-
148
-
'14 • KX-SM-202
Wires for connecting indoor
and outdoor units
Exterior tape
Gas piping
insulation
Liquid piping
Band (accessory)
Pipe cover (accessory)
Remote control unit
Outdoor unit power supply 3 phase 4wiring 380-415V
Indoor unit
Outdoor unit
Earth leakage breaker
(Impulse withstanding type)
Circuit breaker
for cabling
Circuit breaker
for cabling
Earth leakage breaker
R
R
R
R
R
R
Grounding
wire
A
A
C
D
B
B
Distributed, separate power supply system
●
Adding additional refrigerant
Charge additional refrigerant according to the size and length of the liquid piping and unit capacity
.
Determine additional charge volume by rounding to the nearest 0.1 kg.
S
＋P＋
I
4-4. Additional refrigerant charge
Charge additional refrigerant
in the liquid state
.
Be sure to measure the quantity
with a scale in adding refrigerant
.
If you cannot charge all refrigerant with the outdoor unit lying idle, charge it with the unit running in the test run mode. (For the test run method, please refer to Section 8)
t during operation, complete the job within 30min.)
This unit contains
<280,335 : 11.0 kg, 400-560 : 11.5kg, 615,670 : 22.0 kg, 735 : 22.5 kg, 800-1120 : 23.0 kg, 1200-1680 : 34.5 kg> of refrigerant
.
Determine the amount of refrigerant to be charged additionally using the following formula and put down the amount of refrigerant added on the refrigerant charge
volume recording plate provided on the back the front panel.
P =（
L1×0.37
）＋（
L2×0.26
）＋（
L3×0.18
）＋（
L4×0.12
）＋（
L5×0.059
）＋（
L6×0.022
）
L1
：
φ
22.22 total length (m)
L2
：
φ
19.05 total length (m)
L3
：
φ
15.88 total length (m)
L4
：
φ
12.7 total length (m)
L5
：
φ
9.52 total length (m)
L6
：
φ
6.35 total length (m)
φ
22.22
0.37
Refrigerant liquid pipe size
φ
19.05
0.26
φ
15.88
0.18
φ
12.7
0.12
φ
9.52
0.059
φ
6.35
0.022
For gas pipes
For liquid pipes
For oil equalizing pipe
Tightening torque N
・
m
Shaft (valve main body)
7 or less
6~8
14~16
6~8
φ
9.52
φ
12.7
Cap (lid)
30 or less
20~30
25~35
20~30
Cap nut (check joint section)
13
10~12
10~12
S: standard additional refrigerant quantity (kg)
P: Additional refrigerant quantity for piping (kg)
When the Additional refrigerant quantity (S
＋
P
＋
I
) is over the
following table, please separate the refrigerant line.
I
: Additional refrigerant quantity for indoor units (kg)
If the total indoor units capacity is larger than outdoor unit capacity, then calculate the additional refrigerant quantity for indoor units.
D = {(Total indoor units capacity) - (outdoor unit capacity)}
I
= D x 0.01
When D > 0, calculate
I
using the above equation;
When D
≦
0, take it as
I
= 0.
Important
Outdoor unit
S＋P＋
I
(kg)
280-670
735-1350
1425-1680
40
80
100
Outdoor unit
280
335
400
450
475
500
560
615
670
735
S (kg)
0
0
2.1
2.1
6.2
6.2
6.2
0
0
2.1
Outdoor unit
800
850
900
950
1000
1060
1120
1200
1250
S (kg)
4.2
4.2
4.2
12.4
12.4
12.4
12.4
6.3
6.3
Outdoor unit
1300
1350
1425
1450
1500
1560
1620
1680
S (kg)
6.3
6.3
18.6
18.6
18.6
18.6
18.6
18.6
<Example>
When you connect FDC400 to FDT140 x 3 units:
D= 140 x 3 - 400= 20 (> 0)
I
= 20 x 0.01 = 0.2 (kg)
Vacuum gauge check
S
O
S
O
Pay attention to the following points in addition to the above for the R410A and compatible machines.
○
To prevent a different oil from entering, please 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.).
○
(2) Vacuuming
Please pull air
from the check joints of the service valves on both liquid and gas sides
.
Please also
pull air from the oil equalizing pipe
. (Please pull air separately from the rest of the piping by using the oil equalizing valve check joint)
(4) Method of operating service valves
Method of opening/closing a valve
○
Remove the cap, turn the gas pipe side until it comes to the “Open” position as indicated in the
drawing on the right.
○
For the liquid side pipe and oil equalizing pipe side, turn with a hexagonal wrench until the shaft
stops. If excessive force is applied, the valve main body can be damaged. Always use a dedicated
special tool.
○
Tighten the cap securely.
For tightening torque, refer to the table below.
For gas pipes
For cap nut
Cap
For oil equalizing pipe
For liquid pipes
Closed position
Opened position
＜
＞
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.
CAUTION
performance falling short of the design
capacity, pipe clogging due to residue
moisture and/or a compressor failure.
Airtighteness test completed
Vacuuming begins
Vacuuming completed
(Fill oil)
Fill refrigerant
Please run the vacuum pump for at least one hour after the
vacuum gauge shows -101kPa or lower. (-755mmHg or lower)
C
after leaving the system for an hour or more
.
(3) Additional oil charge
When the total pipe length is longer than 510 m, charge 1,000 cc of M-MA32R refrigeration machine oil
from the check joint of gas pipe service valve after the vacuuming.
Nitrogen
gas
(1) Air tightness test
①
Although an outdoor unit itself has been tested for air tightness at the factory, please check the connected pipes and indoor units for air tightness from the check
joint of the service valve on the outdoor unit side. While conducting a test,
keep the service valve shut all the time
.
②
Since refrigerant piping is pressurized to the design pressure of a unit with nitrogen gas for testing air tightness, please connect instruments according the drawing below.
Under no circumstances should chlorine-based refrigerant, oxygen or any other combustible gas be used to pressurize a system
Keep the service valve shut all the time
. Do not open it under any circumstances.
Be sure to pressurize all of the liquid, gas and oil equalizing pipes
.
③
a)
to see if the pressure drops.
b)
to see if the pressure drops.
d)
If no pressure drop is observed with an installation pressurized to
and left for about one day
,
it is acceptable
. When the ambient temperature
changes 1
℃
, the pressure also changes approximately 0.01 MPa. The pressure, if changed, should be compensated for.
After repair, conduct an air-tightness test again.
④
Always pull air from the pipes after the airtightness test.
To indoor unit
Gauge manifold
Lo
Lo knob
Hi
Hi knob
Service valve
Liquid pipe
Oil equalizing
tube
Gas pipe
Outdoor unit 1
Service point
(check joint)
Service valve
Liquid pipe
Oil equalizing
tube
Gas pipe
Outdoor unit 2
CAUTION
Applying excessive pressure can cause an
CAUTION
Please also pull air from the oil equalizing pipe.
Airtight (pressurized) piping
4-3. Air tightness test and air purge
6. ELECTRICAL WIRING WORK
5.
Drainage
4-5. 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.
a) The gas pipe can cause during a cooling operation dew condensation, which will become drain water causing a possible water-leak accident, or reach during a heating
operation as high a temperature as 60
℃
to 110
℃
, posing a risk of burns, when touched accidentally. So, do not fail to dress it with a heat insulation material.
c) 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.
d) Although this air conditioning unit has been tested under the JIS condensation test conditions, the dripping of water may occur when it is operated in a high-humidity atmosphere
(23
℃
or a higher dew point temperature). In such a case, apply an additional heat insulation material of 10 to 20 mm thick to dress an indoor unit body, piping and drain pipes.
When the ambient dew point temperature becomes 28
℃
or higher, or the relative humidity becomes 80% or higher, add further 10 to 20 mm thick heat insulation material.
Electrical installation work must be executed according to the technical standards and other regulations applicable to electrical installations in the country.
Please install an earth leakage breaker without fail
(Since this unit employs inverter control, please
use an impulse withstanding type
to prevent an earth leakage breaker’s false actuation.)
Please note
a) Use only copper wires.
- braided cord (code designation 60245 IEC 51), if allowed in the relevant part 2;
- ordinary tough rubber sheathed cord (code designation 60245 IEC 53);
- ordinary polyvinyl chloride sheathed cord (code designation 60227 IEC 53).
b)
Use separate power supplies for the indoor and outdoor units
.
c) A grounding wire must be connected before connecting the power cable. Provide a grounding wire longer than the power cable.
d)
The power supplies for indoor units in the same system should turn on and off simultaneously
.
e) Ground the unit. Do not connect the grounding wire to a gas pipe, water pipe, lightning rod or telephone grounding wire.
If improperly grounded, an electric shock or malfunction may result.
Never connect the grounding wire to a gas pipe because if gas leaks, it could cause explosion or ignition.
f)
The installation of an impulse withstanding type earth leakage breaker is necessary
. A failure to install an earth leakage breaker can result in an accident such as an electric
.
g) Please do not use a condensive capacitor for power factor improvement under any circumstances. (It does not improve power factor, while it can cause an abnormal overheat accident)
h) For power supply cables, use conduits.
i) Please
do not lay electronic control cables (remote control and signaling wires) and other high current cables together outside the unit
. Laying them together can result in
malfunctioning or a failure of the unit due to electric noises.
j) Power cables and signaling wires must always be connected to the power cable terminal block and secured by cable fastening clamps provided in the unit.
k) Fasten cables so that they may not touch the piping, etc.
l)
When cables are connected, please 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.)
CAUTION
Be sure to record the refrigerant volume,
because the information is necessary to
perform the installation’s maintenance
service.
Pay attention to the following points in addition to the above for the R410A and compatible machines.
●
To prevent a different oil from entering, please 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.).
●
In case when the outdoor unit capacity is 475-560 and the pipe length (X,Y) is in the following conditions, please calculate the reduction refrigerant quantity (E). (See page P161)
・
X<20m and Y<10m. (X : The length from the outdoor unit to the furthest indoor unit. Y : Main pipe length.)
●
●
Do not use a charge cylinder under any circumstances. There is a danger that the composition of the refrigerant will change when R410A is transferred to a cylinder.
●
When charging refrigerant, use liquid refrigerant from a cylinder. If refrigerant is charged in a gas form, the composition may change considerably.
Please note
Put down on the refrigerant charge volume recording plate provided on the back of the front panel the amount of refrigerant calculated from the pipe length
.
●
Where water drained from the outdoor unit may freeze, connect the drain pipe using optional drain elbow and drain grommet.
It is located in back of this front panel.
Model
Power
source
Cable size for power
source (mm
2
)
Wire length
(m)
Rated current
Switch capacity
Size (mm
2
)
Screw type
Moulded-case circuit breaker (A)
Earth wire
Earth leakage breaker
280
335
400
450
475
500
560
3 phase
4 wire
380-415V
50Hz/
380V60Hz
8
8
14
14
22
22
22
74
74
86
86
102
102
102
30
30
50
50
60
60
60
30
30
50
50
60
60
60
3.5
3.5
5.5
5.5
5.5
5.5
5.5
M6
M6
M6
M6
M6
M6
M6
30A30mA less than 0.1 sec
30A30mA less than 0.1 sec
50A100mA less than 0.1 sec
50A100mA less than 0.1 sec
60A100mA less than 0.1 sec
60A100mA less than 0.1 sec
60A100mA less than 0.1 sec
accident. The circuit breaker should isolate all poles under over current.
n) Install isolator or disconnect switch on the power supply wiring in accordance with the local codes and regulations. The isolator should be locked in OFF state in accordance with
EN60204-1.
o) After maintenance, all wiring, wiring ties and the like, should be returned to their original state and wiring route, and the necessary clearance from all metal parts should be secured.
CAUTION
If the earth leakage breaker is exclusively for ground fault protection, then you will need to install a circuit breaker for wiring work.
(1) Method of leading out cables
●
As shown on the drawing in Section 4-2 (1), cables can be laid through the front, right, left or bottom casing.
●
In wiring on the installation site, cut off a half-blank (
φ
50 or oblong hole measuring 40x80) covering a penetration of the casing with nippers.
(2) Notabilia in connecting power cables
Power cables must always be connected to the power cable terminal block and clamped outside the electrical component box.
In connecting to the power cable terminal block, use round solderless terminals.
●
Connect the ground wire before you connect the power cable. When you connect a grounding wire to a terminal block, use
a grounding wire longer than the power cable so that it may not be subject to tension.
●
Do not turn on power until installation work is completed. Turn off power to the unit before you service the unit.
●
Ensure that the unit is properly grounded.
●
Always connect power cables to the power terminal block.
●
To connect a cable to the power terminal block, use a round crimp contact terminal.
●
to external force.
●
In fastening a screw of a terminal block, use a correct-size driver.
Fastening a screw of a terminal block with excessive force can break the screw.
●
For the tightening torque of terminals, refer to the list shown at right.
●
When electrical installation work is completed, make sure that all electrical components within the electrical component
box are free of loose connector coupling or terminal connection.
Request
●
When connecting to the power supply terminal block,
use the crimp terminals for M6 as shown at right.
●
When connecting to the signal terminal block,
use the crimp terminals for M3.5 as shown at right.
6-2. Method of connecting power cables
6-1. Wiring system diagrams
A: Power cable (Main power cable) [4 cores]
B: Signal wire (Super Link wire) [2 cores]
C: Power cable (indoor unit power cable)
[2 cores]
D: Remote control cord
[2 cores (FD
○△△
KXE6 indoor unit)]
Indoor unit power supply: Single-phase 220-240V
(Example of combination)
* Do not connect N-phase wire to the unit when the power supply is 3-phase and 4-wire.
Tightening torque (N
・
m)
0.9~1.2
2.5~2.8
M3.5
M6
Outdoor signal line terminal block
Power cable terminal block, Earth wire
18.5 mm or less
7 mm or less
Please note
a) The method of laying cables has been determined pursuant to the Japanese indoor wiring regulations (JEAC8001). (Please adapt it to the regulations in effect in each country)
b) In the case of distributed, separate power supply system, the listed data represent those of an outdoor unit.
c) For details, please refer to the installation manual supplied with the indoor unit.
Please note
a) The method of laying cables has been determined pursuant to the Japanese indoor wiring regulations (JEAC8001). (Please adapt it to the regulations in effect in each country)
b) Wire length in the table above is the value for when the indoor unit is connect to the power cable in series also the wire size and minimum length when the power drop is less
than 2% are shown. If the current exceeds the value in the table above, change the wire size according to the indoor wiring regulations. (Please adapt it to the regulations in
effect in each country)
c) For details, please refer to the installation manual supplied with the indoor unit.
d) Wires connected to indoor units are allowed up to 5.5 mm
2
. For 8 mm
2
or more, use a dedicated pull box and branch to indoor units with 5.5 mm
2
or less.
Combined total
capacity
of indoor units
Less than 7A
Less than 11A
Less than 12A
Less than 16A
Less than 19A
Less than 22A
Less than 28A
Cable size for
power source
(mm
2
)
Wire length
(m)
2
3.5
5.5
5.5
5.5
8
8
21
21
33
24
20
27
21
2cores x 0.75-2.0
※
Moulded-case circuit breaker
(For ground fault, overload and short circuit protection)
Signal wire size
(mm
2
)
20A 100mA less than 0.1 sec
20A 100mA less than 0.1 sec
20A 100mA less than 0.1 sec
30A 100mA less than 0.1 sec
40A 100mA less than 0.1 sec
40A 100mA less than 0.1 sec
50A 100mA less than 0.1 sec
※
Please use a shielded cable.
Round crimp contact terminal
Wire
PSC012D031A
