Attachment 7 - REF. A-C Outdoor Unit Installation Manual.pdf

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.

MANUAL DE INSTALACIÓN

Para un uso seguro y correcto, lea detalladamente este manual de instalación antes de montar la unidad de aire acondicionado.

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Air-Conditioners OUTDOOR UNIT

PUMY-P36/48/60NKMU2(-BS)

PUMY-HP36/48NKMU

Français

Español

English

Français

Español

English

HFC

utilized

R410A

FOR INSTALLER

POUR L’INSTALLATEUR

PARA EL INSTALADOR

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Contents

1. Safety precautions

► Before installing the unit, make sure you read all the “Safety precautions”.

► Please report to or take consent by the supply authority before connec-tion to the system.

After installation work has been completed, explain the “Safety Precautions” use, and maintenance of the unit to the customer according to the information in the Operation Manual and perform the test run to ensure normal operation. Both the Installation Manual and Operation Manual must be given to the user for keeping.

These manuals must be passed on to subsequent users.

: Indicates a part which must be grounded.

Warning:

Carefully read the labels affixed to the main unit.

Warning:

• The unit must not be installed by the user. Ask a dealer or an authorized technician to install the unit. If the unit is installed incorrectly, water leakage, electric shock, or fire may result.

• For installation work, follow the instructions in the Installation Manual and use tools and pipe components specifically made for use with R410A refrigerant.

• The R410A refrigerant in the HFC system is pressurized 1.6 times the pres-sure of usual refrigerants. If pipe components not designed for R410A refrig-erant are used and the unit is not installed correctly, the pipes may burst and cause damage or injuries. In addition, water leakage, electric shock, or fire may result.

• The unit must be installed according to the instructions in order to minimize the risk of damage from earthquakes, typhoons, or strong winds. An incor-rectly installed unit may fall down and cause damage or injuries.

• The unit must be securely installed on a structure that can sustain its weight.

If the unit is mounted on an unstable structure, it may fall down and cause damage or injuries.

• If the air conditioner is installed in a small room, measures must be taken to prevent the refrigerant concentration in the room from exceeding the safety limit in the event of refrigerant leakage. Consult a dealer regarding the appropriate measures to prevent the allowable concentration from being exceeded.

Should the refrigerant leak and cause the concentration limit to be exceeded, hazards due to lack of oxygen in the room may result.

• Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.

• All electric work must be performed by a qualified technician according to local regulations and the instructions given in this manual. The units must be powered by dedicated power lines and the correct voltage and circuit breakers must be used. Power lines with insufficient capacity or incorrect electrical work may result in electric shock or fire.

• Be sure to connect the power supply cords and the connecting wires for the indoor units, outdoor units, and branch boxes directly to the units (no intermediate connections).

Intermediate connections can lead to communication errors if water enters the cords or wires and causes insufficient insulation to ground or a poor electrical contact at the intermediate connection point.

(If an intermediate connection is necessary, be sure to take measures to prevent water from entering the cords and wires.)

• Use C1220 copper phosphorus, for copper and copper alloy seamless pipes, to connect the refrigerant pipes. If the pipes are not connected correctly, the unit will not be properly grounded and electric shock may result.

• Use only specified cables for wiring. The wiring connections must be made securely with no tension applied on the terminal connections. Also, never splice the cables for wiring (unless otherwise indicated in this document).

Failure to observe these instructions may result in overheating or a fire.

• The terminal block cover panel of the outdoor unit must be firmly attached. If the cover panel is mounted incorrectly and dust and moisture enter the unit, electric shock or fire may result.

• When installing or relocating, or servicing the outdoor unit, use only the specified refrigerant (R410A) to change the refrigerant lines. Do not mix it with any other refrigerant and do not allow air to remain in the lines.

If air is mixed with the refrigerant, then it can be the cause of abnormal high pres-sure in the refrigerant line, and may result in an explosion and other hazards.

The use of any refrigerant other than that specified for the system will cause mechanical failure or system malfunction or unit breakdown. In the worst case, this could lead to a serious impediment to securing product safety.

• Use only authorized accessories and ask a dealer or an authorized techni-cian to install them. If accessories are incorrectly installed, water leakage, electric shock, or fire may result.

• Do not alter the unit. Consult a dealer for repairs. If alterations or repairs are not performed correctly, water leakage, electric shock, or fire may result.

• The user should never attempt to repair the unit or transfer it to another location.

If the unit is installed incorrectly, water leakage, electric shock, or fire may result. If the air conditioner must be repaired or moved, ask a dealer or an authorized technician.

• After installation has been completed, check for refrigerant leaks. If refriger-ant leaks into the room and comes into contact with the flame of a heater or portable cooking range, poisonous gases will be released.

1.1. Before installation

Caution:

• Do not use the unit in an unusual environment. If the air conditioner is installed in areas exposed to steam, volatile oil (including machine oil), or sulfuric gas, areas exposed to high salt content such as the seaside, or areas where the unit will be covered by snow, the performance can be significantly reduced and the internal parts can be damaged.

• Do not install the unit where combustible gases may leak, be produced, flow, or accumulate. If combustible gas accumulates around the unit, fire or explosion may result.

Warning:

Describes precautions that must be observed to prevent danger of injury or death to the user.

Caution:

Describes precautions that must be observed to prevent damage to the unit.

• The outdoor unit produces condensation during the heating operation. Make sure to provide drainage around the outdoor unit if such condensation is likely to cause damage.

• When installing the unit in a hospital or communications office, be prepared for noise and electronic interference. Inverters, home appliances, high-frequency medical equipment, and radio communications equipment can cause the air conditioner to malfunction or breakdown. The air conditioner may also affect medical equipment, disturbing medical care, and communi-cations equipment, harming the screen display quality.

1.2. Before installation (relocation)

Caution:

• Be extremely careful when transporting the units. 2 or more persons are needed to handle the unit, as it weighs 20 kg, 44 lbs or more. Do not grasp the packaging bands. Wear protective gloves to remove the unit from the packaging and to move it, as you can injure your hands on the fins or the edge of other parts.

• Be sure to safely dispose of the packaging materials. Packaging materials, such as nails and other metal or wooden parts may cause stabs or other injuries.

• The base and attachments of the outdoor unit must be periodically checked for looseness, cracks or other damage. If such defects are left uncorrected, the unit may fall down and cause damage or injuries.

• Do not clean the air conditioner unit with water. Electric shock may result.

• Tighten all flare nuts to specification using a torque wrench. If tightened too much, the flare nut can break after an extended period and refrigerant can leak out.

Confirmation of parts attached In addition to this manual, the following part is supplied with the outdoor unit.

It is used for grounding the S terminal of transmission terminal block TB7.

For detail refers to “6. Electrical work”. Grounding lead wire

1. Safety precautions

2. Installation location

3. Installing the outdoor unit

4. Installing the refrigerant piping

5. Drainage piping work

6. Electrical work

7. Test run

8. Special Functions

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1.3. Before electric work

Caution:

• Be sure to install circuit breakers. If not installed, electric shock may result.

• Please follow applicable federal, state, or local codes to prevent potential leakage/electric shock. Or install a ground fault interrupt for the prevention of leakage and electric shock.

• For the power lines, use standard cables of sufficient capacity. Otherwise, a short circuit, overheating, or fire may result.

• When installing the power lines, do not apply tension to the cables. If the connections are loosened, the cables can snap or break and overheating or fire may result.

• Be sure to ground the unit. Do not connect the ground wire to gas or water pipes, lightning rods, or telephone grounding lines. If the unit is not prop-erly grounded, electric shock may result.

• Use circuit breakers (ground fault interrupter, isolating switch (+B fuse), and molded case circuit breaker) with the specified capacity. If the circuit breaker capacity is larger than the specified capacity, breakdown or fire may result.

1.4. Before starting the test run

Caution:

• Turn on the main power switch more than 12 hours before starting operation.

Starting operation just after turning on the power switch can severely damage the internal parts. Keep the main power switch turned on during the operation season.

• Before starting operation, check that all panels, guards and other protective parts are correctly installed. Rotating, hot, or high voltage parts can cause injuries.

• Do not touch any switch with wet hands. Electric shock may result.

• Do not touch the refrigerant pipes with bare hands during operation. The refrigerant pipes are hot or cold depending on the condition of the flowing refrigerant. If you touch the pipes, burns or frostbite may result.

• After stopping operation, be sure to wait at least 5 minutes before turning off the main power switch. Otherwise, water leakage or breakdown may result.

1.5. Using R410A refrigerant air conditioners

Caution

• Use C1220 copper phosphorus, for copper and copper alloy seamless pipes, to connect the refrigerant pipes. Make sure the insides of the pipes are clean and do not contain any harmful contaminants such as sulfuric compounds, oxidants, debris, or dust. Use pipes with the specified thickness. (Refer to page 6) Note the following if reusing existing pipes that carried R22 refrigerant.

- Replace the existing flare nuts and flare the flared sections again.

- Do not use thin pipes. (Refer to page 6)

• Store the pipes to be used during installation indoors and keep both ends of the pipes sealed until just before brazing. (Leave elbow joints, etc. in their packaging.) If dust, debris, or moisture enters the refrigerant lines, oil dete-rioration or compressor breakdown may result.

• Use ester oil, ether oil, alkylbenzene oil (small amount) as the refrigeration oil applied to the flared sections. If mineral oil is mixed in the refrigeration oil, oil deterioration may result.

• Do not use refrigerant other than R410A refrigerant. If another refrigerant is used, the chlorine will cause the oil to deteriorate.

1.6. Precautions for salt damage–resistant model

(“-BS” model)

Although this product (only “-BS” model) has been designed to be resistant to salt damage, observe the following precautions to maintain the performance of the unit.

1. Avoid installing the unit in a location where it will be exposed directly to seawater or sea breeze.

2. If the cover panel may become covered with salt, be sure to install the unit in a location where the salt will be washed away by rainwater. (If a sunshade is installed, it may be difficult for rainwater to clean the panel.)

3. To ensure that water does not collect in the base of the outdoor unit, make sure that the base is level, not at angle. Water collecting in the base of the outdoor unit could cause rust.

• Use the following tools specifically designed for use with R410A refrigerant.

The following tools are necessary to use R410A refrigerant. Contact your nearest dealer for any questions.

Tools (for R410A) Gauge manifold Flare tool

Charge hose Size adjustment gauge Gas leak detector Vacuum pump adapter

Torque wrench Electronic refrigerant charging scale

• Be sure to use the correct tools. If dust, debris, or moisture enters the refriger-ant lines, refrigeration oil deterioration may result.

• Do not use a charging cylinder. If a charging cylinder is used, the composition of the refrigerant will change and the efficiency will be lowered.

1. Safety precautions

4. If the unit is installed in a coastal area, clean the unit with water regularly to remove any salt build-up.

5. If the unit is damaged during installation or maintenance, be sure to repair it.

6. Be sure to check the condition of the unit regularly.

7. Be sure to install the unit in a location with good drainage.

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2. Installation location

2.1. Refrigerant pipe

Refer to Fig. 4-1.

2.2. Choosing the outdoor unit installation location

neighbors.

• Select a location permitting easy wiring and pipe access to the power source and indoor unit.

• Avoid locations where combustible gases may leak, be produced, flow, or accumu-late.

snow fall is anticipated, special precautions such as raising the installation location or installing a hood on the air intake must be taken to prevent the snow from blocking the air intake or blowing directly against it. This can reduce the airflow and a malfunction may result.

2.3. Outline dimensions (Outdoor unit) (Fig. 2-1)

2.4. Constraints on indoor unit installation

You should note that indoor units that can be connected to this outdoor unit have the following constraints.

must not exceed 130% of the outdoor unit capacity (refer to the capacity range of connected units in Table 1).

Table 1: Number of units that can be connected and capacity range of connected units Outdoor unit model name

The capacity of outdoor unit

Number of units that can be connected

Capacity range of connected units

PUMY-P36NKMU2

36 kBtu/h 1 - 9 units 18 - 46.8 kBtu/h

PUMY-HP36NKMU

PUMY-P48NKMU2

48 kBtu/h 1 - 12 units 24 - 62.4 kBtu/h

PUMY-HP48NKMU

PUMY-P60NKMU2 60 kBtu/h 1 - 12 units 30 - 78.0 kBtu/h

Table 2: Rated capacity (cooling) of the indoor units Indoor unit type P05 P06 P08 P12 P15 P18 P24 P30 P36 P48 P54 P72 Rated capacity (Cooling) (kBtu/h)

5 6 8 12 15 18 24 30 36 48 54 72

Example: PUMY-P48NKMU2

PEFY-P24 = 24

PEFY-P18 = 18

PEFY-P18 = 18

Combinations in which the total capacity of indoor units exceeds the capacity of the outdoor unit will reduce the cooling capacity of each indoor unit below their rated cooling capacity. Thus, combine indoor units with an outdoor unit within the outdoor unit’s capacity, if possible.

2.5. Ventilation and service space

Note:

The dimensions given along the arrows above are required to guarantee the air conditioner’s performance. Install the unit in as wide a place as possible for later service or repairs.

2.5.1. Windy location installation

When installing the outdoor unit on a rooftop or other location unprotected from the wind, situate the air outlet of the unit so that it is not directly exposed to strong winds.

Strong wind entering the air outlet may impede the normal airflow and a malfunction may result.

The following shows three examples of precautions against strong winds.

1 Face the air outlet towards the nearest available wall about 50 cm (19-11/16") away from the wall. (Fig. 2-2) 2 Install an optional air guide if the unit is installed in a location where strong winds from a typhoon, etc. may directly enter the air outlet. (Fig. 2-3) A Air guide 3 Position the unit so that the air outlet blows perpendicularly to the seasonal wind direction, if possible. (Fig. 2-4) B Wind direction

Fig. 2-1

Fig. 2-2

Fig. 2-3

Fig. 2-4

13+1

14-9/16

41-11/32

8-7/8 23-5/8

-1

1/

(inch)

B

A

Total rated capacity 60 ≤ 62.4 kBtu/h

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39-3/8 *

5-29/32

11-13/16

-3

/8

7-7/8

11-13/16 7-7/8

5-29/32

39-3/8 * 9-27/32

9-27/32

-1 /1

19-11/16 11-13/16

59-1/16

19-11/16

-1

/1

59-1/16 *

59-1/16 * 19-11/16

39-3/8 23-5/8 78-24/32 *

5-29/32

59-1/16 23-5/8 118-4/32 *

19-11/16

59-1/16 31-1/2

5-

/3

Fig. 2-6

Fig. 2-10 Fig. 2-11

Fig. 2-12 Fig. 2-13 Fig. 2-14

Fig. 2-16Fig. 2-15 Fig. 2-17

Fig. 2-9

Fig. 2-8Fig. 2-7Fig. 2-5

(inch)

2. Installation location

2.5.2. When installing a single outdoor unit

Minimum dimensions are as follows, except for Max., meaning Maximum dimen-sions, indicated.

Refer to the figures for each case.

1 Obstacles at rear (Fig. 2-5) 2 Obstacles at rear and above (Fig. 2-6) 3 Obstacles at rear and sides (Fig. 2-7) 4 Obstacles at front (Fig. 2-8)

* When using the optional air outlet guides, the clearance is 19-11/16" (500 mm) or more.

5 Obstacles at front and rear (Fig. 2-9)

* When using the optional air outlet guides, the clearance is 19-11/16" (500 mm) or more.

6 Obstacles at rear, sides, and above (Fig. 2-10)

• Do not install the optional air outlet guides for upward airflow.

2.5.3. When installing multiple outdoor units

Leave 1" (25 mm) space or more between the units.

1 Obstacles at rear (Fig. 2-11) 2 Obstacles at rear and above (Fig. 2-12)

3 Obstacles at front (Fig. 2-13)

* When using the optional air outlet guides, the clearance is 39-3/8" (1000 mm) or more.

4 Obstacles at front and rear (Fig. 2-14)

* When using the optional air outlet guides, the clearance is 39-3/8" (1000 mm) or more.

5 Single parallel unit arrangement (Fig. 2-15)

* When using the optional air outlet guides installed for upward airflow, the clearance is 39-3/8"

(1000 mm) or more.

6 Multiple parallel unit arrangement (Fig. 2-16)

* When using the optional air outlet guides installed for upward airflow, the clearance is 59-1/16" (1500 mm) or more.

7 Stacked unit arrangement (Fig. 2-17)

shown.

Max. 19-11/16

Max. 11-13/16

Max. 19-11/16

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3. Installing the outdoor unit

• Be sure to install the unit in a sturdy, level surface to prevent rattling noises dur-ing operation. (Fig. 3-1)

<Foundation specifications> Foundation bolt M10 (3/8") Thickness of concrete 120 mm (4-23/32") Length of bolt 70 mm (2-3/4") Weight-bearing capacity 320 kg (705 lbs)

• Make sure that the length of the foundation bolt is within 30 mm (1-3/16") of the bottom surface of the base.

• Secure the base of the unit firmly with four-M10 foundation bolts in sturdy loca-tions.

Installing the outdoor unit

• Do not block the vent. If the vent is blocked, operation will be hindered and break-down may result.

Warning:

• The unit must be securely installed on a structure that can sustain its weight.

If the unit is mounted on an unstable structure, it may fall down and cause damage or injuries.

• The unit must be installed according to the instructions in order to mini-mize the risk of damage from earthquakes, typhoons, or strong winds. An incorrectly installed unit may fall down and cause damage or injuries.

Caution:

• Install the unit on a rigid structure to prevent excessive operation sound or vibration.

4. Installing the refrigerant piping

4.1. Precautions for devices that use R410A refrigerant

• Refer to page 3 for precautions not included below on using air conditioners with

R410A refrigerant.

table to the below. Make sure the insides of the pipes are clean and do not contain any harmful contaminants such as sulfuric compounds, oxidants, debris, or dust.

Warning:

When installing or relocating, or servicing the outdoor unit, use only the speci-fied refrigerant (R410A) to charge the refrigerant lines. Do not mix it with any other refrigerant and do not allow air to remain in the lines.

If air is mixed with the refrigerant, then it can be the cause of abnormal high pres-sure in the refrigerant line, and may result in an explosion and other hazards.

The use of any refrigerant other than that specified for the system will cause mechanical failure or system malfunction or unit breakdown. In the worst case, this could lead to a serious impediment to securing product safety.

Thickness 0.8 mm (1/32 inch) ø15.88 mm (5/8 inch), ø19.05 mm (3/4 inch) Thickness 1.0 mm (5/128 inch)

• Do not use pipes thinner than those specified above.

• The thicknesses listed in the table above are based on Japanese stand-ards. Use pipes with a maximum working pressure of 4.15 MPa [601 PSIG] or higher according to local standards.

Fig. 3-1

B

(inch)

A M10 (3/8") bolt B Base C As long as possible D Vent E Set deep in the ground

C

E

D

A

Min. 18-11/16

Min. 1

M ax

. 1 -3

/1

23-5/8 23-5/8

8-7/8 8-7/8

-9 /1

/6

41-11/32

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4. Installing the refrigerant piping

4.2. Pipe length and height difference (Fig. 4-1)

B

A

H

B C

L r

D e a h b c d

C

C

A

C C C

B

A

A a b c d

C

D e f

H h

L r

C C C C C

A, B, C, D (mm [inch]) Liquid pipe Gas pipe

PUMY-P36/48

ø9.52 [3/8] ø15.88 [5/8]

PUMY-HP36/48

PUMY-P60 ø19.05 [3/4] a, b, c, d, e, f (mm [inch]) Model number Liquid pipe Gas pipe

72 ø9.52 [3/8] ø19.05 [3/4]

Branch kit model

CMY-Y62-G-E

4-Branching header 8-Branching header

CMY-Y64-G-E CMY-Y68-G-E

Piping preparation 1 Table below shows the specifications of pipes commercially available.

Outside diameter Insulation thickness Insulation materialmm (inch) mm (inch)

6.35 (1/4) 8 (5/16)

9.52 (3/8) 8 (5/16)

12.7 (1/2) 8 (5/16)

15.88 (5/8) 8 (5/16)

19.05 (3/4) 8 (5/16)

2 Ensure that the 2 refrigerant pipes are insulated to prevent condensation.

3 Refrigerant pipe bending radius must be 4" (100 mm) or more.

Caution Be sure to use the insulation of specified thickness. Excessive thickness may cause incorrect installation of the indoor unit and branch box, and lack of thickness may cause dew drippage.

Warning:

When pumping down the refrigerant, stop the compressor before disconnect-ing the refrigerant pipes. The compressor may burst and cause injury if any foreign substance, such as air, enters the system.

A Outdoor Unit B First Branch C Indoor unit D Cap

A Outdoor Unit B First Branch C Indoor unit

Fig. 4-1

Conversion formula

P36/48

HP36/48

P60

A+B+C+D+a+b+c+d+e [ 300 m [984 ft] [ 150 m [492 ft] L = A+B+C+D+e [ 150 m [492 ft] [ 80 m [262 ft] R = B+C+D+e [ 30 m [98 ft] H Outdoor higher [ 50 m [164 ft]

Outdoor lower [ 40 m [131 ft]* [ 40 m [131 ft] h [ 15 m [49 ft]

P36/48

HP36/48

P60

A+a+b+c+d+e+f [ 300 m [984 ft] [ 150 m [492 ft] L = A+f [ 150 m [492 ft] [ 80 m [262 ft] R = f [ 30 m [98 ft] H Outdoor higher [ 50 m [164 ft]

Outdoor lower [ 40 m [131 ft]* [ 40 m [131 ft] h [ 15 m [49 ft]

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4. Installing the refrigerant piping

4.3. Connecting pipes (Fig. 4-2) (Fig. 4-3)

• Conduct sufficient anti-condensation and insulation work to prevent water drip-ping from the refrigerant piping. (liquid pipe/gas pipe)

• Increase insulation depending on the environment where the refrigerant piping is installed, or condensation may occur on the surface of the insulation material.

(Insulation material Heat-resistant temperature: 120 °C, 248 °F, Thickness:

15 mm, 5/8 inch or more)

* When the refrigerant piping is used in locations subject to high tempera-ture and humidity such as in the attic, further addition of insulation may be required.

• To insulate the refrigerant piping, apply heat-resistant polyethylene foam between the indoor unit and insulation material as well as to the net between the insulation material filling all gaps.

(Condensation forming on the piping may result in condensation in the room or burns when contacting the piping.)

[Fig. 4-3]

completed.

• Make sure the pipes do not contact the compressor. Abnormal noise or vibration may result.

1 Pipes must be connected starting from the indoor unit.

Flare nuts must be tightened with a torque wrench.

2 Flare the liquid pipes and gas pipes and apply a thin layer of refrigeration oil (Ap-plied on site).

• When usual pipe sealing is used, refer to Table 2 for flaring of R410A refrigerant pipes.

The size adjustment gauge can be used to confirm A measurements.

Warning:

When installing the unit, securely connect the refrigerant pipes before starting the compressor.

Caution:

• Be sure to wrap insulation around the piping. Direct contact with the bare piping may result in burns or frostbite.

Table 2 (Fig. 4-4) mm (inch)

Copper pipe O.D.

A

Flare tool for R410A Flare tool for R22·R407C

Clutch type

A (Fig. 4-3) Copper pipe O.D.

(mm) (inch) Flare dimensions

Copper pipe O.D.

(mm) (inch)

Flare nut O.D.

(mm) (inch)

Tightening torque (N·m)* (ft·lbs)

* 1 N·m 10 kgf·cm

A

B

C D

A Liquid pipe B Gas pipe C Insulation D Taping

Fig. 4-2

Fig. 4-3

A Flare cutting dimensions B Flare nut tightening torque

0.

5°

R1/64" to R1/32" øA

45°± 2°

Fig. 4-4

A Die B Copper pipe

A

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4.4. Refrigerant piping (Fig. 4-5)

Remove the service panel D (three screws) and the front piping cover A (two screws) and rear piping cover B (two screws).

1 Perform refrigerant piping connections for the indoor/outdoor unit when the outdoor unit’s stop valve is completely closed.

2 Vacuum-purge air from the indoor unit and the connection piping.

Evacuation Evacuate with the valve of the outdoor unit closed and evacuate both the connec-tion piping and the indoor unit from the service port provided on the valve of the outdoor unit using a vacuum pump. (Always evacuate from the service port of both liquid pipe and gas pipe.) After the vacuum reaches 650 Pa [abs] [0.0943 psi/5 Torr], continue evacuation for at least one hour or more. Then, stop the vacuum pump and leave it for 1 hour. Ensure the degree of vacuum has not increased. (If the degree of vacuum increase is larger than 130 Pa [0.01886 psi/1.0 Torr], water might have entered. Apply pressure to dry nitrogen gas up to 0.05 MPa [7.25 psi] and vacuum again.) Finally, seal in with the liquid refrigerant through the liquid pipe, and adjust the gas piping to obtain an appropriate amount of the refrigerant during operation.

* Never perform air purging using refrigerant.

3 After connecting the refrigerant pipes, check the connected pipes and the indoor unit for gas leaks. (Refer to 4.5. Refrigerant pipe airtight testing method) 4 Vacuumize the refrigerant lines through the service port of the liquid and gas stop valves. And then open the stop valves completely (for both the liquid and gas stop valves). This will completely connect the refrigerant lines of the indoor and outdoor units.

• If the stop valves are left closed and the unit is operated, the compressor and control valves will be damaged.

• Use a leak detector or soapy water to check for gas leaks at the pipe con-nection sections of the outdoor unit.

• Do not use the refrigerant from the unit to purge air from the refrigerant lines.

Failure to replace and tighten the caps may result in refrigerant leakage. In addition, do not damage the insides of the valve caps as they act as a seal to prevent refrigerant leakage.

5 Use sealant to seal the ends of the thermal insulation around the pipe connec-tion sections to prevent water from entering the thermal insulation.

Refrigerant pipes are protectively wrapped

• The pipes can be protectively wrapped up to a diameter of ø90 mm (3-9/16") before or after connecting the pipes. Cut out the knockout in the pipe cover following the groove and wrap the pipes.

Pipe inlet gap

• Use putty or sealant to seal the pipe inlet around the pipes so that no gaps remain.

(If the gaps are not closed, noise may be emitted or water and dust will enter the unit and breakdown may result.)

Note:

<Triple Evacuation>

• Evacuate the system to 4,000 microns from both service valves. System manifold gauges must not be used to measure vacuum. A micron gauge must be used at all times.

- Break the vacuum with Nitrogen (N2) into the discharge service valve to 0 PSIG.

• Evacuate the system to 500 microns. System must hold the vacuum at 500 microns for a minimum of 1 hour.

• Conduct a rise test for a minimum of 30 minutes.

4.5. Refrigerant pipe airtight testing method

(1) Connect the testing tools.

stop valve A and the gas stop valve B.

(2) Do not add pressure to the specified pressure all at once; add pressure little by little.

1 Pressurize to 0.5 MPa [73 PSIG], wait five minutes, and make sure the pres-sure does not decrease.

2 Pressurize to 1.5 MPa [218 PSIG], wait five minutes, and make sure the pressure does not decrease.

3 Pressurize to 4.15 MPa [601 PSIG] and measure the surrounding tempera-ture and refrigerant pressure.

(3) If the specified pressure holds for about one day and does not decrease, the pipes have passed the test and there are no leaks.

• If the surrounding temperature changes by 1°C [1.8°F], the pressure will change by about 0.01 MPa [1.5 PSIG]. Make the necessary corrections.

(4) If the pressure decreases in steps (2) or (3), there is a gas leak. Look for the source of the gas leak.

4. Installing the refrigerant piping

Fig. 4-6

Fig. 4-7

Fig. 4-8

A Valve F Completely closed B Unit side G Completely open C Service port H Refrigerant piping side (On-site installation) D Handle I Direction the refrigerant flows in E Cap J Wrench hole

C

(1) 1 2

H

B

A E

C

F

D G

B C

J

I

H

E

(2)

B

C

EA

D

Fig. 4-5

A Front piping cover B Piping cover C Stop valve D Service panel E Bend radius : 100 mm - 150 mm (3-15/16″ – 5-7/8″)

C Service port D Open/Close section E Local pipe

F Sealed, same way for gas side G Pipe cover H Do not use a wrench here.

Refrigerant leakage may result.

I Use two wrenches here.

A B

H

I

C

D

E F

G

C

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5. Drainage piping work

4. Installing the refrigerant piping

Outdoor unit drainage pipe connection When drain piping is necessary, use the drain socket or the drain pan (option).

However, it can not be used for PUMY-HP36/48 (Hyper Heating model) Drain socket PAC-SG61DS-E Drain pan PAC-SH97DP-E

6. Electrical work

Fig. 4-9

4.6. Stop valve opening method

The stop valve opening method varies according to the outdoor unit model. Use the appropriate method to open the stop valves.

(1) Gas side (Fig. 4-7) 1 Remove the cap, pull the handle toward you and rotate 1/4 turn in a counterclock-wise direction to open.

2 Make sure that the stop valve is open completely, push in the handle and rotate the cap back to its original position.

(2) Liquid side (Fig. 4-8) 1 Remove the cap and turn the valve rod counterclockwise as far as it will go with the use of a 4 mm [3/16"] hexagonal wrench. Stop turning when it hits the stopper.

2 Make sure that the stop valve is open completely and rotate the cap back to its original position.

Precautions when using the charge valve (Fig. 4-9) Do not tighten the service port too much when installing it, otherwise, the valve core could be deformed and become loose, causing a gas leak.

After positioning section B in the desired direction, turn section A only and tighten it.

Do not further tighten sections A and B together after tightening section A.

Warning:

• When installing the unit, securely connect the refrigerant pipes before starting the compressor.

6.1. Caution

1 Follow ordinance of your governmental organization for technical standard related to electrical equipment, wiring regulations and guidance of each electric power company.

2 Wiring for control (hereinafter referred to as transmission line) shall be (5 cm [2 inch] or more) apart from power source wiring so that it is not influenced by electric noise from power source wiring. (Do not insert transmission line and power source wire in the same conduit.)

3 Be sure to provide designated grounding work to outdoor unit.

4 Give some allowance to wiring for electrical part box of indoor and outdoor units, because the box is sometimes removed at the time of service work.

5 Never connect the main power source to terminal block of transmission line. If connected, electrical parts will be burnt out.

6 Use 2-core shield cable for transmission line. If transmission lines of different systems are wired with the same multiplecore cable, the resultant poor trans-mitting and receiving will cause erroneous operations.

7 Only the transmission line specified should be connected to the terminal block for outdoor unit transmission.

(Transmission line to be connected with indoor unit : Terminal block TB3 for transmission line, Other : Terminal block TB7 for centralized control)

Erroneous connection does not allow the system to operate.

8 In case to connect with the upper class controller or to conduct group operation in different refrigerant systems, the control line for transmission is required between the outdoor units each other.

Connect this control line between the terminal blocks for centralized control.

(2-wire line with no polarity)

When conducting group operation in different refrigerant systems without con-necting to the upper class controller, replace the insertion of the short circuit connector from CN41 of one outdoor unit to CN40.

9 Before turning outdoor unit on, be sure to turn the indoor units and the branch boxes.

* The figure to the left is an example only.

The stop valve shape, service port position, etc., may vary according to the model.

* Turn section A only.

(Do not further tighten sections A and B together.)

C Charge hose D Service port

<Example>

The total length of each liquid line is as follows:

The total capacity of connected indoor unit is as follows:

24 + 15 + 08 + 08 = 55 <Calculation example> Additional refrigerant charge

40 × 19.0

+ 45 × 50.0

+ 3.0 = 6.1 kg (rounded up) 1000 1000

(131 × 0.21 + 148 × 0.55 + 106 = 215 oz)

<Additional Charge> Calculation of refrigerant charge Pipe size Liquid pipe ø6.35

Pipe size Liquid pipe ø9.52

Total capacity of connected indoor units

Amount for the indoor units

P36/48

HP36/48

(m) × 19.0 (g/m) (0.21 (oz/ft))

P36/48

HP36/48

(m) × 50.0 (g/m) (0.55 (oz/ft))

P60 (m) × 27.0 (g/m) (0.29 (oz/ft)) P60 (m) × 70.0 (g/m)

(0.75 (oz/ft)) 55 – 3.0 kg (106 oz)

Included refrigerant amount when shipped from the factory Included refrigerant amount

P36/48 HP36/48 4.8 kg (169 oz)

P60 5.1 kg (180 oz)

At the conditions below:

4.7. Additional refrigerant charge

Additional refrigerant charge Refrigerant for the extended piping is not included in the outdoor unit when the unit is shipped from the factory. Therefore, charge each refrigerant piping system with addi-tional refrigerant at the installation site. In addition, in order to carry out service, enter the size and length of each liquid pipe and additional refrigerant charge amounts in the spaces provided on the “Refrigerant amount” plate on the outdoor unit.

* When the unit is stopped, charge the unit with the additional refrigerant through the liquid stop valve after the pipe extensions and indoor units have been vacu-umized.

When the unit is operating, add refrigerant to the gas check valve using a safety charger. Do not add liquid refrigerant directly to the check valve.

Calculation of additional refrigerant charge

• Calculate the additional charge using the liquid pipe size and length of the ex-tended piping and total capacity of connected indoor units.

• Calculate the additional refrigerant charge using the procedure shown to the right, and charge with the additional refrigerant.

• For amounts less than 0.1 kg, round up the calculated additional refrigerant charge.

(For example, if the calculated charge is 6.01 kg, round up the charge to 6.1 kg.)

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6. Electrical work

6.3. Wiring transmission cables

1 Types of control cables

1. Wiring transmission cables

Types of transmission cable Shielding wire (2-core) CVVS, CPEVS or MVVS Cable diameter More than 1.25 mm2 [AWG 16]

Maximum wiring length Within 200 m [656 ft]

Cable diameter 0.5 to 1.25 mm2 [AWG 20 to AWG 16]*

Remarks When 10 m [32 ft] is exceeded, use cable with the same specifications as transmission line wiring.

* Connected with simple remote controller.

M1 SM2

BA

C

M1 SM2

TB3TB1 TB7

D

L1 L2 GR

6.2. Control box and connecting position of wiring

(Fig. 6-1)

1. Connect the wiring between the outdoor unit and the indoor unit to the trans-mission terminal block (TB3) of the outdoor unit.

Connect the wiring between the outdoor unit and the centralized control system to the transmission terminal block (TB7) of the outdoor unit.

When using shielded wiring, connect the ground of the shielded wiring to the shield terminal (S) of the terminal block (TB3) or (TB7).

If the connection of the outdoor unit’s transmission power supply connector has been changed from CN41 to CN42, connect the shield terminal (S) of the terminal block (TB7) to the screw (D) using the included lead wire.

* The shield (S) terminal of the transmission terminal block (TB3) is connected to the ground (C) when the unit is shipped from the factory.

2. Conduit mounting plates are being provided. Pass the power supply and transmission wires through the appropriate knock-out holes, then remove the knock-out piece from the bottom of the terminal box and connect the wires.

3. Fix power source wiring to terminal box by using buffer bushing for tensile force (PG connection or the like).

Caution:

Never connect the transmission line for the branch box or the central control system transmission line to this terminal bed (TB1B). If the transmission lines are connected, the indoor unit terminal block, branch box terminal block or centralized control terminal block could be damaged.Fig. 6-1

3. MA Remote control cables Kind of remote control cable Sheathed 2-core cable (unshielded) CVV

Cable diameter 0.3 to 1.25 mm2 [AWG 22 to AWG 16] (0.75 to 1.25 mm2 [AWG 18 to AWG 16])*

Remarks Within 200 m [656 ft]

* Connected with simple remote controller.

2 Wiring examples

• Controller name, symbol and allowable number of controllers.

Name Symbol Allowable number of controllers Outdoor unit controller OC –

Indoor unit controller IC

PUMY-P36NKMU2

1 to 9 units per 1 OC

PUMY-HP36NKMU

PUMY-P48NKMU2

1 to 12 units per 1 OCPUMY-HP48NKMU

PUMY-P60NKMU2

Remote controller RC MA Maximum of 2 per group

CONDUIT PLATE:

accessory ø24 knock-out hole (For transmission wires) ø37 knock-out hole (For power supply wires)

CONDUIT WASHER:

accessory

Example of a group operation system with multiple outdoor units (Shielding wires and address setting are neces-sary.)

<Examples of Transmission Cable Wiring> � M-NET Remote Controller (Fig. 6-2) � MA Remote Controller (Fig. 6-3)

<Wiring Method and Address Settings>

a. Always use shielded wire when making connections between the outdoor unit (OC) and the indoor unit (IC), as well for all OC-OC, and IC-IC wiring intervals.

b. Use feed wiring to connect terminals M1 and M2 and the ground terminal on the transmission cable terminal block (TB3) of each outdoor unit (OC) to terminals M1, M2 and terminal S on the transmission cable block of the indoor unit (IC).

c. Connect terminals 1 (M1) and 2 (M2) on the transmission cable terminal block of the indoor unit (IC) that has the most recent address within the same group to the terminal block on the remote controller (RC).

d. Connect together terminals M1, M2 and terminal S on the terminal block for central control (TB7) for the outdoor unit (OC).

e. The jumper connector CN41 on the control panel does not change.

f. Connect the terminal S on the terminal block for central control for the power supply unit to the ground terminal ( ) in the electrical component box.

g. Set the address setting switch as follows.

Unit Range Setting Method IC (Main) 01 to 50 Use the most recent address within the same group of indoor units

IC (Sub) 01 to 50 Use an address, other than that of the IC (Main) from among the units within the same group of indoor units. This must be in sequence with the IC (Main)

OC 51 to 100 Use the most recent address of all the indoor units plus 50

* The address automatically becomes “100” if it is set as “01 - 50”.

MA R/C – Unnecessary address setting (Necessary main/sub setting)

h. The group setting operations among the multiple indoor units is done by the remote controller (RC) after the electrical power has been turned on.

<Permissible Lengths> 1 M-NET Remote controller

If the length exceeds 10 m [33 ft], use a 1.25 mm2 [AWG16] shielded wire. The length of this section (L8) should be included in the calculation of the maximum length and overall length.

2 MA Remote controller

C Screw on the electrical component box (TB3) D Screw on the electrical component box (TB7)

A Power source B Transmission line

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A : Group 1 B : Group 3 C : Group 5 D : Shielded Wire E : Unshielded Wire

6. Electrical work

6.4. Wiring of main power supply and equipment capacity

Schematic Drawing of Wiring (Example) (Fig. 6-4)

A : Switch (Breakers for Wiring and Current Leakage (if you use)) B : Outdoor Unit C : Pull Box D : Indoor Unit

Fig. 6-4

D D

C

A

D D

A

B

C

D

TB7TB3

IC(51)

TB5

(01)

IC

TB5

(03)

IC

TB5

(02)

IC

TB5

(04)

L2

L1

(101)

RC

RC

(104)

OC

TB7

(53)

OC

DC24V

L3

L6

L7

L4 L5

H r r

M1 M2 S M1 M2 S M1 M2 S M1 M2 S

A B

M1 M2 S M1 M2 SSM1 M2 S

TB3

M1 M2 S

M1 M2 S

A B

M1 M2

H

IC

TB5

(05)

IC

TB5

(07)

IC

TB5

(06)

M1 M2 S

M1 M2 S M1 M2 S

(105)

RC

(155)

RC

A BA B

GF

r r

A C

B

D

TB7

IC(51)

TB15 TB15

TB15

MA

(01)

IC

TB5

(03)

IC

TB5TB5

(02)

IC

TB5

(04)

L1

MA

OC

(53)

OC

L3

L7

L4 m

TB3

m m m

M1 M2 S M1 M2 S

TB7

M1 M2 SM1 M2 S

TB3

M1 M2 S

M1 M2 S

M1 M2 S M1 M2 S

M1 M2 S

A B

1 2

1 2 M1 M2 S 1 2

1 2

TB15

A B

L2

L6

H

H

DC24V

IC

(05)

IC

(07)

IC

(06)

MA MA

m m

TB15TB5

M1 M2 S 1 2

TB15TB5

M1 M2 S 1 2

A B A B

TB5

M1 M2 S 1 2

TB15

G

E

F

E m m

� MA Remote Controller

Fig. 6-2 Fig. 6-3

� M-NET Remote Controller

Thickness of Wire for Main Power Supply and On/Off Capacities

Model Power Supply

Minimum Wire Thickness (mm2 [AWG]) Conduit

Size Breaker for

Wiring*1 Breaker for Current Leakage

(if you use) Minimum cir-cuit ampacity

Maximum rating of over current protector deviceMain Cable*2 Ground

Outdoor Unit P36/48

208/230 VAC,

60 Hz

5.3 [AWG10] 5.3 [AWG10] 3/4 inch *3 30 A 30 A 30 mA 0.1 sec. or less 29 A 44 A HP36/48 8.4 [AWG8] 8.4 [AWG8] 3/4 inch 40 A 40 A 30 mA 0.1 sec. or less 36 A 44 A P60 8.4 [AWG8] 8.4 [AWG8] 3/4 inch 40 A 40 A 30 mA 0.1 sec. or less 36 A 45 A

Indoor Unit Refer to installation manual of indoor unit.

*1. Please follow applicable federal, state, or local codes to prevent potential leakage/electric shock. Or install a ground fault interrupt for the prevention of leakage and electric shock.

IMPORTANT

If a current leakage breaker is used, it should be compatible with higher harmonics as this unit is equipped with an inverter. The use of an inadequate breaker can cause the incorrect operation of inverter.

*2. Use copper supply wires. Use the electric wires over the rating voltage 300 V.

*3. Although the conduit size is larger than the size specified for the wire thickness according to UL standards, use a conduit size of 3/4 inch.

Total operating current of the indoor unit Minimum wire thickness (mm2/AWG) Ground-fault interruper *1

(if you use) Local switch (A) Breaker for wiring

(NFB)Main Cable Branch Ground Capacity Fuse F0 = 15 A or less *2 2.1/14 2.1/14 2.1/14 15 A current sensitivity *3 15 15 15 F0 = 20 A or less *2 3.3/12 3.3/12 3.3/12 20 A current sensitivity *3 20 20 20 F0 = 30 A or less *2 5.3/10 5.3/10 5.3/10 30 A current sensitivity *3 30 30 30

Apply to IEC61000-3-3 about max. permissive system impedance.

*1 The Ground-fault interrupter should support inverter circuit.

The Ground-fault interrupter should combine using of local switch or wiring breaker.

*2 Please take the larger of F1 or F2 as the value for F0.

208/230 VAC

60 Hz

208/230 VAC

60 Hz c or D c or D c or D c or D

A B

GR

Power Supply Unit

Power Supply Unit

System controller

System controller

F : Main Remote Controller G : Sub Remote Controller H : Screw on the electrical component box ( ): Address

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6. Electrical work

Never splice the power cable or the indoor-outdoor connection cable, otherwise it may result in a smoke, a fire or communication failure.

Indoor unit V1 V2 Type 1 PEFY-P·NMAU, PVFY-P·NAMU 38.0 1.6

Type 2

PMFY-P·NBMU

19.8 2.4

C : Multiple of tripping current at tripping time 0.01s Please pick up “C” from the tripping characteristic of the breaker.