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Panasonic PAW560MAH2L Installation Instructions Manual

Air handling unit kit
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Air Handling Unit Kit
Installation Instructions
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  Summary of Contents for Panasonic PAW560MAH2L

  • Page 1 Air Handling Unit Kit Installation Instructions ºC ºC...
  • Page 3: Installation Instructions

    Air Handling Unit Kit Installation Instructions Original Installation Instructions (English) Preliminary version as at December 2014 COPYRIGHT © Panasonic Marketing Europe GmbH 2014. All rights reserved.
  • Page 4: Table Of Contents

    Table of Contents General information and safety instructions ............ Introduction ......................... Structure and meaning of notices and symbols .............. Safety instructions ......................Warranty policy ........................Ventilation theory and air handling units ............Purpose of air-conditioning ....................Purpose of ventilation ......................Mechanical ventilation systems ..................
  • Page 5 Connection of external signal lines................... Electric circuit examples ....................Test Run ........................ Control ........................Remote controller ....................... Thermostat........................... 7.2.1 Control and display elements ................... 7.2.2 Operation ........................7.2.3 Initial Settings ......................7.2.4 Error Codes ......................7.2.5 Maintenance and Service ..................7.2.6 Technical data ......................
  • Page 6: General Information And Safety Instructions

    ● PAW-560MAH2 / PAW-560MAH2L ● PAW-280PAH2 / PAW-280PAH2L AHU Kits connect Panasonic ECOi, ECO G and PACi outdoor units to third-party air handling unit systems, using the same refrigerant circuit as the VRF system. Application examples for Panasonic AHU Kits are hotels, offices, server rooms or all large build- ings where air quality control such as humidity control and fresh air is needed.
  • Page 7: Structure And Meaning Of Notices And Symbols

    General information and safety instructions Structure and meaning of notices and symbols Safety notices WARNING This indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION This indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.
  • Page 8: Safety Instructions

    General information and safety instructions Safety instructions WARNING The following precautions need to be followed strictly, in order to avoid hazardous situations, which could result in death or serious injury. Electric shock or fire may result from inadequate or incorrect installation or wiring procedures. ► System installation must only be performed by an experienced electrician. ►...
  • Page 9: Warranty Policy

    General information and safety instructions ► Prevent the refrigerant gas from coming into contact with a fan heater, stove, range, or other source of fire. Incorrect installation can result in falling equipment causing damage, injuries or other accidents. ► Install in a location that is fully strong enough to support the weight of the equipment.
  • Page 10: Ventilation Theory And Air Handling Units

    Ventilation theory and air handling units Ventilation theory and air handling units Purpose of air-conditioning The purpose of air-conditioning is to provide comfortable indoor air conditions for the room oc- cupants and to provide energy saving potentials for the owner. Comfort If room occupants feel “comfortable“...
  • Page 11 Ventilation theory and air handling units Ventilation demands Ventilation must meet the following demands: ● Provide outside air (oxygen) for breathing ● Control of indoor air contaminants ● Covering of the building’s thermal loads (temperature and humidity control) ● Setting of uniform conditions in the occupied zone As the outside or ambient air varies in temperature, humidity, contamination etc., it must be spe- cifically conditioned before being supplied to the target room, so that it meets the defined indoor air requirements.
  • Page 12: Mechanical Ventilation Systems

    Ventilation theory and air handling units and heating coils, variable air volume (VAV) valves, thermostats and other air-handling equip- ment are used. Exhaust Outside Air handling unit (AHU) Supply Dampers air fan Return air fan VAV valve VAV valve Solar radiation Thermostat Thermostat...
  • Page 13: Air Handling Units

    Ventilation theory and air handling units In most cases, the pressure in ventilated spaces is equal to the atmospheric pressure of the outside. This means that the air-flow delivered to a space equals the airflow brought back from a space. Such spaces are described as neutral or balanced. However, in mechanical ventilation systems the supply air and return air flows might be sized differently, when necessary.
  • Page 14 Ventilation theory and air handling units Air handling units can be manufactured targeted at the specific purpose for which they will be used. Possible features comprise, but are not limited to the following non-exhaustive list of characteristics: ● Construction: monoblock or split in separate delivery sections ●...
  • Page 15 Ventilation theory and air handling units Supply/Exhaust type with cross-flow heat exchanger Supply/Exhaust type with mixing chamber Supply exhaust type with rotary heat exchanger...
  • Page 16 Connecting AHU systems via the AHU Kit to ECOi/ECO G or PACi outdoor units The following graphic shows an example for connecting a third-party air handling unit via the Panasonic AHU Kit to Panasonic ECOi/ECO G or PACi outdoor units. External BMS AHU control kit...
  • Page 17: Product Description

    Application examples for Panasonic AHU Kits are hotels, offices, server rooms or all large build- ings where air quality control such as humidity and temperature control and fresh air is needed. The Panasonic AHU Kits offer a wealth of connectivity possibilities so that they can be easily integrated into many systems.
  • Page 18 Product description The light version, denominated by the letter “L” in the model name, contains the following components: ● IP65 case ● Control unit including transformer ● Relays ● Terminal boards ● Remote controller (CZ-RTC2) ● PCBs for the expansion and RAP valves ●...
  • Page 19 Product description CZ-CAPBC2 Mini seri-para I/O unit (advanced version only) ● Easy integration in external AHU control systems and BMS ● Demand control: 40 to 115 % (5 % steps) of nominal current by 0–10 V input signal* ● Target temperature setting by 0–10 V or 0–140 Ω input signal* ●...
  • Page 20: System Lineup

    Product description System lineup System lineup – ECOi systems Capacity Outdoor unit combination AHU Kit combination HP kW all ECOi outdoor units PAW-160MAH2(L) – – 28 U-10ME1E81 – – PAW-280MAH2(L) – – 56 U-20ME1E81 – – PAW-560MAH2(L) – – 84 U-16ME1E81 U-14ME1E81 –...
  • Page 21: Ahu Kit Dimensions And Exterior View

    Product description System lineup – PACi systems Capacity Outdoor unit AHU Kit (kW) PACi Standard PACi Elite Single-phase units Three-phase units Single-phase units Three-phase units – – U-50PE1E5 – U-60PEY1E5 – U-60PE1E5A – U-71PEY1E5 – U-71PE1E5A U-71PE1E8A 10.0 U-100PEY1E5 U-100PEY1E8 U-100PE1E5A U-100PE1E8A PAW-280PAH2(L)
  • Page 22 Product description Exterior view of the AHU Kit Expansion Thermistor x2 Thermistor x2 valve (Refrigerant: E1, E3) (Air: TA, BL) AHU Kit including Thermistor x2 Thermistor PCB, power transformer, terminal block (Refrigerant: E1, E2) (Air: TA) Note: AHU Kit shown with transparent front cover removed.
  • Page 23: Wiring Layout

    Product description Wiring layout Wiring layout – ECOi and ECO G systems TERMINAL CONNECTOR 6P TERMINAL TERMINAL TERMINAL (YEL) EX1 EX2 1Z5 1Z3 OP3 2Z7 M1.1 M1.2 M1.3 M1.4 M1.5 M1.6 COM DI1 DI2 DI3 COM DO2 COM DO1 CZ-RTC2 COM DO2 COM DO1 CZ-CAPBC2 5 7 9...
  • Page 24 Product description TERMINAL CONNECTOR 6P CONNECTOR 6P TERMINAL TERMINAL TERMINAL (YEL) (YEL) EX1 EX2 1Z5 1Z3 OP3 2Z7 M1.1 M1.2 M1.3 M1.4 M1.5 M1.6 M2.1 M2.2 M2.3 M2.4 M2.5 COM DI1 DI2 DI3 COM DO2 COM DO1 CZ-RTC2 COM DO2 COM DO1 CZ-CAPBC2 5 7 9 5 7 9...
  • Page 25 Product description TERMINAL CONNECTOR 6P CONNECTOR 6P TERMINAL TERMINAL TERMINAL (YEL) (YEL) EX1 EX2 1Z5 1Z3 OP3 2Z7 M1.1 M1.2 M1.3 M1.4 M1.5 COM DI1 DI2 DI3 COM DO2 COM DO1 CZ-RTC2 COM DO2 COM DO1 CZ-CAPBC2 5 7 9 5 7 9 3 4 5 SV1 (RED)
  • Page 26 Product description Wiring layout – PACi systems TERMINAL TERMINAL TERMINAL EX1 EX2 1Z5 1Z3 OP3 2Z7 COM DI1 DI2 DI3 COM DO2 COM DO1 CZ-RTC2 COM DO2 COM DO1 CZ-CAPBC2 3 4 5 5 7 9 3 4 5 6 PK1-B EXCT 3WAY...
  • Page 27: Ahu Kit Enclosure Configuration

    Product description AHU Kit enclosure configuration AHU Kit enclosure configuration ºC ºC Note: AHU Kit shown with transparent front cover removed. Mounting boards Upper mounting board Upper mounting board Remote controller (CZ-RTC2) Thermostat (TR-16) External signal control PCB (PAW-T10) Terminal board with 6 connectors (labelled Section A to Section F) each with 20 con- tacts 1 For details see “5.4 Terminal block layout”.
  • Page 28: System Overview

    Product description Lower mounting board Lower mounting board Auxiliary transformer Transformer Relay Single motorized valve PCB Relay Single RAP valve control PCB Double RAP valve control PCB 2 Depending on the model used, the single RAP valve control PCB (10) or double RAP valve control PCB (11) is mounted in this position.
  • Page 29 Product description System example for ECOi single-connection system Air Handling Unit Kit PAW-280MAH2 I/D-O/D Wiring for Thermostat wiring & Solenoid Valve Piping ECOi or ECO G Air Handling Unit Multi-connection system Note: The following restrictions apply only if PAW-560MAH2(L) is used alone or in combination with other AHU Kits. For all other AHU Kits and AHU Kit combinations without PAW-560MAH2(L) no such restrictions apply.
  • Page 30 Product description System example for ECOi multi-connection system (140 kW capacity) Fan operation signal Gas temperature 28 kW Liquid temperature PAW-280MAH2 16 HP 16 HP 18 HP 56 kW PAW-560MAH2 Fan motor control PCB 56 kW Inlet temperature PAW-560MAH2 Outlet temperature Gas tube O_U / I_U communication Liquid tube...
  • Page 31 Product description System Overview – PACi systems Single-connection system only Strainer (liquid pipe & gas pipe) min. Ø 25.4 mm (field supplied) AHU Kit enclosure (complete) Thermistor for heat exchanger pipe middle (E2) AHU system (field supplied) Thermistor for suction air (TA) Remote controller (integrated in AHU Kit enclosure) Inter-unit wiring Outdoor unit Magnetic relay for operating the blower (field sup-...
  • Page 32: Technical Data And Limitations

    Product description Technical data and limitations Important Apart from the technical data and limitations given in the following tables, the technical data and limitations of the relevant outdoor units, local wiring and piping design regulations and approved best practices need to be observed in installation procedures. Technical data and limitations –...
  • Page 33 Product description Technical data and limitations – PACi systems AHU Kit PAW-280PAH2(L) Outdoor unit PACi Standard 1-phase U-60PEY1E5 U-71PEY1E5 U-100PEY1E5 U-125PEY1E5 Nominal cooling capacity 10.0 12.5 Nominal heating capacity 11.2 14.0 Air volume (Cooling) Min (factory) m³/h 1,140 Max (factory) m³/h 1,980 2,100...
  • Page 34 Product description Technical data and limitations – PACi systems (cont.) AHU Kit PAW-280PAH2(L) Outdoor unit PACi Elite 1-phase U-50PE1E5 U-60PE1E5A U-71PE1E5A U-100PE1E5A U-125PE1E5A U-140PE1E5A Nominal cooling capacity 10.0 12.5 14.0 Nominal heating capacity 11.2 14.0 16.0 Air volume (Cooling) Min (factory) m³/h 1,140 1,140...
  • Page 35 Product description Technical data and limitations – PACi systems (cont.) AHU Kit PAW-280PAH2(L) Outdoor unit PACi Elite 3-phase U-200PE1E8 U-250PE1E8 Nominal cooling capacity 20.0 25.0 Nominal heating capacity 22.4 28.0 Air volume (Cooling) Min (factory) m³/h 1,680 2,280 Max (factory) m³/h 3,960 4,440...
  • Page 36 Product description Distance between tube sheets: 1,000 mm Number of row: 3 Minimum number of passes = 12 × 3 × 1.5 × 10 = 5.4 –4 This value must be rounded up to 6. This means that the minimum number of passes is 6 passes. NOTICE Nuisance tripping of high-pressure switch The outdoor unit is equipped with a high-pressure switch, which stops the operation of the air-...
  • Page 37: Installation

    Installation Installation Installation of AHU Kit WARNING Electric shock from live power supply cords Electric shock may result from contact with live power supply cords. ► Wiring installation must only be performed by a qualified electrician. ► Before starting to work on any machines or devices, always switch off the power supply and lock it in switched-off position.
  • Page 38 Installation 2. Loosen the 4 screws in the corners of the enclosure and remove the cover from the enclo- sure. 3. Mount the backside of the enclosure to the wall or surface using field-supplied fixing screws inserted through the previously prepared holes at each corner.
  • Page 39 Installation NOTICE Signal errors through noise from live power supply cords Power supply cords can generate noise, which may cause signal errors, if they are run in close vicinity to any low-voltage control wiring. ► Keep 230 V AC power supply wiring apart from the low-voltage control wiring for sensors etc.
  • Page 40: Installation Of Refrigerant Piping

    Installation Installation of refrigerant piping When installing the refrigerant piping, the following limitations and restrictions need to be observed: ● Maximum actual and equivalent piping length ● Maximum branch pipe length to AHU Kit ● Maximum branch pipe length difference (between longest and shortest piping from the first branch) ●...
  • Page 41: Installation Of Expansion Valve

    Installation Installation of expansion valve Installation of expansion valve – ECOi and ECO G systems NOTICE Damage to the expansion valve wires Exposing the wires of the expansion valve to the outside and/or to direct sunlight might damage the wires and should therefore be avoided. ►...
  • Page 42: Installation Of Thermistors

    Installation ● The coil wire must be inserted drooped in the AHU body with the drooping wire being close to the AHU Kit. Inside of AHU AHU Kit Drooping wire Important If there are multiple heat exchangers in one ECOi system, an individual expansion valve must be installed for each heat exchanger.
  • Page 43: Installation Of Thermistor On Gas Pipe

    Installation ● The thermistor wire must point downwards from the thermistor to avoid water reaching the thermistor. ● The thermistor wire must be inserted drooped in the AHU body with the droop- ing wire being close to the AHU Kit. Inside of AHU AHU Kit Drooping wire...
  • Page 44 Installation 2. Cover the thermistor and pipe with aluminum tape. 3. Cover the aluminum tape with thermal insulation. 4. Fix thermal insulation and wiring with two bands. Then, run the wire downwards in a loop, to avoid putting tension to it. For PAW-280MAH2(L) and PAW-560MAH2(L) 1.
  • Page 45: Installation Of Thermistor On Liquid Pipe

    Installation 4.4.2 Installation of thermistor on liquid pipe Mount “E1” thermistor to liquid pipe of AHU heat exchanger according to the following instructions. 1. Attach the liquid pipe thermistor to the liquid pipe located in the lowest position after the distributor in the heat exchanger. 2.
  • Page 46: Installation Of Thermistor On Heat Exchanger Pipe Middle

    Installation 4.4.3 Installation of thermistor on heat exchanger pipe middle Installation of thermistor on heat exchanger pipe middle – PACi systems Mount “E2” thermistor to heat exchanger pipe middle according to the following instructions. 1. Attach the heat exchanger pipe middle thermistor in the middle of each pass-line (pipe) in the heat exchanger.
  • Page 47: Installation Of Thermistor For Suction And Discharge Air Stream

    Installation 4.4.4 Installation of thermistor for suction and discharge air stream Mount the suction and discharge air thermistors according to the following instructions. 1. For ECOi, ECO G and PACi systems, attach the suction air thermistor (TA) to the position where air suction temperature can be measured.
  • Page 48 Installation 3. Place a NOTE label, which indicates that the jumper wire has been cut, in the following des- ignated areas on the outdoor unit. NOTES* * Position of designated area for NOTES label depends on NOTES* model type.
  • Page 49: Electrical Wiring

    Electrical Wiring Electrical Wiring General precautions on wiring WARNING Electric shock from live power supply cords Electric shock may result from contact with live power supply cords. ► Wiring installation must only be performed by a qualified electrician. ► Before starting to work on any machines or devices, always switch off the power supply and lock it in switched-off position.
  • Page 50: Recommended Wire Lengths And Diameters

    Electrical Wiring Recommended wire lengths and diameters Important ● The letter coding (A to F) used in the following tables refers to the wiring system diagrams in the next section. ● For information on “(A) Power supply of outdoor unit” refer to the “Installation Instructions“...
  • Page 51: Wiring System Diagrams

    Electrical Wiring Wiring system diagrams Wiring system diagram – ECOi systems AHU Kit (No. 1) Power supply Outdoor unit 220 – 240V ~50/60Hz INV unit Ground Power supply Remote 380 – 415V, 3 N~, 50Hz controller Ground Ground Ground Ground AHU Kit (No.
  • Page 52 Electrical Wiring Wiring system diagram – PACi systems For single-phase outdoor units AHU Kit Power supply Outdoor unit 220 – 240V ~50/60Hz INV unit Power supply Ground 220 – 240V ~50/60Hz Remote controller Ground Ground Ground Ground For three-phase outdoor units AHU Kit Power supply Outdoor unit...
  • Page 53 Electrical Wiring 6. Use the standard power supply cables for Europe (such as H05RN-F or H07RN-F which conform to CENELEC(HAR) rating specifications) or use the cables based on IEC standard (245 IEC57, 245 IEC66). 7. When linking the outdoor units in a network, disconnect the terminal extended from the short plug from all but one of the outdoor units.
  • Page 54: Terminal Block Layout

    Electrical Wiring NOTICE Overheating of terminals with resulting unit malfunction or even fire due to loose wiring Loose wiring may cause the terminal to overheat resulting in unit malfunction or a fire hazard. ► When connecting each power wire to the terminal, follow the instructions on how to connect wiring to the terminal (see next section) and fasten the wire securely with the terminal screw.
  • Page 55: Connection Of Wiring To Terminals

    Electrical Wiring Section D Section E Section F Name Description Note Name Description Note Name Description Note Power supply 230 V AC / U1 (OC) IU/OU 5 V AC E1-1 E1 sensor 5 V DC max. 1 A communication Neutral conductor 230 V AC / U2 (OC) IU/OU...
  • Page 56 Electrical Wiring 4. Place the wire-end sleeve into the socket on the connector and replace and tighten the re- moved terminal screw using a flat-blade screwdriver. Screw Special washer Screw and special washer Terminal plate Wire-end sleeve Wire Wire Wire-end sleeve Shielded wire 1.
  • Page 57: Connection Of External Signal Lines

    Electrical Wiring Connection of external signal lines When installing the external signal lines (blower signal output and blower protection input), the following installation requirements need to be observed: ● Blower signal and blower protection lines must be routed through left wiring port below the terminal board.
  • Page 58 Electrical Wiring Blower signal output This fan control is usually at ON position at the time of operating, but becomes OFF in defrosting. Minimum applicable load: 5 V DC, 1 mA 10P Connector / Section D Maximum applicable load: 230 V AC, 2 A X1: Relay (field supplied) If uninterrupted fan operation is needed and cold draft air is avoided for example by some inter- nal bypass etc., the defrost signal (contacts C5, C6 = ON1, ON2) can be used with an additional...
  • Page 59: Electric Circuit Examples

    Electrical Wiring Electric circuit examples Electric circuit example – ECOi systems Multi-connection systems with 3 AHU Kits AHU Kit Field-supplied 10P Connector Blower signal output AHU Kit 10P Connector Blower signal output Blower signal AHU Kit 10P Connector Blower signal output Electric circuit example –...
  • Page 60: Test Run

    Test Run Test Run After installation and before operation of the system, perform a test run according to the Test Run section in the Installation Instructions of the relevant outdoor unit. If alarm messages are indicated on the outdoor unit PCB (by blinking LEDs) or on the wired remote controller, refer to the Alarm Messages section in the Installation Instructions for the relevant outdoor unit.
  • Page 61: Control

    Control Control Remote controller The standard Panasonic wired remote controller CZ-RTC2 is an integral part of the AHU Kit. All control and setting operations for the ECOi, ECO G or PACi system can be performed on this remote controller. Important The relevant control operations are described in the “Operating Instructions”...
  • Page 62: Operation

    Control 7.2.2 Operation Status messages After the thermostat has been switched on, the PV and SV displays jointly show a set sequence of three status messages before they change to the normal view where the current process value is shown on the PV display and the currently set temperature value is shown on the SV display.
  • Page 63 Control Important The set temperature value, which is adjustable by the above procedure, can be used in differ- ent ways and with different functions depending on how the thermostat is used in the individual application. For further information see “7.2.3 Initial Settings”. Changing values in the “Parameter”...
  • Page 64 Control Parameter menu Parameter Parameter name Setting Description code range Inactive – Hysteresis 0 ... 50 Switching difference relative to the set value, unilateral (i. e. the value is added either below (“heating mode”) or above (“cooling mode”) the set value) Proportional band (P) 000 ...
  • Page 65 Control NOTICE System heat-up to temperatures significantly exceeding the set temperature value During Auto-Tuning mode the system may heat up to temperatures significantly exceeding the set temperature value and may cause damage to sensitive applications. ► Before starting the Auto-Tuning mode, the set temperature value should be reduced to an uncritical value. Switching from “heating mode”...
  • Page 66 Switching from 0–10 V to 2–10 V output signals The voltage range for the output signals on terminals 6–7 is factory-set to 0–10 V. Switching the voltage range from 0–10 V to 2–10 V is possible. However, Panasonic recom- mends to keep the factory setting.
  • Page 67: Initial Settings

    Control 5. Use the buttons to change the value to either “1” for “output 2 ... 10V” or “2” (= factory setting) for „output 0 ... 10V“. 6. Confirm the complete parametrization by pressing and holding the button for approxi- matedly 3 seconds.
  • Page 68 Control 6. Restore and fasten the upper mounting board in its original position, and close the AHU Kit enclosure again (see “4.1 Installation of AHU Kit“ – step 5). Case 2: Adjusting the temperature setpoint based on ambient air temperature To set the thermostat for adjusting the temperature setpoint based on ambient air temperature ), perform the following steps: 1.
  • Page 69 Control 6. On the CZ-CAPBC2 PCB, located on the lower mounting board inside the AHU Kit enclo- sure, make sure that switches S1 to S4 are set as follows: a. S1: Set to “OFF-ON-OFF-ON” (factory default on AHU Kit) b. S2: All jumpers are intact, i e. no jumper has been cut. c.
  • Page 70 Control 7. Restore and fasten the upper mounting board in its original position, and close the AHU Kit enclosure again (see “4.1 Installation of AHU Kit“ – step 5). Case 3: 0–10 V demand control by an external BMS To set the thermostat for 0–10 V demand control by an external building management system (BMS), perfom the following steps: 1.
  • Page 71 Control 3. On the CZ-CAPBC2 PCB, cut jumper “JP1”, in order to activate the 0–10 V demand control mode for the external BMS. Make sure that all other jumpers remain intact. 4. On the CZ-CAPBC2 PCB, set switch S3 to “VOLTAGE” or “NO VOLTAGE”, depending on the BMS digital input (DI) configuration.
  • Page 72: Error Codes

    Control 7. Close the AHU Kit enclosure again (see “4.1 Installation of AHU Kit“ – step 5). 8. Via the signal wiring from the external BMS, which is now connected to contacts AI3 and AI4 (see step 2), select the 0–10 V demand control functionality as follows: Input 0 –...
  • Page 73: Technical Data

    Control 7.2.6 Technical data Dimensions (W x H x D) 48 x 48 x 90 (approximately) Required void space 85 mm (approximately) Mounting cut-out (W x H) 44 x 44 (DIN 1/16) Display indicating range °C –50 ... +580 Temperature measuring range °C –50 ...
  • Page 74 www.aircon.panasonic.eu...

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