Mitsubishi Heavy Industries SRK60ZJX-S, Technical Manual

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-
1
10
-
'10 • SR-T-091
<Table of pipe size restrictions>
◎: Standard pipe size ○: Usable △: Restricted to shorter pipe length limits
●
Please consult with our distributor in the area, if you need to recover refrigerant and charge it again.
●
Any combinations of pipe sizes not listed in the table are not usable.
Wires for connecting indoor
and outdoor units
Exterior tape
Gas piping
Insulation
Liquid piping
Band (accessory)
Pipe cover (accessory)
Additional charge volume (kg) = {Main pipe length (m) – Length covered without additional charge shown in the table (m)} ×
Additional charge volume per meter of pipe shown in the table (kg/m)
Formula to calculate the volume of additional refrigerant required
4. ELECTRICAL WIRING WORK
For details of electrical cabling, refer to the indoor unit installation manual.
3. DRAIN PIPING WORK
40
Pipe size
50
60
Liquid pipe ø6.35 ø9.52
Gas pipe ø12.7 ø12.7
Usability ◎ △
Maximum one-way pipe length 30 10
Length covered without additional charge 15 5
Usability ◎ △
Maximum one-way pipe length 30 10
Length covered without additional charge 15 15
Usability ◎ △
Maximum one-way pipe length 30 10
Length covered without additional charge 15 5
Additional charge volume per meter of pipe 0.02kg/m 0.06kg/m
Formula to calculate additional charge volume
※
If you obtain a negative figure as a result of calculation, no additional refrigerant needs to be charged.
Example) When an 60 is installed in a 10m long existing pipe system (liquid
φ
9.52, gas
φ
12.7),
the quantity of refrigerant to charge additionally should be (10m-5m) x 0.06kg/m = 0.3 kg.
7) Additional refrigerant charge
Additional charge volume (kg) = { Main length (m) – Factory charged volume 15 (m) } x 0.02 (kg/m)
*When an additional charge volume calculation result is negative,
it is not necessary to charge refrigerant additionally.
8) Heating and condensation prevention
(1) Dress refrigerant pipes (both gas and liquid pipes) for heat insulation and prevention of dew condensation.
･
Improper heat insulation/anti-dew dressing can result in a water leak or dripping causing damage to household effects, etc.
(2) Use a heat insulating material that can withstand 120 ℃ or a higher temperature. Poor heat insulating capacity can cause heat insulation problems or cable
deterioration.
･
All gas pipes must be securely heat insulated in order to prevent damage from dripping water that comes from the condensation formed on them during a cooling operation
or personal injury from burns because their surface can reach quite a high temperature due to discharged gas flowing inside during a heating operation.
･ Wrap indoor units’ flare joints with heat insulating parts (pipe cover) for heat insulation (both gas and liquid pipes).
･
Give heat insulation to both gas and liquid side pipes. Bundle a heat insulating material and a pipe tightly together so that no gaps may be left between them and wrap them
together with a connecting cable by a dressing tape.
･ Both gas and liquid pipes need to be dressed with 20 mm or thicker heat insulation materials above the ceiling where relative humidity exceeds 70%.
CAUTION
Power cable, indoor-outdoor connecting wires
Always use an earth leakage circuit breaker designed for inverter circuits to
prevent a faulty operation.
NO
Are the existing units our products?
NO
NO
NO
Is the existing pipe system to reuse free of corrosion, flaws or dents?
Repair the damaged parts.
Remove those branches.
Repair the damaged parts.
Check the pipe system for air tightness on the site.
Repair the damaged parts.
NO
NO
NO
NO
No loose pipe supports
NO
YES
START
The existing pipe system is reusable.
The existing pipe system is not reusable.
Install a new pipe system.
YES YES
YES
YES
YES
Are an outdoor unit and an indoor unit connected to the
existing pipe system to reuse?
Is the unit to install in the existing pipe system a
twin-triple-double-twin model?
Is the existing pipe system to reuse free of gas leaks?
(Check whether refrigerant charge was required frequently for
the system before)
Are heat insulation materials of the existing pipe system to
reuse free of peel-offs or deterioration?
(Heat insulation is necessary for both gas and liquid pipes)
Change the branching pipe to a specified type.
Does the existing pipe system to reuse satisfy all of the following?
(1) The pipe length is 30m or less.
(2) The pipe size conforms to the table of pipe size restrictions.
(3) The elevation difference between the indoor and outdoor units
conforms to the following restrictions.
Where the outdoor unit is above: 15m or less
Where the outdoor unit is below: 15m or less
Which of the following refrigeration oils
does the existing unit use?
Suniso, MS, Barrel Freeze, HAB, Freol,
ether oil, ester oil
Please make an
inquiry for
reusability.
※ Check with the flow chart developed for a case where
an existing pipe system is reused for a
twin-triple-double-twin model published as a
technical data sheet.
Change
Change is impossible.
Can Use
Can‘t
Use
Repair is impossible.
Air tightness is
impossible.
Remove is
impossible
Repair is impossible.
Repair
Repair
Repair
Some loose pipe supports
Air tightness is OK
Remove
5. UTILIZATION OF EXISTING PIPING
Check whether an existing pipe system is reusable or not by using the following flow chart.
WARNING
<Where the existing unit can be run for a cooling operation.>
Carry out the following steps with the excising unit (in the order of (1), (2), (3) and (4))
(1) Run the unit for 30 minutes for a cooling operation.
(2) Stop the indoor fan and run the unit for 3 minutes for a cooling operation (returning liquid)
(3) Close the liquid side operation valve of the outdoor unit and pump down (refrigerant recovery)
(4) Blow with nitrogen gas.
※
If discolored refrigeration oil or any foreign matters is discharged
by the blow, wash the pipe system or install a new pipe system.
● For the flare nut, do not use the old one, but use the one supplied with the outdoor unit.
Process a flare to the dimensions specified for R410A.
<Where the existing unit cannot be run for a cooling operation.>
Wash the pipe system or install a new pipe system.
● If you choose to wash the pipe system, please contact our distributor in the area.
●
In cabling, fasten cables securely with cable clamps so that no external force may work on terminal connections.
● Grounding terminals are prorided in the control box.
●
Always perform grounding system installation work with the power cord unplugged.
●
Connect a pair bearing a common terminal number with an indoor-outdoor connecting wire.
● For an installation measuring 15 m or shorter in pipe length, please charge the refrigerant volume charged for shipment at the
factory, when you recharge refrigerant after servicing etc.
Aren’t there any loose pipe supports?
Are there any branch pipes with no indoor unit connected?
Electrical installation work must be performed by an electrical installation service provider qualified by a power provider of the country.
Electrical installation work must be executed according to the technical standards and other regulations applicable to electrical installations in the country.
●
Do not use any supply cord lighter than one specified in parentheses for each type below.
･
braided cord (code designation 60245 IEC 51),
･
ordinary tough rubber sheathed cord (code designation 60245 IEC 53)
･
flat twin tinsel cord (code designation 60227 IEC 41);
Use polychloroprene sheathed flexible cord (code designation 60245 IEC57) for supply cords of parts of appliances for outdoor use.
●
Ground the unit. Do not connect the grounding wire to a gas pipe, water pipe, lightning rod or telephone grounding wire.
If impropery grounded, an electric shock or malfunction may result.
●
A grounding wire must be connected before connecting the power cable. Provide a grounding wire longer than the power cable.
●
The installation of an impulse withstanding type earth leakage breaker is necessary. A failure to install an earth leakage breaker can result in an
acccident such as an electric shock or a fire.
●
Do not turn on the power until the electrical work is completeted .
●
Do not use a condensive capacitor for power factor improvement under any circumstances. (It dose not improve power factor, while it can cause
an abnormal overheat accident)
●
For power supply cables, use conduits.
●
Do not lay electronic control cables (remote control and signaling wires) and other cables together outside the unit. Laying them together can result
in the malfunctioning or a failure of the unit due to electric noises.
●
Fasten cables so that may not touch the piping, etc.
●
When cables are connected, make sure that all electrical components within the electrical component box are free of loose connector coupling or
terminal connection and then attach the cover securely. (Improper cover attachment can result in malfunctioning or a failure of the unit, if water
penetrates into the box.)
●
Always use a three-core cable for an indoor-outdoor connecting cable. Never use a shield cable.
L
Outdoor unit
Switchgear or Circuit breaker
N
1 2/N 3
1 2/N 3
Indoor unit
Earth leakage breaker
(Harmonic resistant type)
Cable clamp
Power supply terminal block
○
It holds cables in place and protect the terminal
connection from external force.
○ This clamp is for the cable in the outside
diameter 9~15mm.
Please adjust it when not suitable.
○
It holds cables in place and protect the terminal
connection from external force.
○
Please be sure to carry out D-type (type III)
grounding work.
Interconnecting and
grounding wires
(minimum)
40
50
60
2.0
mm 2 30A 16A
1.5mm×4
15A,30mA,
0.1sec or less
Switchgear or Circuit Breaker
Switch breaker Over current protector
rated capacity
Earth leakage breaker
● The specifications shown in the above table are for units without heaters. For units with heaters, refer to
the installation instructions or the construction instructions of the indoor unit.
●
Switchgear or Circuit breaker capacity which is calculated from MAX. over current should be chosen along the
regulations in each country.
●
The cable specifications are based on the assumption that a metal or plastic conduit is used with no more than
three cables contained in a conduit and a voltage drop is 2%. For an installation falling outside of these
conditions, please follow the internal cabling regulations. Adapt it to the regulation in effect in each country.
Power souce
(minimum)
Model Phase
Single-phase
Grounding terminal
Take care so that installed pipes may not touch components within a unit.
If touching with an internal component, it will generate abnormal sounds and/or vibrations.
4) On-site piping work
IMPORTANT
How to remove the side cover
● Carry out the on site piping work with the operation valve fully closed.
●
Give sufficient protection to a pipe end (compressed and blazed, or with an adhesive tape) so
that water or foreign matters may not enter the piping.
● Bend a pipe to a radius as large as practical.(R100~R150) Do not bend a pipe repeatedly to correct
its form.
● Flare connection is used between the unit and refrigerant pipe. Flare a pipe after engaging a
flare nut onto it. Flare dimensions for R410A are different from those for conventional R407C.
Although we recommend the use of flaring tools designed specifically for R410A, conventional
flaring tools can also be used by adjusting the measurement of protrusion B with a protrusion
control gauge.
● Tighten a flare joint securely with a double spanner.
Please remove the screw of a side cover and remove to the front.
A
B
Flared pipe end : A
(mm)
φ
6.35
φ
12.7
Copper
pipe outer
diameter
0
ー
0
．
4
Ａ
9 ． 1
16.6
Copper pipe protrusion for flaring : B
(mm)
φ 6.35
φ
12.7
Copper
pipe outer
diameter
In the case of a rigid (clutch) type
With an R410A tool With a conventional tool
0 〜 0.5 1.0 〜 1.5
CAUTION
CAUTION
Do not apply force beyond proper fastening torque in tightening the flare nut.
Fix both liquid and gas operation valves at the valve main bodies as illustrated on the right, and then fasten them,
applying appropriate fastening torque.
Tightening angle ( ° ) Tightening torque (N
･
m)
φ 6.35 (1/4")
φ
12.7 (1/2")
14 〜 18
49 〜 61
45
〜
60
30
〜
45
150
250
Recommended length of a tool handle (mm) Operation valve size (mm)
Use a torque wrench. If a torque wrench is
not available, fasten the flare nut manually
first and then tighten it further, using the
left table as a guide.
Do not hold the valve cap area with a spanner.
5) Air tightness test
① Although outdoor and indoor units themselves have been tested for air tightness at the factory, check the connecting pipes after the installation work for air tightness from the
operation valve’s check joint equipped on the outdoor unit side. While conducting a test, keep the operation valve shut all the time.
a) Raise the pressure to 0.5 MPa, and then stop. Leave it for five minutes to see if the pressure drops.
b) Then raise the pressure to 1.5 MPa, and stop. Leave it for five more minutes to see if the pressure drops.
c) Then raise the pressure to the specified level (4.15 MPa), and record the ambient temperature and the pressure.
d) If no pressure drop is observed with an installation pressurized to the specified level and left for about one day, it is acceptable. When the ambient Temperature fall 1 ℃ , the pressure
also fall approximately 0.01 MPa. The pressure, if changed, should be compensated for.
e) If a pressure drop is observed in checking e) and a) – d), a leak exists somewhere. Find a leak by applying bubble test liquid to welded parts and flare joints and repair it. After
repair, conduct an air-tightness test again.
② In conducting an air-tightness test, use nitrogen gas and pressurize the system with nitrogen gas from the gas side. Do not use a medium other than nitrogen gas under any circumstances.
Gas side
operation valve
Check joint
Pressurize
Close
Outdoor unit
Indoor unit
＜ Work flow ＞
6) Evacuation
Airtighteness test completed
Fill refrigerant
Vacuum gauge check
Vacuuming completed
Vacuuming begins
Run the vacuum pump for at least one hour after the vacuum
gauge shows -101kPa or lower. (-755mmHg or lower)
Confirm that the vacuum gauge indicator does not rise even if
the system is left for one hour or more.
When the system has remaining moisture
inside or a leaky point, the vacuum gauge
indicator will rise.
Check the system for a leaky point and
then draw air to create a vacuum again.
Cable clamp
INSTALLATION TEST CHECK POINTS
After installation
Check the following points again after completion of the installation, and before turnig on the power. Conduct a test run again and ensure that the unit operates properly.
Explain to the customer how to use the unit and how to take care of the unit following the instruction manual.
Screw
Side cover
(1) Calculate a required refrigerant charge volume from the following table.
In case of faulty wiring connection, the indoor unit stops,
and then the run lamp turns on and the timer lamp blinks.
Use cables for interconnection wiring to avoid loosening of the wires.
CENELEC code for cables Required field cables.
H05RNR4G1.5 (Example) or 245IEC57
H
05
R
N
R
4or5
G
1.5
Harmonized cable type
300/500 volts
Natural-and/or synth. rubber wire insulation
Polychloroprene rubber conductors insulation
Stranded core
Number of conductors
One conductor of the cable is the earth conductor
(yellow/green)
Section of copper wire (mm 2 )
Power cables and connecting wires are securely fixed to the terminal block.
The power supply voltage is correct as the rating.
The drain hose is fixed securely.
Operational valve is fully open.
No gas leaks from the joints of the operational valve. The pipe joints for indoor and outdoor pipes have been insulated.
The reverse flow check cap is attached.
The cover of the pipe cover (A) faces downward to prevent rain from entering.
Gaps are properly sealed between the pipe covers (A) (B) and the wall surface / pipes.
3) Refrigerant pipe wall thickness and material
●
Select refrigerant pipes of the table shown on the right wall thickness and material as specified for each pipe size.
Pipe diameter [mm]
Minimum pipe wall thickness [mm]
Pipe material*
6.35
0.8
O-type pipe
12.7
0.8
O-type pipe
*Phosphorus deoxidized seamless copper pipe ICS 23.040.15, ICS 77.150.30
NOTE
●
Select pipes having a wall thickness larger than the specified minimum pipe thickness.
● This unit contains factory charged refrigerant covering 15m of refrigerant piping and additional refrigerant charge on the
installation site is not required for an installation with up to 15m refrigerant piping.
When refrigerant piping exceeds 15m, additionally charge an amount calculated from the pipe length and the above table
for the portion in excess of 15m.
●
If an existing pipe system is used, a required refrigerant charge volume will vary depending on the liquid pipe size.
For further information, please see “5. UTILIZATION OF EXISTING PIPING.”
0.02 1.40 15 Model 40, 50, 60
Additional charge volume (kg)
per meter of refrigerant piping
(liquid pipe
φ
6.35)
Refrigerant volume charged
for shipment at the factory
(kg)
Installation’s pipe length (m)
covered without additional
refrigerant charge
NOTE
Put down the refrigerant volume calculated from the pipe length onto the caution label attached on
the back side of the service panel.
(2) Charging refrigerant
●
Since R410A refrigerant must be charged in the liquid phase, you should charge it, keeping the container
cylinder upside down or using a refrigerant cylinder equipped with a siphon tube.
●
Charge refrigerant always from the liquid side service port with the operation valve shut. When you find it
difficult to charge a required amount, fully open the outdoor unit valves on both liquid and gas sides and
charge refrigerant from the gas (suction) side service port, while running the unit in the cooling mode. In
doing so, care must be taken so that refrigerant may be discharged from the cylinder in the liquid phase all
the time. When the cylinder valve is throttled down or a dedicated conversion tool to change liquid-phase
refrigerant into mist is used to protect the compressor, however, adjust charge conditions so that
refrigerant will gasify upon entering the unit.
●
In charging refrigerant, always charge a calculated volume by using a scale to measure the charge volume.
●
When refrigerant is charged with the unit being run, complete a charge operation within 30 minutes.
Running the unit with an insufficient quantity of refrigerant for a long time can cause a compressor failure.
Pay attention to the following points in addition to the above for the R410A and compatible machines.
○
To prevent a different oil from entering, assign dedicated tools, etc. to each refrigerant type. Under no circumstances must a
gauge manifold and a charge hose in particular be shared with other refrigerant types (R22, R407C, etc.).
○
Use a counterflow prevention adapter to prevent vacuum pump oil from entering the refrigerant system.
(three-way valve)
Charge hose
(Designed specifically for R410A)
Compound pressure gauge
Pressure gauge
Gauge Manifold
(Designed specifically for R410A)
Handle Hi.
Vacuum pump
Vacuum pump adapter
(Anti-reverse flow type)
(Designed specifically for R410A)
Charge hose
(Designed specifically for R410A)
Check joint
-0.1MPa
(-76cmHg)
Handle Lo
Operation Valve
Operation Valve
(two-way valve)
Operation Valve
Cap
Operation Valve
Cap
tightening torque (N·m)
Operation valve cap
tightening torque (N·m)
Check joint blind nut
φ 6.35 (1/4")
φ 12.7 (1/2")
20 〜 30
10 〜 12
25
〜
35
Operation valve size
(mm)
Securely tighten the operation valve cap and the check joint blind nut after adjustment.
● When condensed water needs to be
led to a drain, etc., install the unit on
a flat base (supplied separately as an
optional part) or concrete blocks.
Then, please secure space for the drain
elbow and the drain hose.
● Execute drain piping by using a drain elbow and drain
grommets supplied separately as optional parts, where
water drained from the outdoor unit is a problem.
●
Water may drip where there is a larger amount of drain
water. Seal around the drain elbow and drain grommets
with putty or adequate caulking material.
● Condensed water may flow out from vicinity of operation
valve or connected pipes.
Do not put a grommet
on this hole.
This is a supplementary
drain hole to discharge
drain water, when a large
quantity of it is gathered.
CAUTION
Clearance
Where you are likely to have several days of sub-zero
temperatures in a row, do not use a drain elbow and
drain grommets. (There is a risk of drain water
freezing inside and blocking the drain.)
●
RWC012A029B
Drain elbow
Grommet
Drain hose
(
To be procured on the installer's part
)