Mitsubishi Heavy Industries SRK20ZG-S Tech Manual
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Mitsubishi Heavy Industries SRK20ZG-S Tech Manual

Inverter wall mounted type room air-conditioner ( split system, air to air heat pump type )
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Manual No. '06 . SRK-T . 060
INVERTER WALL MOUNTED TYPE
ROOM AIR-CONDITIONER
( Split system, air to air heat pump type )
SRK20ZG-S, SRK25ZG-S, SRK35ZG-S, SRK50ZG-S

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  • Page 1 Manual No. ’06 . SRK-T . 060 INVERTER WALL MOUNTED TYPE ROOM AIR-CONDITIONER ( Split system, air to air heat pump type ) SRK20ZG-S, SRK25ZG-S, SRK35ZG-S, SRK50ZG-S...

  • Page 2: Table Of Contents

    CONTENTS 1 GENERAL INFORMATION..............1 1.1 Specific features................1 1.2 How to read the model name ............1 2 SELECTION DATA ................2 2.1 Specifications ................2 2.2 Range of usage & limitations ............6 2.3 Exterior dimensions ..............6 2.4 Piping system ................
  • Page 3 6 MAINTENANCE DATA ................32 6.1 Troubleshooting procedures for electrical equipment ....32 6.2 Servicing ..................51 7 INTERFACE KIT (OPTIONAL PARTS)..........52 7.1 Applicable model................52 7.2 List of connectable devices ............52 7.3 Exterior dimensions ..............52 7.4 Circuit board component layout ..........52 7.5 System configuration..............

  • Page 4: General Information

    1.1 Specific features The “MITSUBISHI HEAVY INDUSTRIES, LTD” room air-conditioner: SRK series are of split and wall mounted type and the unit consists of indoor unit and outdoor unit with refrigerant precharged in factory. The indoor unit is composed of room air cooling or heating equipment with operation control switch and the outdoor unit is composed of condensing unit with compressor.

  • Page 5: Selection Data

    2 SELECTION DATA 2.1 Specifications Model SRK20ZG-S (Indoor unit) (220/230/240V) SRC20ZG-S (Outdoor unit) Model SRK20ZG-S SRC20ZG-S Item Cooling capacity 2000 (500~2800) Heating capacity 2700 (500~4600) Power source 1 Phase, 220-240V, 50Hz Cooling input 0.44 (0.1~0.91) Running current (Cooling) 2.4/2.3/2.2 Heating input 0.62 (0.09~1.27)
  • Page 6 Model SRK25ZG-S (Indoor unit) SRC25ZG-S (Outdoor unit) (220/230/240V) Model SRK25ZG-S SRC25ZG-S Item Cooling capacity 2500 (500~3000) Heating capacity 3400 (500~4800) Power source 1 Phase, 220-240V, 50Hz Cooling input 0.62 (0.1~0.97) Running current (Cooling) 3.1/3.0/2.9 Heating input 0.93 (0.09~1.30) Running current (Heating) 4.5/4.3/4.1 Inrush current 4.5/4.3/4.1...
  • Page 7 Model SRK35ZG-S (Indoor unit) SRC35ZG-S (Outdoor unit) (220/230/240V) Model SRK35ZG-S SRC35ZG-S Item Cooling capacity 3500 (500~3900) Heating capacity 4200 (500~5100) Power source 1 Phase, 220-240V, 50Hz Cooling input 1.05 (0.1~1.22) Running current (Cooling) 4.9/4.7/4.5 Heating input 1.14 (0.09~1.32) Running current (Heating) 5.3/5.1/4.9 Inrush current 5.3/5.1/4.9...
  • Page 8 Model SRK50ZG-S (Indoor unit) SRC50ZG-S (Outdoor unit) (220/230/240V) Model SRK50ZG-S SRC50ZG-S Item Cooling capacity 5000 (600~5300) Heating capacity 5800 (600~7900) Power source 1 Phase, 220-240V, 50Hz Cooling input 1.66 (0.12~2.1) Running current (Cooling) 7.6/7.3/7.0 Heating input 1.70 (0.11~2.71) Running current (Heating) 7.9/7.5/7.2 Inrush current 7.9/7.5/7.2...

  • Page 9: Range Of Usage & Limitations

    Frequency of ON-OFF cycle (Inching prevention 10 minutes) (Inching prevention 5 minutes) ON and OFF interval Max. 3 minutes 2.3 Exterior dimensions (1) Indoor unit Models SRK20ZG-S, 25ZG-S, 35ZG-S, 50ZG-S Unit: mm Piping hole right(left) Terminal block 206.5 133.5 102.5 102.5...
  • Page 10 (2) Outdoor unit Models SRC20ZG-S, 25ZG-S, 35ZG-S Unit: mm Drain holes (ø20) 313.1 349.5 439.1 104.9 165.1 18.9 61.9 2-16×12 Terminal block Service valve (Liquid) Flare connection ø6.35 (1/4'') 138.4 33.5 Service valve (Gas) Flare connection ø9.52 (3/8'') Model SRC50ZG-S 286.4 Drain holes 203.1...

  • Page 11: Piping System

    2.4 Piping system Models SRK20ZG-S, 25ZG-S, 35ZG-S Indoor unit Outdoor unit Cooling cycle Heating cycle Outdoor air Flare connection Service valve temp. sensor (Gas) Humidity sensor (35 type only) Muffler Piping Check joint (Gas) ø9.52 4 way valve Accumulator Room temp.

  • Page 12: Selection Chart

    0.92 1.00 How to obtain the cooling and heating capacity Example : The net cooling capacity of the model SRK20ZG-S with the piping length of 15m, indoor wet-bulb temperature at 19.0˚C ✕ ✕ and outdoor dry-bulb temperature 35˚C is Net cooling capacity = 2000 0.975...

  • Page 15: Outline Of Operation Control By Microcomputer

    4 OUTLINE OF OPERATION CONTROL BY MICROCOMPUTER 4.1 Operation control function by remote control switch Remote control Models All models S Operation section FAN SPEED button OPERATION MODE select button Each time the button is pushed, the Each time the button pushed, the indicator is switched over in turn.

  • Page 16: Unit On/Off Button

    4.2 Unit ON/OFF button When the remote control batteries become weak, or if the remote control is lost or malfunctioning, this button may be used to turn the unit on and off. (1) Operation Push the button once to place the unit in the automatic mode. Push it once more to turn the unit off. (2) Details of operation The unit will go into the automatic mode in which it automatically determines, from room temperature (as detected by sensor), whether to go into the cooling, thermal dry or heating modes.

  • Page 17: Flap And Louver Control

    4.5 Flap and louver control Control the flap and louver by AIRFLOW (UP/DOWN) and (LEFT/RIGHT) button on the wireless remote control. (1) Flap Each time when you press the AIRFLOW (UP/DOWN) button the mode changes as follows. (Flap stopped) (Swing) •...

  • Page 18: Auto Operation

    4.6 3D auto operation Control the flap and louver by 3D AUTO button on the wireless remote control. Air flow selection and air flow direction are automatically controlled, allowing the entire room to efficiently conditioned. (1) During Cooling and Heating (Including auto cooling and heating) (a) Air flow selection is determined according to room temperature and setting temperature.

  • Page 19: Timer Operation

    4.7 Timer operation (1) Comfortable timer setting (ON timer) If the timer is set at ON when the operation select switch is set at the cooling or heating, or the cooling or heating in auto mode operation is selected, the comfortable timer starts and determines the starting time of next operation based on the initial value of 15 minutes and the relationship between the room temperature at the setting time (temperature of room temperature sensor) and the setting temperature.

  • Page 20: Outline Of Heating Operation

    (a) Fuzzy operation Deviation between the room temperature setting correction temperature and the suction air temperature is calculated in accordance with the fuzzy rule, and used for control of the air capacity and the inverter speed. Model SRK20ZG-S SRK25ZG-S SRK35ZG-S SRK50ZG-S...

  • Page 21: Outline Of Cooling Operation

    (2) Detail of control in each mode (Pattern) (a) Fuzzy operation During the fuzzy operation, the air flow and the inverter speed are controlled by calculating the difference between the room temperature setting correction temperature and the suction air temperature. Model SRK20ZG-S SRK25ZG-S SRK35ZG-S SRK50ZG-S Fan speed...

  • Page 22: Protective Control Function

    4.12 Protective control function (1) Frost prevention for indoor heat exchanger (During cooling or dehumidifying) (a) Operating conditions Indoor heat exchanger temperature (detected with Th2) is lower than 5ºC. 10 minutes after reaching the inverter command speed except 0 rps. Inverter command (b) Detail of anti-frost operation...
  • Page 23 ◆ < II > (a) Operating conditions: When the outdoor air temperature sensor (Th5) is 22ºC or lower continues for 30 seconds while outdoor speed is other than 0rps. (b) Detail of operation: 1 The lower limit of inverter command speed is set to C(D)rps and even if the speed becomes lower than C(D)rps, the speed is kept to C(D)rps.
  • Page 24 (5) Heating overload protective control (a) Operating conditions: When the unit is operating with the outdoor unit speed other than 0 rps or when the outdoor air temperature sensor (Th5) rose beyond 22ºC for 30 seconds continuously. (b) Detail of operation: 1 Taking the upper limit of control speed range at 60 rps, if the output speed obtained with the fuzzy calculation exceeds the upper limit, the upper limit value is maintained.
  • Page 25 (7) Compressor overheat protection (a) Purpose: It is designed to prevent deterioration of oil, burnout of motor coil and other trouble resulting from the compressor overheat. (b) Detail of operation 1) Speeds are controlled with temperature detected by the sensor mounted on the discharge pipe. (Example) Fuzzy 4 rps After lapse of 3 min.
  • Page 26 (12) Indoor fan motor protection When the air conditioner is operating and the indoor fan motor is turned ON, if the indoor fan motor has operated at 300 rpm or under for more than 30 seconds, the unit enters first in the stop mode and then stops the entire system. (13) Serial signal transmission error protection (a) Purpose: Prevents malfunction resulting from error on the indoor ↔...

  • Page 27: Application Data

    5 APPLICATION DATA SAFETY PRECAUTIONS ¡ Please read these “Safety Precautions” first then accurately execute the installation work. ¡ Though the precautionary points indicated herein are divided under two headings, WARNING and CAUTION , those points which are related to the strong possibility of an installation done in error resulting in death or serious injury are listed in the WARNING section.

  • Page 28: Selection Of Location For Installation

    5.1 Selection of location for installation (1) Indoor unit Where there is no obstructions to the air flow and where the cooled air can be evenly distributed. (b) A solid place where the unit or the wall will not vibrate. Right A place where there will be enough space for servicing.

  • Page 29: Installation Of Indoor Unit

    5.2 Installation of indoor unit (1) Installation of installation board (a) Fixing of installation board Look for the inside wall structures (Intersediate support or INSTALLATION SPACE (INDOOR UNIT) (FRONT VIEW) pillar and firaly install the unit after level surface has been checked.) Unit : mm Space for...
  • Page 30 (3) Preparation of indoor unit (a) Mounting of connecting wires 1) Remove the lid(R). 2) Remove the wiring clamp. 3) Connect the connecting wire securely to the terminal block. Terminal block Use cables for interconnection wiring to avoid loosening of the wires.
  • Page 31 [Drain hose changing procedures] 1. Remove the drain hose. 2. Remove the drain cap. 3. Insert the drain cap. 4. Connect the drain hose. ¡Remove the drain hose, ¡Remove it with hand or ¡Insert the drain cap which was removed at ¡I n s e r t t h e d r a i n h o s e making it rotate.

  • Page 32: Installation Of Outdoor Unit

    5.3 Installation of outdoor unit (1) Installation of outdoor unit Make sure that the unit is stable in installation. Fix the unit to stable base. When installing the unit at a higher place or where it could be toppled by strong winds, secure the unit firmly with foundation bolts, wire, etc.
  • Page 33 (3) Air purge Tighten all flare nuts in the pipings both indoor and outside will so as not to cause leak. Connect service valve, charge hose, manifold valve and vacuum pump as is illustrated below. Open manifold valve handle Lo to its full width, and perform vacuum or evacuation. Continue the vacuum or evacuation operation for 15 minutes or more and check to see that the vacuum gauge reads –...

  • Page 34: Test Run

    (3) Explain to the customer on the correct usage of the air conditioner in simple layman’s terms. (4) Make sure that drain flows properly. (5) Standard operation data (220/230/240V) Model SRK20ZG-S SRK25ZG-S SRK35ZG-S SRK50ZG-S Item –...

  • Page 35: Maintenance Data

    6 MAINTENANCE DATA 6.1 Troubleshooting procedures for electrical equipment (1) Cautions 1 If you are disassembling and checking an air conditioner, be sure to turn off the power before beginning. When working on indoor units, let the unit sit for about 1 minute after turning off the power before you begin work. When working on an outdoor unit, there may be an electrical charge applied to the main circuit (electrolytic condenser), so begin work only after discharg- ing this electrical charge (to DC 10 V or lower).
  • Page 36 (4) Troubleshooting procedure (If the air conditioner runs) Confirm the contents of the customer complaint. The cause of the trouble can be specifically identified. Eliminate the cause of the trouble and perform an Check the self-diagnosis display. operation check. See page 34. Is an error code displayed by Using the Service Mode, access the self-diagnosis the self-diagnosis function?
  • Page 37 (5) Self-diagnosis table When this air conditioner performs an emergency stop, the reason why the emergency stop occurred is displayed by the flashing of display lights. If the air conditioner is operated using the remote control 3 minutes or more after the emergency stop, the trouble display stops and the air conditioner resumes operation.
  • Page 38 (6) Service mode (Trouble mode access function) This air conditioner is capable of recording error displays and protective stops (service data) which have occurred in the past. If self-diagnosis displays cannot be confirmed, it is possible to get a grasp of the conditions at the time trouble occurred by checking these service data.
  • Page 39 *3: To count the number of flashes in the service mode, count the number of flashes after the light lights up for 1.5 second initially (start signal). (The time that the light lights up for 1.5 second (start signal) is not counted in the number of flashes.) In the case of current safe (heating CT1) (example: stop code “32”) The RUN light (10’s digit) flashes 3 times and the TIMER light (1’s digit) flashes 2 times.

  • Page 40: Temperature Setting

    2 Stop data Remote control setting Displayed data Temperature Operation Fan speed switching switching setting Cooling 21°C Displays the reason for the stop (stop code) the previous time when the air conditioner was stopped by protective stop control. 22°C Displays the reason for the stop (stop code) 2 times previous when the air conditioner was stopped by protective stop control. 23°C Displays the reason for the stop (stop code) 3 times previous when the air conditioner was stopped by protective stop control.
  • Page 41 Number of flashes when in service mode Stop code Error content Auto Error Occurrence conditions Cause TIMER recovery display light Error code light Minor category Major category (10’s digit) (1’s digit) Current Overcharge 4 time 1 time Cooling overload 1 When there is a current safe stop in overload 1 mode safe Compressor lock...
  • Page 42 Note (1) The number of flashes when in the Service Mode do not include the 1.5 second period when the lights light up at first (starting signal). (See the example shown below.) In the case of current safe (heating CT1) (example: stop code “32”) The RUN light (10’s digit) flashes 3 times and the TIMER light (1’s digit) flashes 2 times.
  • Page 43 (e) Room temperature sensor temperature, indoor heat exchanger sensor temperature, outdoor air tempera- ture sensor temperature, outdoor heat exchanger sensor temperature table Units: C TIMER light (1’s digit) RUN light (10’s digit) Buzzer sound (minus) (sounds for 0.1 second) (does not sound) * If no data are recorded (error code is normal), the display for each sensor becomes as shown below.
  • Page 44 Discharge pipe temperature table Units: C TIMER light (1’s digit) RUN light (10’s digit) Buzzer sound (minus) (sounds for 0.1 second) (does not sound) * If no data are recorded (error code is normal), the display for each sensor becomes as shown below. Sensor value displayed when the error code is normal Sensor name -64 C...
  • Page 45 Service data record form Model Customer Date of investigation Machine name Content of complaint Display results Remote control settings Display content Content of displayed data Temperature setting Operation switching Fan speed switching Buzzer (Yes/No.) RUN light (Times) TIMER light (Times) Error code on previous occasion.
  • Page 46 (7) Inspection procedures corresponding to detail of trouble [Broken sensor wire, Sensor error connector poor connection] Is connector connection good? Correct connection. Is sensor resistance value good? Replace sensor. Replace PCB. ◆ Sensor temperature characteristics ◆ Discharge pipe sensor temperature characteristics (Room temp., indoor unit heat exchanger Temperature (˚C) Resistance (kΩ)

  • Page 47: Current Cut

    [Open phase on compressor output Current cut terminal, compressor lock] Does current cut operate when operating inverter with compressor Defective inverter wire disconnected? Is output voltage applied to all 3 Defective inverter phases of power transistor? Secure space for suction Is there any shortcircuit? and blow out.

  • Page 48: Over Heat Of Compressor

    [Gas shortage, defective discharge Over heat of compressor pipe sensor] Connector connection check, resistance Is discharge pipe sensor resistance value good? value check, replacement of discharge pipe sensor (page 43) Check if there are any Does trouble persist after Is sufficient quantity of refrigerant places where gas is leaking.
  • Page 49 [Defective fan motor, connector Outdoor fan motor error poor connection, defective PCB] Is connector connection good? Correct connector connection Is DC fan motor resistance value good? * Disconnect the fan motor connector, then investigate the DC fan motor and out- door unit circuit board sepa- Replace outdoor fan motor rately.
  • Page 50 (b) Outdoor unit Phenomenon Operation Sensor mode Shortcircuit Broken wire Cooling System can be operated normally. System can be operated normally. Heat exchanger sensor Heating Defrosting is not performed. Defrosting is performed for 10 minutes at approx. 45 minutes. Cooling System can be operated normally.
  • Page 51 (10) How to make sure of remote control Is remote Remote control control normal? defects Replace the display. Again pushing operating switch Is the unit operable with remote Normal control? Abnormality is not Operating the unit? found. Defective remote control Does unit ON/OFF button operates? Note (1) Check method of remote control...

  • Page 54: Servicing

    6.2 Servicing (1) Evacuation The evacuation is an procedure to purge impurities..noncondensable gas, air, moisture from the refrigerant equipment by using a vacuum pump. Since the refrigerant R410A is very insoluble in water, even a small amount of moisture left in the refrigerant equipment will freeze, causing what is called water clogging.

  • Page 55: Interface Kit (Optional Parts)

    7 INTERFACE KIT (OPTIONAL PARTS) 7.1 Applicable model Name Type SRK20ZG-S, SRK25ZG-S Interface kit SC-BIK-E SRK35ZG-S, SRK50ZG-S 7.2 List of connectable devices Name Type Wired remote control RC-E1R Super link adapter SC-AD-ER Center console SC-SLA1-ER, SC-SLA2A-ER, SC-SLA3-ER 7.3 Exterior dimensions 7.4 Circuit board component layout...

  • Page 57: Installation Of Interface Kit

    7.6 Installation of interface kit Accessories included in package Please check to make sure all the accessories have been included. Part name Quantity Indoor unit connection cable (total cable length: 2 m) Wood screws (for mounting the interface: ø4 × 25) Tapping screws (for mounting the clamp and interface mounting bracket) Interface mounting bracket Clamp (for the indoor unit)
  • Page 58 Connecting the interface and the indoor unit u Remove the upper case of the interface. • Take out the 2 screws in the interface case. i Install the indoor unit’s connection cables in the interface. • Connect the connectors of the indoor unit connection cables to the connectors on the interface’s circuit board. (4 places) o Fasten the indoor unit connection cables using clamps.
  • Page 59 Wired remote control connection Please see the instructions in the wired remote control’s manual concerning connections to the wired remote control. Cut jumper wire “J2” on the circuit board. Caution: Both the wired remote control and the wireless remote control supplied with the indoor unit cannot be used together.
  • Page 60 Super link adapter connection See the super link adapter’s manual concerning connections to the super link adapter. 1Cut jumper wire (J2) on the circuit board. Caution: This device cannot be used together with the wireless remote control which is supplied with the indoor unit. Jumper wire (J2) 2Connections between the interface and super link adapter Names of recommended signal wires...
  • Page 61 Interface installation Install the interface so that the connection cable can reach the indoor unit (approximately 1.3 m). Wiring inlet If the connection cable is extended, operation will be faulty, so do not extend the cable. Fasten the unit to a wall, pillar or similar location. Use a side cutter or similar tool to open the thin knockouts in the case for running wires.

  • Page 62: Wired Remote Control

    7.7 Wired remote control (Optional parts) The figure below shows the remote control with the cover opened. Note that all the items that may be displayed in the liquid crystal display area are shown in the figure for the sake of explanation. Characters displayed with dots in the liquid crystal display area are abbreviated.

  • Page 63: Insatallation Of Wired Remote Control

    The length of each wire that should be left after 7.8 Installation of wired remote control a sheath is removed is as follows: (Optional parts) (1) Selection of installation location Length of the Avoid the following locations section where a sheath is removed (a) Direct sunlight.

  • Page 64: Setting Functions Using The Wired Remote Control

    7.9 Setting functions using the wired remote control (1) The default settings of this unit's functions are as follows: If you want to charge a setting, follow the procedure found in the installation manual and set to your desired setting. For the method of setting, please refer to the installation manual of a remote control unit.
  • Page 65 (2) Function setting method Operating guide message (a) Stop the air conditioner Function description: B , Settting: C Function number: A (b) Press the SET and MODE buttons simultaneously for 3 seconds or longer. The screen display will be switched as follows: Confirm Button “...
  • Page 66 When “I/U FUNCTION ” is selected. 1 The screen display will be switched as follows: “ I/U SELECT” “ SET” “I/U No.00” (blinking) I/U No.00 2 Press either button. Select the indoor unit number that you want to change settings. If only one indoor unit is connected, the indoor unit number will not charge, so please proceed to Step 3.
  • Page 67 (3) Changing the remote control set temperature range (a) It is possible to change the set temperature range using the remote control. 1) The upper and lower set temperature limits can be set from the remote control. Upper limit value setting: Effective during heating. The temperature can be set within a range of 20~30ºC. Lower limit value setting: Effective when running in modes other than the heating mode (AUTO, COOL, FAN, DRY): The temperature can be set within a range of 18~26ºC.

  • Page 68: Super Link Adapter

    • If the RESET button is pressed during a setting operation, the display returns to the previously displayed setting screen. However, settings which have not been fixed become invalid, so exercise caution. * If “NO DISP CHANGE” is selected in No. 12, “TEMP RANGE SET” of the remote control’s functions, of the function setting modes, the remote control’s display does not change even if the temperature range has been changed.
  • Page 69 (3) Installation (a) Accessories Printed circuit board Metal box Metal cover Insulating rubber sheet Pan head screw Locking support Band Binding band ø4 × 8r 2 units for fixing the printed circuit board for binding wires, 5 pieces made of nylon 4 units (b) Metal box dimension 22.5 2-ø6...

  • Page 70: Operation Permission/Prohibition Control

    7.11 Operation permission/prohibition control The air conditioner operation is controlled by releasing the jumper wire (J3) on the interface kit board and inputting the external signal into the CnT. (1) The operation mode is switched over between Permission and Prohibition by releasing the jumper wire (J3) on the interface kit control board.

  • Page 71: External Control (Remote Display)/Control Of Input Signal

    7.12 External control (remote display)/control of input signal (1) External control (remote display) output Following output connectors (CNT) are provided on the printed circuit board of interface kit. • Operation output: Power to engage DC 12V relay (provided by the customer) is outputted during operation. •...

  • Page 72: Refrigerant Piping Installation/Servicing Manual For Air Conditioners Using R410A

    REFRIGERANT PIPING INSTALLATION/SERVICING MANUAL FOR AIR CONDITIONERS USING R410A (These materials are extracted from document issued by The Japan Refrigeration and Air Conditioning Industry Association) 8.1 Outline 8.1.1 Refrigerant R410A (1) Adoption of R410A in air conditioners In 1974, it was pointed out that the ozone layer in the upper stratosphere (about 20 ~ 40 km above ground) might have been damaged by the ozone depleting substances such as CFC (chlorofluorocarbon) and HCFC (hydrochlorofluorocarbon).

  • Page 73: Refrigerant Piping Installation

    (3) Lubricating oils for R410A As the lubricating oils for R22, mineral oils, alkylbenze synthetic oils, etc. have so far been used. As R410A features less solubility with these conventional lubricating oils such as mineral oils, the lubricating oils tend to stay within the refrigeration cycle. As the lubricating oils highly soluble with R410A, ester, ethereal and other synthetic oils are available.
  • Page 74 (2) Joints For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants. a) Flare joints Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.
  • Page 75 d) Flare processing øD Make certain that a clamp bar and copper pipe have been cleaned. By means of the clamp bar, perform the flare processing correctly. Use either a flare tool for R410A or conventional flare tool. Flare processing dimensions differ according to the type of flare tool. Be careful. When using a conventional flare tool, be sure to secure “dimension A”...

  • Page 76: Storage Of Piping Materials

    Table 8. Flare and flare nut dimensions for R22 [unit: mm] Dimension (mm) Nominal Outer diameter Thickness Flare nut width diameter (mm) (mm) 6.35 9.52 13.0 13.5 12.70 16.2 16.0 12.9 15.88 19.4 19.0 16.0 (2) Flare connecting procedures and precautions a) Make sure that the flare and union portions do not have any scar or dust, etc.
  • Page 77 (2) Identification a) Piping set A copper pipe as piping set for R410A must have a thickness as stated in Table 3 (see on page 70), and, as shown in Tables 5 and 6 (see on page 72), it also differs from R22 in flare processing and flare nut dimensions. So, it is necessary to choose a piping set suitable for R410A.
  • Page 78 (3) Flux a) Reasons for the use of flux • By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler. • In the brazing process, it prevents the metal surface from being oxidized. •...

  • Page 79: Installation, Removal And Servicing

    Reducing valve Flow meter Stop valve From the nitrogen cylinder Piping Nitrogen gas Rubber plug for sealing Fig.5 Prevention of oxidation during brazing * Cautions during brazing 1 General cautions 1) The brazing strength should be high as required. 2) After operation, airtightness should be kept under a pressurized condition. 3) During brazing do not allow component materials to become damaged due to overheating.
  • Page 80 (1) Tools exclusive for R410A a) Gauge manifold • As R410A is characterized by high pressure, conventional tools cannot be used. Table 11. Differences between conventional high/low pressure gauges and those for R410A Conventional gauges Gauges exclusive for R410A High pressure -0.1~3.5MPa -0.1~5.3MPa gauge (red)
  • Page 81 e) Flare tool (clutch type) • A flare tool for R410A is provided with a large clamp bar receiving hole so that the projection of the copper pipe from the clamp bar can be set at 0~0.5 mm in flare processing, and also features higher spring strength for increased expansion pipe torque.
  • Page 82 8.3.2 New installation work (when using new refrigerant piping) (1) Air purge by vacuum pump and gas leakage inspection (see Fig. 6) a) Connect the charge hose to the outdoor unit. 1 b) Connect the charge hose to the vacuum pump adapter. 2 At this time, keep the control valves in the fully closed position.
  • Page 83 f) After charging liquid refrigerant into the air conditioner by closing the charging valve, stop operation by fully closing the gauge manifold’s valve Lo. 2 5 g) Quickly remove the charge hose from the service port. 6 When stopped halfway, refrigerant being cycled will be released. h) After securing the caps on the service port and control valve, check the caps’...

  • Page 84: Refrigerant Recovery

    8.3.6 Refrigerant recharging at servicing When it becomes necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps. (For details, see the instruction manual prepared by the equipment manufacturer) 1) Connect the charge hose to the outdoor unit’s service port. 2) Connect the charge hose to the vacuum pump adapter.
  • Page 85 (4) Recovering procedures a) According to the instructions for handling the refrigerant recovering equipment (described in the attached instruction manual), operate the equipment to recover refrigerant. b) During the operation, take care of the following cautions. 1 Ascertain that the refrigerant recovering equipment is running as required and always monitor the state of operation so that adequate steps can be taken in an emergency.
  • Page 86 b) Charge hose (pressure resistant hose for fluorocarbon) and packing • It is 1/4B in thickness and available in various lengths, etc. • Use a hose whose pressure resisting performance is higher than 5.2 MPa (52 kg/cm • Generally, a setting fixture is provided only on one end. (4) Gauge manifold Hose Setting...
  • Page 87 INVERTER WALL MOUNTED TYPE ROOM AIR-CONDITIONER Air-Conditioning & Refrigeration Systems Headquarters 16-5, 2-chome, Kounan, Minato-ku, Tokyo, 108-8215, Japan Fax : (03) 6716-5926 No.116(1.1A) R...

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