VRVIII_installation_manual - English Version

8/10/2019 VRVIII_installation_manual - English Version

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1. Work Flow by Process

1

Pre-workDetermination of the work classification

Preparation of the installation drawing

Work(1) Sleeve work ............................Consider the downward gradient of the drain pipes. 2

(2) Indoor unit installation .............Confirm the model names to avoid any installation mistakes. 3

(3) Piping support ........................Use supports within the designated support intervals. 5

(4) Refrigerant piping work .........Pay attention to the principles of dry, clean and tight. 9

(5) Drain piping work ..................Maintain a downward gradient of at least 1/100. 22

(6) Duct work (indoor) ................Ensure that a sufficient airflow is maintained. 26

(7) Insulation work ......................Ensure that there are no gaps at the joints between insulation materials. 27

(8) Control wiring work ...............Use applicable two-core wires. 30

(Do not use multi-core.)

(9) Outdoor unit installation ........ Make considerations to prevent short-circuiting and maintain a workspace for servicing. 32

(10) Air tightness test ....................Make a final confirmation that there is no pressure drop at 4 MPaG for 24 hours. 34

(11) Vacuum drying ......................Use a vacuum pump that can achieve an ultimate vacuum of 100.7 kPaG or lower. 36

(12) Additional refrigerant charge ... Enter the additional refrigerant charge amount onto the outdoor unit and the log book. 39

The above order represents the general procedure. It may differ depending on the local conditions and actual circumstances.

*Please note that lengths without any units are all in millimeters (mm) throughout this document.

Legend

Caution: Points of caution at the job site

One point lesson: Expertise gained from onsite work

Case example: An actual example of onsite work


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2. Work by Process and Key Points(1) Sleeve work

2

125109

15.9

8073

8076

8079

125105

10095

10098

125102

125101

125105

10089

10092

10096

10092

10095

10099

10083

10086

10083

10086

10089

10093

8070

8073

38.1

8067

8080

25.4 28.6 31.8 34.99.5 12.7 19.1 22.2

19.1

6.4

9.5

12.7

15.9

D L1 R 1

L3

R 2

L2

D L1 R 1

L3

R 2

L2

10

10

5

10

5

10

10

10

5

10

5

10

10

5

10

5

10

Note that the beam structure limits the allowable area for the placement of through-holes.

Cover both ends of the sleeves with masking tape to prevent any concrete from entering

Insulation thickness: Liquid piping 10 mmGas piping 10 mm

Workprocedure

Meeting with theconstruction

company

Determination ofthe location andsleeve diameter

Installation Confirmation

~Working points~ Determination of the placement of the through-holesDetermine the placement so that the drain piping is at a downward gradient of at least 1/100.Consider the thickness of the insulation material when determining the sleeve diameters forrefrigerant piping and drain piping.

Diameter of liquid pipinginsulation material

Diameter of gas pipinginsulation material

Sleeve inner diameterUpper cell: Sleeve diameterLower cell: (Calculated value)

At least 3 x [(R1 + R2)/2]

At least D/2Location into which the sleeve cannot beinserted throu h the beam

At least D/4 and 150 mm

B (gas piping diameter)

A (liquid piping diameter)


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2. Work by Process and Key Points(2) Installation of indoor units

3

D r a i n s i d e

P i p i n g s i d e

D r a i n s i d e

P i p i n g s i d e

1) 2) 3) 4)

1) Transporting(1) Determine the transporting route.(2) Transport the indoor units to the installation location in the original packing. Do not remove the packing until it

is to be installed.(3) When receiving the products, be sure to check for any blemishes or dents.

How to prevent the installation of the wrong indoorunit model or in the wrong location.Before transporting the indoor unit, attach a sheet ofpaper to a visible spot on the packing that notes theinstallation location and the system number.

2) Determination of installation locationThe following explains the procedure in the event an insert is notcontained within the package.

(1) Confirm the space required for servicing and installation.(2) Confirm the piping direction and air discharge direction.

The space required for servicing and installation maydiffer depending on the model. Please confirm thedetails in the installation manual or the like.

(3) Mark the center of the indoor unit with chalk lines,using the base point lines drawn on the floor as a guide.

(4) Using the upper packing material, mark the suspension locations on the floor based on the center of the unit.

(5) Use a laser pointer or the like to transfer the suspension location from the floor to the ceiling slab, and use a drillto open up a pilot hole.

If a pilot hole for the anchors leads to a steel beam, be sure to try another location for the hole.

1F reception roomAC1-1

Installation space for FXFQ

Suspension locationLaser pointer

Ceiling

Trans-porting

~Working points~Installation procedures differ according to the indoor unit model. Be sure to conduct all workaccording to the accompanying installation manual.

At least 1,500 mm

At least 200 mm

At least 1,500 mm

At least 1,500 mm

At least 1,500 mm At least 200 mm

Workprocedure

Center of the unit

Base point line

Unitsuspensionlocation

Upper packingmaterial

Determination ofinstallation location

Indoor unitinstallation

Installation ofsuspension bolts


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(2)Installation of indoor units

4

3) Installation of suspension bolts(1) Determine the length of the suspension bolts according to the height of the installation.(2) Before installing, place the nuts (2; locally procured parts) and washers (2; accessories) on the suspension bolt

(double-nut on the lower side of the bolt).(3) After installing, adjust the nut on the lower side to the installation height.

(4) For the upper washer, use the attached washer plate to secure.

Check the installation manual for the installation height whenattaching optional accessories.

The height of the indoor unit can easily be adjusted by loosening thedouble nut.Re-tighten the double nut after completing adjustment. The suspension bolt size (M10 or W3/8) is compatible with all models.If the suspension bolt length is 1.5 m or longer, attach a steady braceon the longitudinal side of the suspension pitch.

4) Indoor unit installation(1) Install the indoor unit level.(2) When installing manually, first hook the main unit's suspention bracket onto the suspension bolts on opposing

corners to suspend the indoor unit. And, if suspending the indoor unit with a device such as a lifter, remove thelower nut on the suspension bolt before doing so.

(3) After installing the indoor unit, be sure to protect it with a plastic bag or the like.

If you assume that the temperature and humidity in the ceiling space exceed 30 C and RH80%,reinforce the insulation (thickness) of the indoor unit.

(Use polyethylene foam or glass wool with a thickness of at least 10 mm.)

How to protect the indoor unit

Why protect it?Dust and the like can get on the filter and heat exchanger, adverselyaffecting capacity.

After all work is complete, be sure to remove the protective plastic covering and the like fromthe indoor unit.

Washer plate(accessory)

Insert

[Secure the washer]

Upper nut

Washer (accessory)

Suspension bracket

Tighten(double-nut)

[Secure the suspension bracket]

An example of steady braceinstallation

Steadybrace bolt

A t l e a s t

1 , 5

0 0


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(3) Piping support

6

Suspension bandwith turnbuckle

Support of horizontalrefrigerant piping

Suspensionband with turnbuckle

Polyvinylpipe

Suspension bolt supportingfixture (for shaped steel)

Suspension bolt supporting fixture (for flat decks)

Vertical piping support

(example)

2) Installation of suspension bolts and supporting fixtures

Horizontal piping support

Minimize the length of the suspension boltsConsider the downward gradient when determining thelength of the drain piping suspension bolts.When supporting the refrigerant piping, place a hard pad(e.g., polyvinyl-chloride pipe) between the supportingfixture and insulation material as shown in the photo to theright in order to prevent crushing of the insulation materialfrom the weight of the piping.

Never provide additional piping support from the piping.

Vertical piping support

Allow sufficient space for maintenance and insulationinstallation when determining the distance between the unit bodysurface and piping as well as the piping interval when many pipes arelaid in parallel.

Legs for vertical band Vertical band

Battledore bolt T-shape legwith washer

Special supporting fixtures for vertical piping

Brazing areas

~Working points~Attach refrigerant piping support on top of the insulation material.With regard to drain piping support, first secure the pipes directly with the supporting fixturesand then place the insulation materials on top of this.

Anchor

Leg for vertical band

Vertical band


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(3) Piping support

8

Spot support (drain piping)

Bend support

Support around the indoor unit The horizontal section of the drain piping

after the first upward section The piping connection with the drain hose

accessory

Through-hole support

Drain hose accessory

Support point

300~500

300~500

Support points

300

300


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2. Work by Process and Key Points(4) Refrigerant piping work

9

~Working points~Adhere to the following three basic principles when conducting refrigerant piping work:

1) 2) 3)

1) Protection (covering)Protection (covering) during storage and work involving refrigerant piping is the most important type of work inorder to prevent water/moisture, contaminants or dust from entering into the piping.

If water/moisture, contaminants or dust enter into the refrigerant piping, not only will it preventthe air conditioner from operating normally but it will also cause a malfunction of the machineand significant inconvenience for the customer. Your utmost effort is required in preventing thisfrom occurring.

During storage(1) Make sure to protect (cover) both pipe ends.

Do not use piping that has not been protected (covered).

(2) Do not lay refrigerant pipes directly onto a floor surface, but use a table or the like when placing them.

Dry Clean Tight

No water/moisture inside

Do not let water/moisture in

No dust/contaminants inside

Do not let dust/contaminants inNo leakage of refrigerant

[The 3 basic principles of refrigerant piping]

Protection(covering)

Pipeprocessing

Workprocedure

Water/moisture

Dust/contaminants Leak

Unitconnection


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(4) Refrigerant piping work Flaring-

11

2) Pipe processingFlaring This is one method of connecting refrigerant piping of a diameter of 15.9 mm or smaller to an air

conditioner.

(1) Pipe cutting

Use a pipe cutter with left rotation.

Feed the blade of the pipe cutter bit by bit into the pipe with each rotation.

Excessive feeding of the blade can disfigure the pipe so special care is required.

(2) Processing of the cut surface

Remove burrs from the tip of the cut surface with a file. Remove burrs from the inner portion of the pipe, using a reamer or scraper. Use the file again in order to remove burrs from the tip. Use the reamer or scraper again in order to remove burrs from the inner portion of the pipe.

When processing the cut surface, face it down to prevent any swarf from falling into the pipe. Make sure that the bur s are completely removed, as not removing the burrs sufficiently can

result in a refrigerant gas leak at the flare.

(3) Flaring Insert a flare nut into the pipe before flaring. Ensure that the size of the flare is within the prescribed range.

Note that an appropriate size for the flare is virtually the same as thatof the union.

The size of the flare will become larger in proportion to Dimension Ato the right. Note that Dimension A differs according to the flaring toolmanufacturer.

Pipe cutter

Reamer

Flaring tool

File

Facing downFacing down

Burrs

Scraper

X Y

XY

A


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(4) Refrigerant piping work Bending-

12

045

90

045

90

Clampinglever

Handle

Handle

Pipe

YY

Bending Some of the tools used to bend refrigerant pipes are electric-type, hydraulic-type, lever-type andratchet-type benders. Following is a description of the work procedure with a lever-type bender:

The bending dimensions depend on whether they are taken from

the left or right end.(1) Measure the finished dimensions from the right or left end of the pipe.

(2) Insert the pipe into the bender. Align the end of the handle with the '0' mark on the

clamping lever.

(3) Align the mark on the pipe with the 'R' or 'L' on thehandle by adjusting the pipe.

(4) Move the handle to bend the pipe to the desired angle.

Bend the pipe slowly to prevent pleating or deformation ofthe inner curve of the pipe.

Do not bend beyond 90 .

If the handle does not have the 'L' mark(1) Mark the finished dimension from the left end.

(2) Insert the copper tube into the bender Align the end of the handle with the '0' mark on the clamping lever.

(3) Insert the same size of pipe into the bender slot so that the pipe becomes parallel to the clamping lever. Align the center line (middle)of that pipe with the mark on the pipe.

(4) Use the handle to bend the pipe to the desired angle.

X

Deformation due topleating Deformation due todamage Appropriate bend

Lever-type bender

End of the handle

Mark0

From the right

From the left

Same sizeof pipe

End of the handle

Mark

Clampinglever

0


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(4) Refrigerant piping work Pipe expansion -

13

Pipe expansion Two pipes can be connected by expanding the end of the refrigerant pipe, inserting theother pipe in question inside and brazing the connection.

(1) Remove the burrs on the cut surface with a reamer or scraper.

Note that excessive deburring can thin the walls of the pipe and cause vertical (lengthwise)cracking when expanding.

(2) Slightly expand the tip of the head.

(3) Insert the other pipe fully into the tip portion of the head,close the lever and expand the pipe.

(4) This may leave vertical scratches on the inner surface of the pipeso rotate the pipe to remove them.

Expander


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(4) Refrigerant piping work Brazing-

14

Brazing Brazing refers to the use of a metal with a lower melting temperature than that of the base metalas well as the alloy of these metals as solder in order to joint the two base metals without meltingthem. To heat the solder, a combustion flame of flammable gas (e.g., acetylene, propane) andoxygen is used. The following is an explanation of the work procedure when using acetylene:

If certification is required in your country, be sure to have all work conducted by a certifiedindividual.

Be sure to wear all the necessary protective gear (e.g., eye protectors, leather gloves), as fire isbeing used.

Always have handy fire prevention equipment such as a fire extinguisher. For solder, use a phosphor copper metal (silver composition: 0%). Don't use a cutting torch.

For brazing

In order to ensure safety when lighting the flame, be sure to use an acetylene regulator with aflashback arrester.

[Standards for selecting the outer diameter of the pipe to be brazed and nozzle diameter (French standards)]

Outer diameter Nozzle diameter (mm) Nozzle number 6.4 9.5

12.7 15.9 19.1

1.2 #200

22.2 1.3 #225 25.4 1.4 #250 31.8 1.5 #315 38.1 1.6 #400 44.5 1.7~1.8 #450~500

If the nozzle is too large, it makes preheating and heating difficult. If too small, brazingtakes too long. Use a nozzle that suits the outer diameter of the pipe to be brazed.

For nitrogen replacement

Welding torch

Oxygenregulator

Acetylene regulator(with flashback arrester)

Twin hoseWelding kit

Nitrogen cylinder Nitrogen gas regulator Pressure hose Valve

Tapered nozzle


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15

N 2 N 2N 2N 2 N 2

Procedure 1. Confirmation of an appropriate gap between the pipe and joint

An appropriate gap is when the pipe can be inserted into the joint and held upside downwithout falling.

Procedure 2. Nitrogen replacement PurposeA voluminous oxide film develops on the inner surface of the pipe during brazing. The film can clog,among other parts, the solenoid valve, capillary tube and compressor's oil pump inlet, hampering normaloperation. In order to prevent this from occurring, it is necessary to replace the air within the pipe withnitrogen. This work is referred to as nitrogen replacement.

(1) Set up the required tools as shown below:

It is even more effective to open up a small hole in the tape to release the nitrogen aftercovering the end of the pipe with tape or the like.Use of the tapered nozzle results in efficient replacement.

(2) Adjust the nitrogen gas pressure to 0.02 (MPaG) or so.

If the nitrogen pressure is too high, it may cause the brazing filler metal (solder) not to reachcompletely around the pipe or pinholes to develop in it. Make sure that the pressure is notexcessively high.

Use of nitrogen with a purity of at least 99.99% is recommended. Be sure to note that use of alesser purity nitrogen may likely result in oxide film formation.

The effects of nitrogen replacement

Taping Tapered nozzle

Valve

Nitrogen gas regulator

Nitrogen cylinder

Taping Pressure hose

No nitrogen replacementThe inner surface of the pipe has blackened

due to the oxide film.

Nitrogen replacementThe inner surface of the piping is clean.


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16

A and B Largetemperaturedifference

Uniform temperaturearound thecircumference

600 C780 C 780 C

780 C

400 C

600 C780 C 780 C

Non-uniformtemperature aroundthe circumference

A and B Sametemperature

B

B

Procedure 3. Preheating

Point 1: Heat both base metals evenly. (The inner and outer pipes and the circumference)

Point 2: Heat until an appropriate temperature for applying the brazing filler metal (solder).640~780 C (where the base metals change color from reddish black to red)

Point 3: Torch flame adjustment and flame

intensity adjustment Conduct brazing with a reducing flame.

(Roughly a 5 cm carburizing flame) Change the flame intensity according

to the size of the base metal.

Point 4: Flame angle (heat control) Make the flame angle 80 to 85 .

8085

Flamecore

Carburizingflame

Outerflame

Innerpipe

Outer pipe

Innerpipe

Outer pipe

A p p r o p r i a

t e

h e a

t i n g r a n g e

B r o a

d h e a

t i n g

r a n g e

Roughly5 cm

Too early to apply the brazingfiller metal

(base metal temperatureof 500 to 600 C)

Appropriate timing for applicationof solder material

(base metal temperatureof 640 to 780 C)

Too late to apply the brazing fillermetal

(base metal temperatureof 800 to 1,000 C)


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17

Carburizing flame Carburizing flame

Distance from the carburizing flame tip Flame location Flame direction

Procedure 4. Brazing filler metal application

Point 1: Confirm the range of brazing filler metal application (spread range)

Roughly5 mm

2~3mm

Distance from the carburizing flame tip Flame location

Flame direction

2~3 mmFlame loss

Overlap Not overlappingresults in a gasleak


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18

Point 2: Confirm the volume of the brazing filler metal flow (differs according to the basemetal heating range)

Point 3: Melt the brazing filler metal from the rod tip (melt it gradually, gently applying it uponthe base metal)

Point 4: The angle of flame and brazing filler metal Increase the flame angle slightly compared to preheating

Make the angle between the brazing filler metal and flame roughly 90 .

During preheating

During brazing

Appropriateheatingrange

Excessivelybroad heatingrange

Excessivelynarrow heatingrange

Excessiveflow of brazingfiller metal

Lack of flowof brazingfiller metal

Brazing fillermetal

Brazing fillermetal

Roughly 90

80~85

Hangingbrazing fillermetal


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19

Point 5: Confirm visually. (Final confirmation of the distance from the carburizing flame tip,location of flame on the pipe and flame direction)

It is relatively easy to apply the brazing filler metal when the pipe is facing down or sideways.But, if the pipe is facing up, it is relatively difficult to spread it and can result in a refrigerant

leak. Therefore, make efforts to enable brazing with the pipe facing down or sideways.

Procedure 5. Cooling Cool the brazed location with a moist cloth or the like to enable work afterward and

prevent burns.

Do not turn off the nitrogen until the pipe is completely cooled down. If the nitrogen gas isstopped before the pipe has sufficiently been cooled down, i t will result in the development ofan oxide film on the inner surface of the pipe.

1~2 mm

Distance from thecarburizing flame tip

Location of flameon the pipe

Flame direction(Move the flame up/down and

left/right at a right angle to the pipe)

Final confirmation

2~3 mm

Facing down Facing sideways Facing up

Relatively easy Relatively difficult


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(4) Refrigerant piping work Refrigerant branch pipe (REFNET joint)

20

Refrigerant branch pipe (REFNET joint)

1. Install the REFNET joint horizontally or perpendicularly.

2. Install the REFNET header horizontally.Example of liquid-side header installation Example of gas-side header installation

Create at least 500 mm of a straight pipe section before and after branches when connectingrefrigerant branch pipe to the field pipe. Bending the pipe too close to the branch can lead to complaints about abnormal

noise.

Example of refrigerant branch pipe installation

Installing the REFNET joint while it is leaning at an angle can cause refrigerant drift, resultingin abnormal noise or preventing normal operation. Be sure to install it horizontally.

Horizontal

Perpendicular

At least 500

At least 500 At least 1,000

Ceiling

Supporting fixture(locally procured)

Horizontal Horizontal

Ceiling

Mount

(locally procured)

A. Arrow view


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(4) Refrigerant piping work Flare connection

21

3) Unit connectionFlare connection

(1) Apply refrigerant oil (ethereal oil, ester oil) to the inner

surface of the flare.(2) Turn the flare nut 3 or 4 times to the machine union side by hand.

Be sure to use the flare nuts that come with the unit.

If the flare nut cannot be turned by hand, there may be a shaft misalignment of the flare andunion. Please try again.

(3) Tighten to the prescribed torque value using the torque wrench

Tighten, using a technique that employs both the torque wrench and (spanner) monkeywrench.

Be careful, as tightening excessively can cause gas leakage due to flare nut cracking and thelike.

When tightening with a spanner (monkey wrench) because a torque wrench is unavailable:

When tightening a flare nut with a spanner, there comes a point where the tightening torqueincreases rapidly. From that point, tighten only with an angle shown in the table below.

Note that tightening the flare nut with a spanner longer than the recommended tool lengthshown in the table below can result in excessive tightening.

Marking the flare nut with a magic marker or the like after it has been tightened prevents theworker from forgetting to tighten the flare nut.

Tightening torque standards for flare nuts

Pipe outer diameter Tightening torque (N cm) 6.4 1420~1720 9.5 3270~3990

12.7 4950~6030 15.9 6180~7540 19.1 9720~11860

Pipe outer diameterTightening angle(rough standard)

Recommended lengthof tool being used

6.4 60 ~90 Approx. 150 mm 9.5 60 ~90 Approx. 200 mm

12.7 30 ~60 Approx. 250 mm 15.9 30 ~60 Approx. 300 mm 19.1 25 ~35 Approx. 450 mm

Torque wrench Refrigerant oil

Marking

Where the refrigerantoil is applied

Tool length


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2. Work by Process and Key Points(5) Drain piping work

22

H

H

H

H

1) 2) 3)

Do not connect drain pipes to the building'ssanitary sewer pipes or waste pipes as it maycause an odor problem.

Reverse gradient of the drain pipingIn some cases it is difficult to ensure the required drainpiping gradient within the ceiling spaces when otherpiping and equipment crowd the area. Most of suchproblems can be averted by prior consultation with theinstallers handling the other equipment.

1) Indoor unit side drain piping

The installation procedures for drain piping at the indoor unit side differ by the model, so alwayscheck the installation manual before installing.

Indoor units in which the drain piping connection becomes a negative pressure require a draintrap (see below) for each unit. In addition, the drain trap requires a cleanout for cleaning.

Workprocedure

Drain flowtest

~Working points~Ensure a downward gradient of the drain piping of at least 1/100.Keep the drain piping as short as possible in order to prevent air pockets.

Indoor unitFXMQ

Indoor unitFXMQ

H: At least 50 mm

Drain trap

Cleanout

Attach a cleanout to allowfor cleaning

Example of drain trap installation

Indoorunit

Downward gradient of at least 1/100(1 cm/1 m)

1/100 gradient

Collective drainpiping

Indoor unitside drain

piping

Indoor unitinstallation


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(5) Drain piping work

23

Drain-up height

Main drain piping

(1) Connect the attached drain hose (flexible type) to the indoor unit's drain outlet.

Be sure to use the drain hose that comes with the unit.The flexible type prevents any undue stress on the drain pan.

Do not bend the drain hose in the middle so as to prevent any excessive force on it. Bendingcan lead to a water leak.

(2) Tighten the indoor unit's drain connection and drain hose with the attached hose band.

Do not attach the indoor unit's drain connection and drain hose (accessory) with adhesive.It complicates removal of the drain hose from the machine during maintenance and the like.

(3) Install the drain branch piping up to the main drain pipe.

Refer to the illustration below for connection from the indoor unit to the main pipe.

If the main drain pipe has already been installed and the required gradient for the drain branch pipingcannot be achieved, maximize the drain-up height.(Confirm the drain-up height with the installation manual as it differs depending on the model.)

Indoor unit

Example of installation

Allows for adjustmentof the angle

Drain pain Insulation material (band section)

Insulation material(piping section)

Attached drain hose

Hose band

Drain branch piping

Main drain pipe


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24

2) Collective drain piping

An example of a connection from the main drain pipe to a vertical pipeIt is ideal to use a Y joint. If it is not locally available, a T joint can also be used.

Maximize the size of the main drain pipe as much as possible.

Attach a cleanout (cap) at the top of the main drain pipe for water flow tests.Minimize the number of indoor units per group as few as possible in order to prevent thedrain piping from becoming too long.

3) Drain flow test(1) Conduct a drain flow test before insulation work.

(2) Use the cleanout on the main drain pipe for the water flow test.

In the case of polyvinyl piping, use of colored adhesive prevents workers from forgetting toreplace the plug.

Connection to vertical pipe with a Y joint Connection to vertical pipe using a T joint

Cleanout

T joint

Y joint

Example of drain piping installation

Main drain piping

Vertical drain piping

Vent piping

Drain branch piping


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25

(Reference) Inner diameters of the main drain piping and vertical drain piping

Calculate the drainage volume based on the number of indoor units connected to the main drain pipe. The innerdiameter of the piping can be determined using the following method:

6 liters per hour per 1 HP is a rough measure for drainage volume from the indoor units.

For example, in the event of 3 units with 2 HP and 2 units with 3 HP:6 L/hr 2 HP 3 units + 6 L/hr 3 HP 2 units = 72 L/hr.

(1) The relationship between the inner diameter of the main drain pipe and allowable drainage volume when usingcollective piping (in the case of an air vent)

Note: Calculated assuming that the water ratio within the piping is 10%.Round off the allowable flow rate to the nearest whole number.The pipe after collection should have an inner diameter of at least 34 mm.

(2) The relationship between the inner diameter of the vertical drain pipe and allowable drainage volume whenusing collective piping (in the case of an air vent)

Note: Round off the allowable flow rate to the nearest 10.Vertical pipes within collective piping should have an inner diameter of at least 34 mm.

Allowable flow rate [L/hr]PVC

Inner piping diameter

(Reference value: mm) Gradient=1/50 Gradient 1/100Comments

PVC25 19 39 27

PVC32 27 70 50

Not suitable for the main drainpiping due to the limited allowableflow rate

PVC40 34 125 88

PVC50 44 247 175

PVC63 56 473 334

Suitable for the main drain piping

PVC Inner piping diameter

(Reference value: mm) Allowable flow rate [L/hr] Comments

PVC25 19 220

PVC32 27 410

Not suitable for vertical drain piping in thecase of collective piping

PVC40 34 730

PVC50 44 1,440

PVC63 56 2,760

PVC75 66 5,710

PVC90 79 8,280

Can be used for vertical drain piping in thecase of collective piping


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2. Work by Process and Key Points(7) Insulation work

27

[Materials]For the insulation, use materials that can sufficiently withstand the temperature of the piping.

Heat-pump typeHeat resistant polyethylene foam (that can withstand temperatures over 120 C)

Cooling-only typePolyethylene foam (that can withstand temperatures over 100 C)

Polyethylene foam (heat resistant temperature: 70 ~ 80 C)

If you assume that the temperature and humidity around the refrigerant pipe might exceed30 C and RH80%, please use insulation with a thickness of 20 mm or more.

Polyethylene foam insulation material cannot be used in some areas (Hong Kong) due to thefire codes. Therefore, confirm this in advance.

Be sure to insulate connections (brazed, flared, etc.) after they have passed air tightness tests.

Be sure to insulate both the gas and liquid piping individually.

Be careful not to leave any gaps in the insulation joints. Be careful not to use damaged insulation material.

Workprocedure

Refrigerantpiping work

Insulation work(other than theconnections)

Air tightnesstest

Insulation work(the

connections)

Drain pipingwork

Insulation work(other than the

connections)

Drain flow testInsulation work

(the

connections)

Gap in the insulation joint Damaged insulation material

Insulate both the gas and liquidi in to ether

Insulate the gas and liquid pipingindividually

Insulate only the gas piping

Liquidpiping

Insulation material

Gaspiping

Liquid piping

Insulation material

Gaspiping

Insulation material

GaspipingLiquid piping

Insulation material

~Working points~Insulation work does not allow for checks/tests, so ensure that any maintenance and repair on theinsulation joints and the like is done properly.


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(7) Insulation work

28

Example of a polyvinyl tubebeing used

Suspension bandwith turnbuckle

Polyvinyl tube

Indoor unit flares Use the following guide to conduct insulation work properly up to the base of the refrigerant piping on the

indoor units.

(1) Wind the joint insulation material (accessory) around the flares on both the liquid and gas piping.

Always face the joint of the insulation material upward.

(2) Securely fasten both ends of the joint insulation material with the clamp material (accessory).(3) Wind sealer over the joint insulation material only for flares on the gas piping side.

Be sure to always conduct the above work after the air tightness test.

Supporting fixture insulation

When supporting the horizontal piping, the weight of the piping tends to crush the insulationat the support spots and cause condensation.At support spots, either reinforce the insulation material using tape with insulating propertiesor provide support with a hard-type wide polyvinyl tube to spread the weight.Be careful not to wind any adhesive tape used for a temporary hold too tightly.

Reinforcement of the insulation material cuts

Insulation material shrinks with time, so it is recommended that the insulation material cuts bereinforced with tape with insulation material after applying a special adhesive.

Gas pipingLiquid piping

Flare insulation work guidePiping insulation

material

(machine side)

Supporting fixture

Insulating reinforcementtape (5t 50w)

Insulation material

(only gas piping side)Tighten the section thatoverlaps with the piping

insulation material

Sealer (accessory)

Wind from the base of themachine to the upperportion of the flare nutconnectionJoint insulation material (accessory)

Flare nutconnectionFace the joint

upward

Piping insulationmaterial

(locally procured)

Attach to the base

Clamp material (accessory)


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(7) Insulation work

29

+200+200

When inserting the insulation material into a gap

In consideration of possible shrinking of the insulation material in the future, insert insulationmaterial that is 200 mm longer than the gap into the gap. The work that follows is the same asthe above-mentioned (3).

Reinforcement of insulation material at bends

Try to minimize the number of cuts in the insulation material (one cut is ideal).Consider where to cut the insulation material so that its reinforcement after bending can beconducted at a straight pipe portion.

L + Approx. 200 mm of insulation material

Special adhesive

Reinforcement tape with insulation material


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2. Work by Process and Key Points(8) Control wiring work

30

Indoor

Indoor

Normal condition(when sending)

Interference condition(when sending)

RC

RC4-core cable(stray capacitancebetween cables)

[Compatible wiring types]Use the following 2-wire sheathed vinyl cords or cables:

Vinyl cabtyre cord (round type) VCTF JIS C3306

Vinyl cabtyre cord (flat-round type) VCTFK JIS C3306

600V vinyl-insulated vinyl cabtyre cable VCT JIS C3312

600V vinyl-insulated vinyl sheathed cabtyre cable (round type) VVR JIS C3342

Vinyl-insulated vinyl sheathed control cable CVV JIS C3401

Instrumentation cable with braided screen (shielded wire) MVVS JIS C3102

If shielded wires are not properly grounded on one end, it can lead to communication problems.Therefore, when using a shielded wire, be sure to ground one end.

1. Use wires of a thickness between 0.75 mm 2 and 1.25 mm 2.

Thin type

When wiring over an extended distance, transmission may become unstable due to the drop in voltage.

Moreover, it predisposes the wiring to noise effects. Thick type

When using daisy-chain wiring, 2 wires cannot be inserted into the indoor terminal block.

2. Never use multi-core wiring (more than 2 cores).

Signal interference occurs, resulting in transmission errors.

The same thing that happens when using multi-core cables will occur when many single-core wiresare inserted into the conduit.

In the case of a thick type2 wires cannot be inserted into the terminal block

[When using multi-core cables: Example of the VRV series]

Cross-section of a VCTF

Conductor

Insulation

Sheath

~Working points~Prepare a system diagram and check your work to prevent miswiring.


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(8) Control wiring work

31

3. Never bind communication wires over an extended distance.

The insulation distance between wires shortens, predisposing the wires to interference.

4. Never wire with bound control wiring

Strong and weak currents may mix together, so it is recommended not to use multi-core wires.

(It affects the wire withstanding voltage among other things.)

5. Keep the control wiring and power wiring separate

Due to the influence of the electrostatic and electromagnetic coupling, a disturbing wave that interferes

with the signal wiring is induced, leading to malfunctions. When laying the signal wiring parallel to the power wiring, it is recommended to separate them with a

distance shown in the table below:

6. Use the same type of wires for power wiring within the same system.

Mixing the wire types can lead to communication problems.

Power supply capacity for powerwiring

Separation distance betweenpower wiring and control wiring for

Daikin air conditioners

Separation distance between powerwiring for other equipment and

control wiring for Daikin airconditioners

Less than 10A At least 300 mm

50A At least 500 mm

100A At least 1,000 mm

220V or

more

More than 100A

At least 50 mm

At least 1,500 mm

Indoor unit

Indoor unit

RC

RC

[Poor example] [Good example]

RemotecontrolPCB

Start/Sto (6-core wire)

RemotecontrolPCB

Start/Stop


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2. Work by Process and Key Points(9) Outdoor unit installation

32

Precautions when preparing foundations for outdoor units

Support the unit with a foundation that is at least 66 mm wideWhen attaching the rubber cushion, attach it to the whole bearing face of the foundationThe height of the foundation should be at least 150 mm from the floorSecure the unit to the foundation using the foundation bolts, nuts and washers(Use four sets of M12-type foundation bolts, nuts and washers)The optimum length of the foundation bolts from the surface of the foundation is20 mm

Make considerations for the drain outletPay attention to the floor strength and waterproofing when installing outdoor units on the roof.

Workprocedure

Outdoor unitinstallation

For anything 8 HP or above,use of small concrete blocksat the four bottom corners ofthe outdoor unit as afoundation is not possible.However, this is possiblewith the 5 HP models.

Middle of themachine

Required forany machine ofat least 8 HP

Middle of themachine

Required forany machine ofat least 8 HP

Model A mm B mmRXYQ5P 635 497RXYQ8P

RXYQ10PRXYQ12P,14PRXYQ16P,18P

930 792

1240 1102 7 2 2

7 3 7

6 3 1

A t l e a s

t 7 6 5

A

B

At least 67

4-1522.5 (Foundation bolt hole)

Foundation drawing for outdoor unit

2 0

Foundationpreparation


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(9) Outdoor unit installation

33

A t l e a s

t 1

. 5 m

A t

l e a s t

1 m

A t l e a s t 1 m

A t l e a s t 1 . 5 m

A t l e

a s t 1

m

A t l e a s t 1 . 5 m

A t l e a s t 1 .5 m

Securing space for servicing/maintenanceIt is important to make considerations for space for servicing/maintenance.

Note that replacement of the compressor may become difficult depending on the piping route.

Prevention of short-circuitingShort-circuiting can occur if the outdoor unit is not installed in a location with good ventilation.

Note that it may be necessary to install discharge ducts in cases as shown in the illustrations below:

N M when L 1 m.

K M when L < 1 m.

Note that Dimension K refers to the dimensions

necessary when installing a single unit.

Refer to 'Standards for installing

upward-discharging outdoor units' when

installing on each floor.

No special measures are

required if L 3 m.

If L < 3 m, a discharge duct with

duct resistance of less than 8

mmH 2O is necessary.

Dimension K for single unit

installation requires being

slightly larger.

Considerations when installing inverter air conditionersBe sure to secure enough space for servicing/maintenance according to the instructions in the installation manual.

Inverter air conditioners may induce noise from other electronic equipment. When selecting alocation for installation, maintain sufficient distances from radios, PCs, stereos and the like inconsideration of the installation of the air conditioner and power wiring.

Radios, PCs, stereos, etc.

Foundation

Not enough space forservicing/maintenance!(Impossible to remove thecompressor.)

Indoor unit

Indoor unit RC Cooling/heating

changeoverRC

Branching switch,overcurrent circuit breaker

Branching switch,overcurrent circuitbreaker

Forshort-circuiting

prevention

Dischargeduct

Installing under eaves Measures for obstacles above


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2. Work by Process and Key Points (10) Air tightness tests

34

4.0

3.5

2.0

1.5

1.0

0.5

0

4.0

3.5

2.0

1.5

1.0

0.5

0

1) 2) 3)

1) Evacuation of refrigerant piping

Connect the gauge manifold to the service ports on the liquid and gas piping. Operate the vacuum pump until the

pressure reaches below 100.7kPaG (755mmHg). Operate the vacuum pump for about 30 minutes, though it maydiffer depending the respective piping length.

2) Nitrogen pressurization

(1) Pressurize the liquid and gas piping for each refrigerant circuit according to the following steps:(Be sure to use nitrogen gas.)

Step 1: Pressurize at 0.3 MPaG for approx. 3 minutes

Step 2: Pressurize at 1.5 MPaG for approx. 5 minutes Step 3: Pressurize at 4.0 MPaG for roughly 24 hours

Even pressurized at 4.0 MPaG, a short time does not allow fordetection of smaller leaks.Be sure to pressurize for 24 hours in Step 3.

Never pressurize at a pressure above 4.0 MPaG.

~Working points~Be sure to evacuate the piping before the air tightness test.

Be sure to always use nitrogen gas for the air tightness test.The air tightness test pressure is the design pressure for air conditioners.

Workprocedure Completion ofrefrigerant piping

work

Nitrogenpressurization

Check for dropin pressure

Pass

Leak check

Evacuation

4)

Example of the air tightness test

Allows for detection of large leaks

Allows for detection of smaller leaks

[Time chart]

Step3 If no pressure drop, PASS

Step1

3 minutes 5 minutes Time

24 hours

Pressure

MPaG

Step2


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(10) Air tightness tests

35

3) Check for pressure drop If there is no pressure drop, it has passed the test.

Any differences in ambient temperature between during pressurization and during check for pressure drops willnecessitate correction because pressure changes by roughly 0.01 MPaG per 1

C.

Correction value: (Temperature during pressurization Temperature during check) x 0.01 MPaG(Example)

Pressure used for pressurization Ambient temperaturePressurization 4.00MPaG 25 C

24 hours later 3.95MPaG 20 C

In this case, the correction would be 0.05 MPaG so you can determine there has been no pressure drop(indicating a PASS).

4) Leak check If a drop in pressure has been detected, search for the leak site by applying soapy water to the surface of the piping connections (flares, brazed spots) and charge the hose connections.

It is rare to conduct an air tightness test on everything from the outdoor unit to indoor unit at thesame time. If a pressure drop has been detected, it takes a lot of time to check where the leak is.An efficient method to check is on a block-by-block basis in accordance with the work schedule.

After conducting the air tightness test, leaving the pressure between 0.2 and 0.3 MPaG in thepiping allows for the prevention of contamination in the piping.

The work can be conducted efficiently if the pressurization assemblyis prepared beforehand.

(1)

(3)

(2)

Shaft

(1) For each floor, check from the indoor unit to the

vertical pipe within each shaft.(2) Check the above (1) and the vertical piping within

each shaft.(3) Check all piping from the indoor unit to the vertical

piping to the outdoor unit.


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2. Work by Process and Key Points(11) Vacuum drying

36

~What is vacuum drying?~Using a vacuum pump, the moisture (liquid) in the piping is changed to vapor (gas) and expelled out of the

piping in order to dry the inside of the piping.At 1 atmospheric pressure (101.3 kPa or 760 mmHg), the boiling point (evaporation temperature) for water is100 C. However, the closer the pressure within the piping comes to reaching a vacuum state as a result of usingthe vacuum pump, the lower the boiling point becomes. Once the boiling point falls below the outdoortemperature, the water will evaporate.

If the outdoor air temperature is 7.2 C, vacuum drying cannot be conducted unless the pressure is lowered

below 100.3 kPaG ( 752mmHg). Therefore, when conducting vacuum drying, 'selection and maintenanceof the vacuum pump' is important.

Selection of the vacuum pump Note the following two points when selecting a vacuum pump.1. Select one that allows for pressure to be brought below 100.7 kPaG ( 755 mmHG).2. Select one that allows for relatively high discharge volume.

(One with at least 40 L/min. is recommended.)

Before conducting the vacuum drying work, be sure to check with a vacuum gauge that the pressurereaches a level below 100.7 kPaG.

Use special tools for R410A (e.g., gauge manifold, charge hose).Reasons: Refrigerant oils differ between R410A and R22. Using different tools will result inrefrigerant oils being mixed between the two, which will result in the development of impuritiesand the clogging of the refrigerant circuit.

Water boiling point Absolute pressure Gauge pressurekPa mmHgGmmHg kPaG

After passing airtightness test

Vacuumdrying

Vacuum testWorkprocedure

Necessary degreeof vacuum

Outdoor temperaturerange

Evaporatingpoint

Temperature (

C)

G a u g e p r e s s u r e

k P a

G (

m m

H g

)

A b s o

l u t e p r e s s u r e

k P a

( m m

H g

)


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(11) Vacuum drying

37

Vacuumstate

(1 hour)

Vacuumdrying

(2 hours) Additional refrigerant charge

(Refer to the following chapter.)

There are two methods of vacuum drying depending on the onsite conditions so selectively use them.1) Normal vacuum dryingThis is the common method.

(1) Vacuum drying (1st time) Connect a gauge manifold to the service ports of the liquid and gas piping and operate the vacuum pump for at least 2 hours. (The pressure must be below 100.7 kPaG or 755 mmHg.)

If the pressure does not fall below 100.7 kPaG or 755 mmHg even after vacuuming for 2 hours, theremay either be moisture or a leak in the circuit. Vacuum for 1 more hour to confirm this.

If the pressure does not fall below 100.7 kPaG or 755 mmHg even after vacuuming for 3 hours,check for the leak site.

(2) Vacuum testLeave the system in a vacuum state below 100.7 kPaG or 755 mmHg for at least 1 hour and confirmthat the gauge indicator does not rise.

Conduct evacuation from both the liquid and gas piping. There are various types of functioningcomponents in an indoor unit and evacuating only from one (liquid or gas) piping may result in abreak in the vacuum state.

If the gauge indicator rises, there may be moisture remaining or a leak in the circuit.

Pressurized side

Vacuumed side

Atmosphericpressure

+0.05 MPaG

0 MPaG

-26.7 kPaG

-53.3 kPaG

-80.0 kPaG

-93.3 kPaG

-101.3 kPaG

-100.7 kPaG

[Normal vacuum drying time chart]


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(11) Vacuum drying

38

Additional refrigerant charge

Vacuum state (1 hour)Vacuum drying (1 hour)

Vacuum break

Vacuum drying (2 hours)

2) Special vacuum dryingSpecial vacuum drying is conducted when there is a risk of moisture within the piping.For example,

When work has been done during the rainy season and there is a risk of condensation within the piping When the work has taken a long time and there is a risk of condensation within the piping When there is a risk that rain has entered into the piping during work

The special vacuum drying incorporates at least one vacuum break process using nitrogen gas during thenormal vacuum drying process.

(1) Vacuum drying (1st time) Connect a gauge manifold to the service ports of the liquid and gas piping and operate the vacuum pump for at least 2 hours.(The pressure must be below 100.7 kPaG or 755 mmHg.)

If the pressure does not fall below 100.7 kPaG or 755 mmHg even after vacuuming for 2 hours, theremay either be moisture or a leak in the line. Vacuum for 1 more hour to confirm this.

If the pressure does not fall below 100.7 kPaG or 755 mmHg even after vacuuming for 3 hours,check for a leak site.

(2) Vacuum break (1st time)

Pressurize with nitrogen to 0.05 MPaG.(The nitrogen gas is a dry nitrogen, so breaking the vacuum state with it increases the effectiveness of thevacuum drying.)

(3) Vacuum drying (2nd time)Operate the vacuum pump for at least 1 hour.Determinations: The pressure must reach at least 100.7 kPaG or 755 mmHg. If it does not even after 2hours of operation, repeat steps (2) (vacuum break) and (3) (vacuum drying).

(4) Vacuum testLeave the system in a vacuum state below 100.7 kPaG or 755 mmHg for at least 1 hour and confirm thatthe gauge indicator does not rise.If the gauge indicator rises, there may be moisture remaining or a leak in the circuit.

Be sure to use nitrogen gas when conducting vacuumbreak.

[Special vacuum drying time chart]

Pressurized side

Vacuumed side

Atmosphericpressure

+0.05 MPaG

0 MPaG

-26.7 kPaG

-53.3 kPaG

-80.0 kPaG

-93.3 kPaG-101.3 kPaG

-100.7kPaG

-100.7kPaG


41/44

2. Work by Process and Key Points(12) Additional refrigerant charge

39

(1) Calculation of the additional refrigerant charge amount

Accurately assess the length of the refrigerant piping to calculate the amount of additional refrigerant charge.(For calculating the formula, refer to the equipment design materials for the respective models.)

Be sure to enter the calculated additional refrigerant charge amount on the 'additionalrefrigerant charge instruction label' on the outdoor unit.(The data will be needed for maintenance.)

(2) After completing the vacuum drying, leave the air conditioner OFF, open Valve A and charge the calculatedadditional refrigerant from the cylinder via the liquid side stop valve service port using pressure difference.

Be sure to charge the refrigerant in a liquid state.(Cylinders with siphons allow for charging of liquid refrigerant in a standing position.)

Use a digital scale to measure.

If the refrigerant cannot be charged due to pressure equalization,(3) Close Valve A and then open Valve B.(4) Turn on the outdoor and indoor unit power supplies.(5) Completely open up the gas and liquid side stop valves.

Be sure to charge refrigerant from the refrigerant charge port.

(6) Turn the additional refrigerant charge operation to ON using the setting mode while leaving the air conditionerOFF.

Refer to the 'Service Precautions' label on the outdoor unit's electrical box cover for theprocedures regarding additional refrigerant charge operation.

(7) Once the required volume of refrigerant has been charged, push the confirmation button (BS1) on the PCB(A1P) to stop the operation.

Workprocedure

Additionalrefrigerant charge

Calculation of additionalrefrigerant charge amount

based on piping length

Indoor unit

Gas side stop valve

Outdoor unitLiquid side stop valve

Refrigerantcylinder with

siphon

Cylinder

Gauge

Gaugemanifold

ValveB

Valve A

Refrigerant charge port

After completion ofvacuum drying


42/44

NN oo tt ee


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VRVIII_installation_manual - English Version

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