacuation process has

been completed.

BC controller (standard)

BC controller (sub)

Indoor unit (72, 96)

BC controller (main)

Indoor unit (06 ~ 54)

9. Additional refrigerant charge

At the time of shipping, the heat source unit is charged with the refrigerant. As this

charge does not include the amount needed for extended piping, additional charg-

ing for each refrigerant line will be required on site. In order that future servicing

may be properly provided, always keep a record of the size and length of each

refrigerant line and the amount of additional charge by writing it in the space pro-

vided on the heat source unit.

9.2. Precautions concerning piping connec-

tion and valve operation

•

Conduct piping connection and valve operation accurately.

•

Flange type side connecting pipe is assembled in factory before shipment.

For brazing to the connecting pipe with flange, remove the connecting pipe

with flange from the ball valve, and braze it outside of the unit.

9.1. Calculation of additional refrigerant

charge

During the time when removing the connecting pipe with flange, remove

the seal attached on the rear side of this sheet and paste it onto the flange

surface of the ball valve to prevent the entry of dust into the valve.

•

Calculate the amount of additional charge based on the length of the piping

extension and the size of the refrigerant line.

The refrigerant circuit is closed with a round, close-packed packing upon

shipment to prevent gas leak between flanges. As no operation can be

done under this state, be sure to replace the packing with the hollow pack-

ing attached at the piping connection.

Use the table to the below as a guide to calculating the amount of additional

charging and charge the system accordingly.

If the calculation results in a fraction of less than 0.1 kg [4 oz], round up to the

next 0.1 kg [4 oz]. For example, if the result of the calculation was 10.62 kg

[373.3 oz], round the result up to 10.7 kg [376 oz].

At the mounting of the hollow packing, wipe off dust attached on the flange

sheet surface and the packing. Coat refrigerating machine oil (Ester oil,

ether oil or alkylbenzene [small amount]) onto both surfaces of the pack-

ing.

High pressure

pipe size

Total length of

ø19.05 [3/4]

Additional

refrigerant

charge

High pressure

pipe size

Total length of

ø15.88 [5/8]

High pressure

pipe size

Total length of

ø12.7 [1/2]

High pressure

pipe size

Total length of

ø9.52 [3/8]

[Fig. 9.2.1] (P.3)

Close-packed packing

Hollow packing

(m) × 0.16 (kg/m)

(in) × 1.72(oz/ft)

(kg) [oz]

(m) × 0.11 (kg/m)

(in) × 1.18 (oz/ft)

(m) × 0.12 (kg/m)

(in) × 1.29 (oz/ft)

(m) × 0.06 (kg/m)

(in) × 0.65 (oz/ft)

•

After evacuation and refrigerant charge, ensure that the handle is fully open. If

operating with the valve closed, abnormal pressure will be imparted to the

high- or low-pressure side of the refrigerant circuit, giving damage to the com-

pressor, four-way valve, etc.

High pressure

pipe size

Total length of

ø6.35 [1/4]

+ α1 + α2

Determine the amount of additional refrigerant charge by using the formula,

and charge refrigerant additionally through the service port after completing

piping connection work.

(m) × 0.024 (kg/m)

(in) × 0.26 (oz/ft)

•

After completing work, tighten the service port and cap securely not to gener-

ate gas leak.

Indoor No. 1: 15 A: ø19.05 [3/4] 40 m [131 ft] a: ø6.35 [1/4] 10 m [32 ft]

No. 2: 72 B: ø9.52 [3/8] 10 m [32 ft] b: ø9.52 [3/8] 5 m [16 ft]

Flare machining dimension for systems using R410A is larger than that for

systems using other types of refrigerant in order to increase the air tightness.

At the

conditions

below:

No. 3: 15

No. 4: 12

No. 5: 24

c: ø6.35 [1/4] 10 m [32 ft]

d: ø6.35 [1/4] 10 m [32 ft]

e: ø9.52 [3/8] 10 m [32 ft]

Refer to the table on the below for flare machining dimensions, and follow the

regulations set forth by the local authorities. Seal off the opening of the pipe

with a closure material (not supplied) to keep small animals from entering the

pipe if that is a concern.

The total length of each liquid line is as follows:

ø19.05 [3/4]: A = 40 m [131ft]

flare machining dimension (mm)

outer diameter

ø9.52 [3/8]: B + b + e = 10 [32] + 5 [16] + 10 [32] = 25 m [80 ft]

ø6.35 [1/4]: a + c + d = 10 [32] + 10 [32] + 10 [32] = 30 m [96 ft]

dimension A

R410A

9.1

size in inches

Therefore,

Additional refrigerant charge

= 40 [131] × 0.16 [1.72] + 25 [80] × 0.06 [0.65]

+ 30 [96] × 0.024 [0.26] + 2.0 [71oz] = 10.7 kg [376oz]

ø6.35

ø9.52

1/4"

3/8"

1/2"

5/8"

3/4"

13.2

ø12.70

ø15.88

ø19.05

16.6

19.7

24.0

Indoor No. 1: 08 A: ø19.05 [3/4] 40 m [131 ft] a: ø6.35 [1/4] 10 m [32 ft]

No. 2: 06 B: ø9.52 [3/8] 10 m [32 ft] b: ø6.35 [1/4] 5 m [16 ft]

No. 3: 12 C: ø12.7 [1/2] 10 m [32 ft] c: ø6.35 [1/4] 10 m [32 ft]

No. 4: 12 D: ø9.52 [3/8] 10 m [32 ft] d: ø6.35 [1/4] 10 m [32 ft]

flare nut size (mm)

dimension B

R410A

17.0

At the

conditions

below:

outer diameter

size in inches

ø6.35

ø9.52

1/4"

3/8"

1/2"

5/8"

3/4"

No. 5: 12

No. 6: 72

No. 7: 06

e: ø6.35 [1/4] 10 m [32 ft]

f: ø9.52 [3/8] 10 m [32 ft]

g: ø6.35 [1/4] 5 m [16 ft]

22.0

ø12.70

ø15.88

ø19.05

26.0

29.0

The total length of each liquid line is as follows:

ø19.05 [3/4]: A = 40 m [131 ft]

36.0

ø12.7 [1/2]: C = 10 m [32 ft]

[Fig. 9.2.2] (P.3)

ø9.52 [3/8]: B + D + f = 10 [32] + 10 [32] + 10 [32] = 30 m [96 ft]

ø6.35 [1/4]: a + b + c + d + e + g = 10 [32] + 5 [16] + 10 [32] + 10 [32] + 10 [32] +

5 [16] = 50 m [160 ft]

<A> [Ball valve (Low press. side/flanged type)]

[Ball valve (High press. side/flared type)]

<C> This figure shows the valve in the fully open state.

Therefore,

Valve stem

Additional refrigerant charge

= 40 [131] × 0.16 [1.72] + 10 [32] × 0.12 [1.29] + 30 [96] × 0.06 [0.65] +

50 [160] × 0.024 [0.26] + 2.5 [89] + 2.0 [71] = 15.1 kg [531 oz]

[Fully closed at the factory, when connecting the piping, when evacuating, and

when charging additional refrigerant. Open fully after the operations above are

completed.]

Stopper pin [Prevents the valve stem from turning 90° or more.]

Packing (Accessory)

[Manufacturer: Nichiasu corporation]

[Type: T/#1991-NF]

Value of α1

Total capacity of connecting indoor units

to Model 30

α 1

1.0 kg [36 oz]

1.5 kg [53 oz]

2.0 kg [71 oz]

2.5 kg [89 oz]

Connecting pipe (Accessory)

[Use packing and securely install this pipe to the valve flange so that gas leakage

will not occur. (Tightening torque:40 N·m [400 kg·cm]) Coat both surfaces of the

packing with refrigerating machine oil. (Ester oil, ether oil or alkylbenzene [small

amount])]

Models 31 to 60

Models 61 to 126

Models 127 to 180

Open (Operate slowly)

Value of α2

Cap, copper packing

[Remove the cap and operate the valve stem. Always reinstall the cap after opera-

tion is completed.(Valve stem cap tightening torque:23 ~ 27 N·m [230 ~ 270 kg·cm])]

α 2

0 kg [0 oz]

BC controller (standard, main only)

BC controller (sub) connected (one)

BC controller (sub) connected (two)

1.0 kg [36 oz]

2.0 kg [71 oz]

Service port

Caution:

[Use this port to evacuate the refrigerant piping and add an additional charge at

the site.

Open and close the port using a double-ended wrench.

Always reinstall the cap after operation is completed. (Service port cap tightening

torque: 12 ~ 15 N·m [120 ~ 150 kg·cm])

•

Always remove the connecting pipe from the ball valve and braze it out-

side the unit.

- Brazing the connecting pipe while it is installed will heat the ball valve and

cause trouble or gas leakage. The piping, etc. inside the unit may also be

burned.

Use ester oil, ether oil or alkylbenzene (small amount) as the refrigerat-

ing machine oil to coat flares and flange connections.

- The refrigerating machine oil will degrade if it is mixed with a large amount of

mineral oil.

Flare nut

[Tightening torque: Refer to the following table.

Loosen and tighten this nut using a double-ended wrench.

Coat the flare contact surface with refrigerating machine oil (Ester oil, ether oil or

alkylbenzene [small amount])]

•

Keep the ball valve closed until refrigerant charging to the pipes to be

added on site has been completed. Opening the valve before charging

the refrigerant may result in unit damage.

ø15.88 [5/8] (PQRY-P72)

ø19.05 [3/4] (PQRY-P96)

ø19.05 [3/4] (PQRY-P72)

ø22.2 [7/8] (PQRY-P96)

Do not use a leak detection additive.

Field piping

9.3. Airtight test, evacuation,and refrigerant

charging

Appropriate tightening torque by torque wrench:

Copper pipe external dia. (mm [in])

ø6.35 [1/4]

Tightening torque (N·m / kg·cm)

Airtight test

14 to 18 / 140 to 180

35 to 42 / 350 to 420

50 to 57.5 / 500 to 575

75 to 80 / 750 to 800

100 to 140 / 1000 to 1400

Perform with the ball valve of the heat source unit closed, and pressurize the

connection piping and the indoor unit from the service port provided on the ball

valve of the heat source unit. (Always pressurize from both the high press pipe

and the low press pipe service ports.)

ø9.52 [3/8]

ø12.7 [1/2]

ø15.88 [5/8]

ø19.05 [3/4]

[Fig. 9.3.1] (P.4)

Tightening angle standard:

Nitrogen gas

Lo knob

To indoor unit

Hi knob

System analyzer

Ball valve

Pipe diameter (mm [in])

ø6.35 [1/4], ø9.52 [3/8]

ø12.7 [1/2], ø15.88 [5/8]

ø19.05 [3/4]

Tightening angle (°)

60 to 90

Low press. pipe

Service port

High press. pipe

Heat source unit

30 to 60

20 to 35

Observe the following restrictions when conducting an air tightness test to prevent

negative effects on the refrigerating machine oil. Also, with nonazeotropic refriger-

ant (R410A), gas leakage causes the composition to change and affects perform-

ance. Therefore, perform the airtightness test cautiously.

[Fig. 9.2.3] (P.3)

Note:

If a torque wrench is not available, use the following method as a standard:

When you tighten the flare nut with a wrench, you will reach a point where

the tightening torque will abruptly increase. Turn the flare nut beyond this

point by the angle shown in the table above.

Airtight test procedure

Restriction

1. Nitrogen gas pressurization

•

If a flammable gas or air (oxygen) is used as the pressurization

gas, it may catch fire or explode.

(1) After pressurizing to the design pressure (4.15 MPa [601 psi]) using nitrogen gas, allow it to

stand for about one day. If the pressure does not drop, airtightness is good.

However, if the pressure drops, since the leaking point is unknown, the following bubble test

may also be performed.

(2) After the pressurization described above, spray the flare connection parts, brazed parts, flanges,

and other parts that may leak with a bubbling agent (Kyuboflex, etc.) and visually check for

bubbles.

(3) After the airtight test, wipe off the bubbling agent.

2. Pressurization using refrigerant gas and nitrogen gas

•

Do not use a refrigerant other than that indicated on the unit.

Sealing with gas from a cylinder will cause the composition of

the refrigerant in the cylinder to change.

(1) Pressurizing to a gas pressure of approximately 0.2 MPa [29 psi], pressurize to the design

pressure (4.15 MPa [601 psi]) using nitrogen gas.

However, do not pressurize at one time. Stop during pressurization and check that the pres-

sure does not drop.

•

Use a pressure gauge, charging hose, and other parts especially

for R410A.

(2) Check for gas leaks by checking the flare connection parts, brazed parts, flanges, and other

parts which may leak using an R410A compatible electric leak detector.

(3) This test may be used together the with bubble type gas leak test.

•

An electric leak detector for R22 cannot detect leaks of R410A.

Do not use a haloid torch. (Leaks cannot be detected.)

Caution:

Only use refrigerant R410A.

•

Use a gauge manifold, charging hose, and other parts for the refrigerant

indicated on the unit.

- The use of other refrigerant such as R22 or R407C, which contains chlorine, will

deteriorate the refrigerating machine oil or cause the compressor to malfunction.

•

Use a graviometer. (One that can measure down to 0.1 kg [4 oz].)

Use a vacuum pump with a reverse flow check valve.

(Recommended vacuum gauge: ROBINAIR 14830A Thermistor Vacuum

Gauge)

Evacuation

Also use a vacuum gauge that reaches 65 Pa [abs] [0.00943 psi/0.5Torr]

or below after operating for five minutes.

Evacuate with the ball valve of the heat source unit closed and evacuate both

the connection piping and the indoor unit from the service port provided on the

ball valve of the heat source unit using a vacuum pump. (Always evacuate from

the service port of both the high press pipe and the low press pipe.) After the

vacuum reaches 650 Pa [abs] [0.0943 psi/5 Torr], continue evacuation for at

least one hour or more.

Refrigerant Charging

Since the refrigerant used with the unit is nonazerotropic, it must be charged in

the liquid state. Consequently, when charging the unit with refrigerant from a

cylinder, if the cylinder does not have a syphon pipe, charge the liquid refriger-

ant by turning the cylinder upside-down as shown in Fig.9.3.3. If the cylinder

has a syphon pipe like that shown in the picture on the right, the liquid refriger-

ant can be charged with the cylinder standing upright. Therefore, give careful

attention to the cylinder specifications. If the unit should be charged with gas

refrigerant, replace all the refrigerant with new refrigerant. Do not use the re-

frigerant remaining in the cylinder.

* Never perform air purging using refrigerant.

[Fig. 9.3.2] (P.4)

System analyzer

Ball valve

Lo knob

Hi knob

Low press. pipe

Three-way joint

R410A cylinder

To indoor unit

High press. pipe

Valve

Service port

Valve

Scale

[Fig. 9.3.3] (P.4)

Vacuum pump

Heat source unit

Syphon pipe

In case of the cylinder having no syphon pipe.

Note:

•

Always add an appropriate amount of refrigerant. Also always seal the

system with liquid refrigerant.Too much or too little refrigerant will cause

trouble.