INSTALLATION INSTRUCTIONS Mini VRF System Air Conditioner This air conditioner uses the refrigerant R410A. NOTE External diameter of service port R410A: 5/16" Model No. Outdoor Units Type U Outdoor Unit Type Mini VRF System 36 52 U-36LE1U6 U-52LE1U6 U-36LE1U6E* U-52LE1U6E* * Salt-Air Damage Resistant Specifications.
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. When Installing… 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.
When Servicing CAUTION • Turn the power OFF at the main power box (mains) before opening the unit to check or repair electrical parts and wiring. • 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. • Keep your fingers and clothing away from any moving parts.
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 Seamless 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).
3-2. Use R410A exclusive cylinder only. Valve Single-outlet valve (with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown. Liquid 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).
CONTENTS Page Page 4. ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . 22 4-1. General Precautions on Wiring 4-2. Recommended Wire Length and Wire Diameter for Power Supply System 4-3. Wiring System Diagram IMPORTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Please Read Before Starting Check of Density Limit Precautions for Installation Using New Refrigerant 1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 1-1.
1. GENERAL 1-3. Type of Copper Tube and Insulation Material 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. If you wish to purchase these materials separately from a local source, you will need: 1-1. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 1. Deoxidized annealed copper tube for refrigerant tubing. 2.
1-5. Tubing Size Table 1-2 Main Tubing Size (LA) 38,200 (11.2) BTU/h (kW) System horsepower Gas tubing 52,900 (15.5) 4 6 ø5/8" (ø15.88) ø3/4" (ø19.05) Liquid tubing ø3/8" (ø9.52) Unit: in. (mm) Note: If the system consists of only one indoor unit with an outdoor 6HP (Type 52), the main tube of the unit (LA) should be ø19.05. Convert ø19.05 to ø15.88 using a reducer (field supply) close to the indoor unit and then make the connection. Table 1-3 Main Tubing Size After Distribution (LB, LC...
Table 1-8 Refrigerant Charge Amount at Shipment (for outdoor unit) Heat pump unit (Single-phase) (oz) U-36LE1U6 U-36LE1U6E U-52LE1U6 U-52LE1U6E 123 123 1-8. System Limitations Table 1-9 System Limitations U-36LE1U6 U-52LE1U6 U-36LE1U6E U-52LE1U6E Outdoor units 6 Number of max. connectable indoor units Max. allowable indoor/outdoor capacity ratio 9 50 – 130% 1-9.
Always check the gas density limit for the room in which the unit is installed. to 30 ° Tube branching methods (horizontal use) 15 WARNING 1-10. Check of Limit Density B 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. B Horizontal A line View as seen from arrow A Arrow view CAUTION Pay special attention to any location, such as a basement, etc.
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 CZ-P160BK1U 76,400 BTU/h (22.4 kW) or less For indoor unit CZ-P160BK1U Use: For indoor unit (Capacity after distribution joint is 76,400 BTU/h (22.4 kW) or less.
1-13. 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. Required additional refrigerant charge (oz) = 0.602 × (a) + 0.279 × (b) (a): Liquid tubing ● Total length of ø3/8" (ft.) (b): Liquid tubing Total length of ø1/4" (ft.
Example: L1 L2 LA LB Main tube of unit LC LN n 1st branch Unit distribution tube 1 7 type ● 9 type 3 n–1 12 type 18 type Example of each tubing length Main tubing Distribution joint tubing LA = 131 ft. LB = 16 ft. LC = 16 ft. LD = 49 ft. ● 2 Indoor side 1 = 16 ft. 2 = 16 ft. 3 = 7 ft. 4 = 20 ft. 5 = 16 ft. Obtain charge amount for each tubing size Note that the charge amounts per 3.3 ft. are different for each liquid tubing size. ø3/8" (ø9.52) → LA + LB + LC + LD : 212 ft. × 0.602 oz/ft.
2. SELECTING THE INSTALLATION SITE Exhaust fan 2-1. Outdoor Unit Hot air AVOID: ● heat sources, exhaust fans, etc. (Fig. 2-1) ● damp, humid or uneven locations Heat source Outdoor unit DO: ● choose a place as cool as possible. ● choose a place that is well ventilated and outside air temperature does not exceed maximum 113°F constantly. ● allow enough room around the unit for air intake/ exhaust and possible maintenance. (Fig.
2-2. Air Discharge Chamber for Top Discharge Be sure to install an air discharge chamber (field supply) in the field when: ● it is difficult to keep a space of min. 20 in. between the air discharge outlet and an obstacle. ● Air discharge the air discharge outlet is facing a sidewalk and discharged hot air may annoy passers-by. Refer to Fig. 2-5. 2-3.
Unit front, air discharge chamber 2 Unit left side, air discharge chamber 3 Unit right side, air discharge chamber 4 Reinforcement brackets, 4 locations 9-7/16 3 4 1 21-5/32 42-29/32 39-1/4 12-7/32 2-3/4 Rectangular hole 9-27/32 12-15/32 Rectangular hole 22-13/32 21-13/32 1 2-3/4 Rectangular hole 9-27/32 21-5/32 Rectangular hole 1-1/8 1-3/8 9-7/16 9-27/32 1-1/8 1-3/8 2 12-15/32 1 11-13/16 2-5.
Reference for air-discharge chamber (field supply) Required space around outdoor unit If an air discharge chamber is used, the space shown below must be secured around the outdoor unit. If the unit is used without the required space, a protective device may activate, preventing the unit from operating. Min. 7-7/8 Min. 39-3/8 (1) Single-unit installation Unit: in. CAUTION The top and both sides must remain open.
2-7. Dimensions of Snow Ducting Reference diagram for snow-proof ducting (field supply) Fastened by screws at 13 locations 30-3/32 1 Unit top, snow-proof vent 2 Unit left side 3 Unit right side 4 Unit reverse side 4 Unit: in.
Reference diagram for snow-proof ducting – 1 Space requirements for setting – (1) [Obstacle to the front of unit] [Obstacle to the rear of unit] ● Top is open: ● Top is open: (1) Single-unit installation Min. D Min. A Min. H (1) Single-unit installation (2) Obstacles on both sides Min. B (2) Multiple-unit installation (2 or more units) Min. C Min. I Min. G Min. I Min. J (3) Multiple-unit installation (2 or more units) H Min. E Min. E I J 19-11/16 11-13/16 39-3/8 Min. E Min.
Reference diagram for snow-proof ducting – 2 Space requirements for setting – (2) [Obstacles to the front and rear of unit] ● The top and both sides must remain open. Either the obstacle to the front or the obstacle to the rear must be no taller than the height of the outdoor unit. Q Min. O Min. P (1) Single-unit installation Dimension Q If a snow protection duct is attached after the unit is installed, verify that dimension Q is 19-11/16" or more. O P 39-3/8 5-29/32 Min. 11-13/16 Q Min.
3. HOW TO INSTALL THE OUTDOOR UNIT 3-1. Installing the Outdoor Unit ● Refer to the Fig. 3-1 for the anchor bolt dimensions. ● Be sure to anchor the feet with the anchor bolts (M10 or 3/8"). In addition, use anchoring washers on the top side. (Use large square 1-1/4" × 1-1/4" SUS washers with diameters of 3/8".) (Field supply) Drain port (2 locations) 6-47/64 25-63/64 8-5/8 5-29/32 33/64 33/64 33/64 3-2.
4. ELECTRICAL WIRING 4-1. General Precautions on Wiring (7) Regulations on wire diameters differ from locality to locality. For field wiring rules, please refer to your LOCAL ELECTRICAL CODES before beginning. (1) Before wiring, confirm the rated voltage of the unit as shown on its nameplate, then carry out the wiring closely following the wiring diagram.
4-3. Wiring System Diagram L1 Power supply 208 / 230V, 60Hz, 1-PH L2 Remote Controller WHT 1 BLK 2 L1 L2 Ground B A Outdoor unit INV unit U1 1 U2 2 * L1 L2 L1 L2 Power supply 208 / 230V, 60Hz, 1-PH Ground R1 1 2 R2 L1 Power supply 208 / 230V, 60Hz, 1-PH L2 Remote Controller WHT 1 BLK 2 Indoor unit (No. 1) * A Indoor unit (No. 2) * * Disconnect switch (Field Supply) * NOTE: Disconnect Switch may be needed by the National/Local code.
CAUTION (1) When linking outdoor units in a network, disconnect the terminal extended from the short plug (CN003, 2P Black, location: right bottom on the outdoor main control PCB) from all outdoor units except any one of the outdoor units. (When shipping: In shorted condition.) For a system without link (no connection wiring between outdoor units), do not remove the short plug. (2) Do not install the inter-unit control wiring in a way that forms a loop. (Fig.
WARNING Loose wiring may cause the terminal to overheat or result in unit malfunction. A fire hazard may also exist.Therefore, ensure that all wiring is tightly connected. When connecting each power wire to the terminal, follow the instructions on “How to connect wiring to the terminal” and fasten the wire securely with the fixing screw of the terminal plate. How to connect wiring to the terminal ■ For stranded wiring Stranded wire Strip 3/8".
5. HOW TO PROCESS TUBING Deburring 5-1. Connecting the Refrigerant Tubing After Before Use of the Flaring Method Many of conventional split system air conditioners employ the flaring method to connect refrigerant tubes which run between indoor and outdoor units. In this method, the copper tubes are flared at each end and connected with flare nuts. Flaring Procedure with a Flare Tool (1) Cut the copper tube to the required length with a tube cutter. It is recommended to cut approx. 1 – 2 ft.
Caution Before Connecting Tubes Tightly (1) Apply a sealing cap or water-proof tape to prevent dust or water from entering the tubes before they are used. Apply refrigerant lubricant (2) Be sure to apply refrigerant lubricant to the matching surfaces of the flare and union before connecting them together. This is effective for reducing gas leaks. (Fig. 5-4) Fig.
5-3. Insulating the Refrigerant Tubing Two tubes arranged together Liquid tubing Tubing Insulation ● Thermal insulation must be applied to all unit tubing, including distribution joint (purchased separately). * For gas tubing, the insulation material must be heat resistant to 248°F or above. For other tubing, it must be heat resistant to 176°F or above. Insulation material thickness must be 25/64" or greater.
5-4. Taping the Tubes (1) At this time, the refrigerant tubes (and electrical wiring if local codes permit) should be taped together with armoring tape in 1 bundle. To prevent the condensation from overflowing the drain pan, keep the drain hose separate from the refrigerant tubing. Clamp Insulated tubes Drain hose (2) Wrap the armoring tape from the bottom of the outdoor unit to the top of the tubing where it enters the wall. As you wrap the tubing, overlap half of each previous tape turn.
6. AIR PURGING Manifold gauge Air and moisture in the refrigerant system may have undesirable effects as indicated below. ● ● ● ● ● pressure in the system rises operating current rises cooling (or heating) efficiency drops moisture in the refrigerant circuit may freeze and block capillary tubing water may lead to corrosion of parts in the refrigerant system Fig.
(3) Do a leak test of all joints of the tubing (both indoor and outdoor) and both gas tube and liquid tube service valves. Bubbles indicate a leak. Wipe off the soap with a clean cloth after the leak test. (4) After the system is found to be free of leaks, relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder. When the system pressure is reduced to normal, disconnect the hose from the cylinder.
CAUTION Use a cylinder designed for use with R410A. Manifold valve Pressure gauge Charging additional refrigerant ● Lo Hi Charging additional refrigerant (calculated from the liquid tube length as shown in Section 1-7 “Additional Refrigerant Charge”) using the liquid tube service valve. (Fig. 6-5) ● Use a balance to measure the refrigerant accurately.
7. TEST RUN 7-1. Preparing for Test Run ● Before attempting to start the air conditioner, check the following. ON (1) All loose matter is removed from the cabinet, especially steel filings, bits of wire, and clips. (Power must be turned ON at least 5 hours before attempting test run) (2) The control wiring is correctly connected and all electrical connections are tight. (3) The transportation pads for the indoor fan have been removed. If not, remove them now.
7-2. Test Run Procedure Items to Check Before the Test Run 1. Turn the remote power switch on at least 5 hours before the test, in order to energize the crankcase heater. 2. Turn the outdoor service valves (2 locations) to the full-open positions. ● Recheck the items to check before the test run. Unit No. setting switch (S004) Set the No. of indoor units. ● CASE 1 NO Are the inter-unit control wires connected to more than 1 refrigerant system? (Check the link wiring.
7-3. Outdoor Unit PCB Setting CN33 CN51 CN50 S003 S002 D043 (LED2) S004 D042 (LED1) Fig.
Examples of the No. of indoor units settings No. of indoor units Indoor unit setting (S004) (Rotary switch, red) 1 Set to 1 1 unit (factory setting) Set to 2 9 9 units 2 2 units Set to 9 Examples of refrigerant circuit (R.C.) address settings (required when link wiring is used) System address No.
7-4. Auto Address Setting Basic wiring diagram: Example (1) • If link wiring is not used (The inter-unit control wires are not connected to multiple refrigerant systems.) Indoor unit addresses can be set without operating the compressors. No. 1 unit settings (S004) System address (system 1 setting) (S003) ON 1 2 No. of indoor units (8 units setting) (S004) (S002) ON 1 8 OFF Unit No.
Basic wiring diagram: Example (2) If link wiring is used * When multiple outdoor units exist, remove the socket that is used to short-circuit the terminal plug (CN33) from all outdoor unit PCBs except for 1. Alternatively, move the sockets to the “OPEN” side . No. 1 unit settings System address (system 1 setting) (S003) (S004) (S002) ON ON No. of indoor units (6 units setting) 1 6 1 2 OFF Outdoor unit system 1 Leave the socket that is used to short-circuit the terminal plug. (CN33) Unit No.
Case 1 Automatic Address Setting (no compressor operation) ● Indoor and outdoor unit power can be turned ON for each system separately. Indoor unit addresses can be set without operating the compressors. Automatic Address Setting from Outdoor Unit 1. On the outdoor unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the DIP ON switch (S003) is set to “0.” ON (These are the settings at the time of factory shipment.) 1 2 OFF 2.
Case 2 Automatic Address Setting in Heating Mode ● Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating. Therefore perform this process only after completing all refrigerant tubing work. Automatic Address Setting from Outdoor Unit 1. Perform steps 1 and 2 in the same way as for Case 1 . 2. Turn the indoor and outdoor unit power ON at all systems. ↓ 3.
Case 3 Automatic Address Setting in Cooling Mode ● Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating. Therefore perform this process only after completing all refrigerant tubing work. Automatic address setting can be performed during Cooling operation. Automatic Address Setting from Outdoor Unit 1. Perform steps 1 and 2 in the same way as for Case 1 . 2.
Display during automatic address setting ● On outdoor unit PCB LED 2 1 Blink alternately * Do not short-circuit the automatic address setting pin (CN51) again while automatic address setting is in progress. Doing so will cancel the setting operation and will cause LEDs 1 and 2 to turn OFF. * When automatic address setting has been successfully completed, both LEDs 1 and 2 turn OFF. * LED 1 is D042. LED 2 is D043.
Checking the indoor unit addresses Use the remote controller to check the indoor unit address. 1. Press and hold the button and button for 4 seconds or longer (simple settings mode). 2. The address is displayed for the indoor unit that is connected to the remote controller. (Only the address of the indoor unit that is connected to the remote controller can be checked.) 3. Press the button again to return to normal remote control mode.
7-5. Caution for Pump Down Pump down means refrigerant gas in the system is returned to the outdoor unit. Pump down is used when the unit is to be moved, or before servicing the refrigerant circuit. CAUTION ● This outdoor unit cannot collect more than the rated refrigerant amount as shown by the nameplate on the back. ● If the amount of refrigerant is more than that recommended, do not conduct pump down. In this case use another refrigerant collecting system. 7-6.
Alarm message Possible cause of malfunction Serial communication errors Mis-setting Improper setting. This alarm message shows when the indoor unit for multiple-use is not connected to the outdoor unit. L02 Duplication of main indoor unit address setting in group control. Duplication of outdoor R.C. address setting. There are 2 or more indoor units Priority set remote controller controllers which have operation mode priority in 1 refrigerant circuit.
DC0811-0 Printed in Japan
