Aisin AWGP180E1NHS Installation Instructions Manual

Outdoor unit. combination multi type 15 ton (180.000 btu/h)

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Operation manual (42 pages)

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Page 1 621471-43050 Always read before installation. Aisin Gas Heat Pump Air Conditioner GHP OUTDOOR UNIT INSTALLATION INSTRUCTIONS Combination Multi Type [Model 15 ton (180.000 Btu/h)] Applicable models Gas type Outdoor unit Natural gas Combination Multi type 15 ton (180.000 Btu/h) AWGP180E1NHS...
Page 2 Safety Precautions � In this manual, the precautions to prevent injuries and damages that can occur if this unit is improperly installed are divided into and covered under the “ Warning” and “ Caution” graphics. In addition, “symbols” are used to indicate proper instructions.
Page 3: Table Of Contents
TABLE OF CONTENTS Main Unit and Piping Before Installing...........4 4-2. Refrigerant piping installation specifications..14 4-3. Refrigerant piping - Selecting branch pipes 1-1. Acceptable Installation location ....... 4 and permissible lengths........ 18 1-2. Combinations and capacities of 4-4. Precautions during the installation the outdoor units and indoor units ....
Page 4: Before Installing
Before Installing 1-1. Acceptable installation location � Altitude: under 2624’ 8” (800m) above sea level � Wind velocity: under 98’ 5” ft/s (30m/s), and in a place where the airflow does not directly go into the air intake on the right side of the machine �...
Page 5: Combinations And Capacities Of The Outdoor Units And Indoor Units
1. Before Installing 1-2. Combinations and capacities of the outdoor units and indoor units Important reminder � Install the indoor units that correspond to indoor air conditioning load. Otherwise, the units frequently repeat start and stop. That could result in breakdown of the units. �...
Page 6: Parts Provided
1-3. Parts provided The following parts are provided with this outdoor unit. Check the contents. Name This manual (INSTALLATION INSTRUCTIONS) INSTALLATION Shape INSTRUCTIONS Quantity Name ) (inch) i l ( ) (inch) Shape 2 type, each 1 piece 1 type, 1 piece Quantity (Inner diameter: 1-1/4”/ Outer diameter: 1-1/8”) (Inner diameter: 5/8”/ Outer diameter: 1/2”)
Page 7: Transporting Outdoor Unit
2. Transporting Outdoor Unit Transporting Outdoor Unit 2-1. Check the transporting route � Make sure that the route to the installation site and any openings are large enough for the outdoor unit to be transported through. � Make sure that the route to the installation site has the strength to withstand the weight of the outdoor unit. 2-2.
Page 8: Installation
Installation 3-1. Selecting the location for installation Warning � Never install the outdoor unit at an indoor location. � Never install the outdoor unit at a location where the exhaust gas could flow into the room. If the outdoor unit is installed near the intake/exhaust port to the room, window or ventilation port, the exhaust gas could flow into the room and cause gas poisoning or an accident due to lack of oxygen.
Page 9 3. Installation Important reminder � Always install the outdoor unit at a location where its operating noise and vibration will not cause problems for those below or surrounding the unit. (This is especially important when installing in res- idential areas.) �...
Page 10: Space Required For Installation
3-2. Space required for installation 1) Provide sufficient distance from flammable materials Warning � Install the outdoor unit in the proper distance from flammable items as required by the rel- evant local and national regulations, and technical standards. If the distance does not meet the requirements, it could result in a fire. 2) Installation space Caution �...
Page 11: Foundation And Anchor Bolt Specifications
3. Installation 3-3. Foundation and anchor bolt specifications 1) Foundation shape Warning � The foundation must provide a firm and level surface for installing the outdoor unit so that the outdoor unit does not tip over in the event of strong winds (gust, etc.) or earthquakes. If the foundation strength is insufficient, the outdoor unit could tip over and cause fuel gas leakage or injury.
Page 12 2) Anchor bolts Warning � Use anchor bolts that satisfy the specifications shown in the table below. Make sure the legs of the outdoor unit are firmly secured with washers and bolts. If the strength is insufficient, the unit could tip over and cause fuel gas leakage or injury. Required anchor bolt pull out resistance strength Anchor bolt (Required locally)
Page 13: Refrigerant Piping
4. Refrigerant Piping Refrigerant Piping 4-1. Outline diagram of refrigerant piping [Combined installation] [Stand-alone installation]...
Page 14: Refrigerant Piping Installation Specifications
4-2. Refrigerant piping installation specifications � Follow the restriction shown in the table below when installing new refrigerant piping. [Combined installation] Item Refrigerant piping diameter *1 Permissible height Permissible piping Outdoor Unit inch (mm) difference (m) length (m) Refrigerant (Combination Multi) Equivalent length/ Outdoor unit is Outdoor unit is...
Page 15 4. Refrigerant Piping � Reducer selection for combined installation (inch) (inch) I. D. 1-1/4” I. D. 5/8” I. D. 1-1/4” I. D. 5/8” connection Item Mark Name Specification (inch) Remark Provided with the O.D.1-1/4” - I.D.1-1/8” Reducer outdoor unit Vapor refrigerant Copper pipe 1-1/8”...
Page 16 � Precautions for combined installation � Arrange the refrigerant piping for both liquid and vapor between the outdoor units so that the piping is level or has upward gradient to prevent the refrigerant oil from accumulating in the piping. � Connect the refrigerant piping between the outdoor units to the stop valve as shown in the following figure A or B.
Page 17 4. Refrigerant Piping FOR VAPOR PIPING ONLY, a 8” or more rise could be added if needed. (See below) 6-1/2’ (2 m) or less � Secure straight portion for 26” (660 mm) or more after branching of the Combination Multi connection kit. 26”...
Page 18: Refrigerant Piping - Selecting Branch Pipes And Permissible Lengths
4-3. Refrigerant piping - Selecting branch pipes and permissible lengths [Combined installation] * Follow the piping specification shown below when installing new refrigerant piping. As for renewal specification, when reusing existing piping, confirm that the existing piping meets the pipe specification shown. �...
Page 19 4. Refrigerant Piping Important Reminder � In the case of header branching or line-header combined branching, indoor units with capacity of 96.000 Btu/h or larger cannot be connected after the header branching (c, d, e or f in the right figure). Connect the indoor units with capacity of 96.000 Btu/h or larger to line branching (a or b in the right figure).
Page 20 Header branching Layout example (When 6 indoor units are connected) Note: If there is a height differ- ence between the loca- tions indoor outdoor units, apply a 32’ 10” small “trap pipes” only on (10 m) the vapor line at least every 32’...
Page 21 4. Refrigerant Piping Line - header combined branching Layout example (When 6 indoor units are connected) Note: If there is a height differ- ence between the loca- tions indoor outdoor units, apply a 32’ 10” small “trap pipes” only on (10 m) the vapor line at least every 32’...
Page 22 [Stand-alone installation] * Follow the piping specification shown below when installing new refrigerant piping. As for renewal specification, when reusing existing piping, confirm that the existing piping meets the pipe specification shown. � Make sure that the total extension refrigerant piping length is 1706ft or less. �...
Page 23 4. Refrigerant Piping Important Reminder � In the case of header branching or line-header combined branching, indoor units with capacity of 96.000 Btu/h or larger cannot be connected after the header branching (c, d, e or f in the right figure). Connect the indoor units with capacity of 96.000 Btu/h or larger to line branching (a or b in the right figure).
Page 24 Header branching Layout example (When 6 indoor units are connected) Note: If there is a height differ- ence between the loca- 32’ 10” tions indoor (10 m) outdoor units, apply a small “trap pipes” only on the vapor line at least every 32’...
Page 25 4. Refrigerant Piping Line - header combined branching Layout example (When 6 indoor units are connected) Note: If there is a height differ- ence between the loca- 32’ 10” tions indoor (10 m) outdoor units, apply a small “trap pipes” only on the vapor line at least every 32’...
Page 26: Precautions During The Installation Of Refrigerant Piping
4-4. Precautions during the installation of refrigerant piping 1) Precautions against refrigerant leakage Warning � Check that the refrigerant never exceeds the limit concentration in the room even if the refrigerant vapor leaks inside the room. If the refrigerant concentration in the room should exceed the limit concentration, an accident due to lack of oxygen could occur.
Page 27 4. Refrigerant Piping 2) General precautions Warning � This equipment uses non-flammable refrigerant, R410A exclusively. Never charge with other refrigerant, air, oxygen, propane, or other materials. Doing so could cause an explosion or a fire. � Be sure to remove any flammable materials before brazing. Failure to do so could cause a fire.
Page 28 � Sealing test and vacuuming � In order to prevent mixing of other refrigerant or refrigerant oil, be sure to use a gauge manifold, charge hose and vacuum pump that are exclusively for R410A. � Be sure to perform a sealing test. If R410A leaks, there is a possibility that the composition of the refrigerant inside the equipment will change.
Page 29 4. Refrigerant Piping � Precautions when connecting flare nuts Warning � Tighten the flare nuts with an open-end wrench and a torque wrench to check that the tightening torque is proper. If the torque is not proper, the refrigerant may leak and cause an accident due to lack of oxy- gen due to broken or loosened joints.
Page 30: Notes For Branch Piping
4-5. Notes for branch piping Important reminder � When connecting the branch pipe, do not bend the main pipe near the connection. If such bending is unavoidable, make a minimum of 6”(150 mm) of straight portion. Main Straight portion pipe However, do not use a bent pipe with an external diameter of (6”...
Page 31: Stop Valve Connections And Opening/Closing
4. Refrigerant Piping 4-6. Stop valve connections and opening/closing 1) Stop valve connections � Both of liquid and vapor line piping’s must be brazed when connecting. Important reminder � Connect refrigerant piping with the stop valves on the outdoor unit fully closed (factory default). Do not operate the stop valves until all the refrigerant piping for the indoor and outdoor units have been connected, and the refrigerant leakage test, vacuuming operation and additional refrigerant charging has been completed.
Page 32: Refrigerant Vapor Leakage Test And Vacuuming
4-7. Refrigerant vapor leakage test and vacuuming 1) Refrigerant vapor leakage test Warning � After the refrigerant piping has been installed; always perform a sealing test to confirm that no refrigerant vapor is leaking. If the refrigerant should leak and the refrigerant vapor exceeds the limit concentration, it could cause an accident due to lack of oxygen.
Page 33 4. Refrigerant Piping Vacuuming with a vacuum pump Important reminder � Vacuuming must be performed with the stop valves on the outdoor unit “fully closed”. � Do not perform an air purge with the refrigerant inside the outdoor unit or the refrigerant tank. �...
Page 34: Charging The Refrigerant
4-8. Charging the refrigerant Important reminder � When charging the refrigerant, accurately measure the length of the piping and charge the proper amount of refrigerant. If the amount of refrigerant is not proper, performance will decline or a breakdown could occur. �...
Page 35: Refrigerant Piping Insulation And Heat Retention
4. Refrigerant Piping 1. Place the tank (with the siphon pipe Stop attached) on the refrigerant scale. valve Outdoor unit (fully closed) Vapor line 2. Remove the charge hose from the vac- uum pump and connect it to the tank. Service ports 3.
Page 36 [Combined installation] 5 ft 5 ft 5 ft 5 ft 5 ft 5 ft 5 ft...
Page 37: Fuel Gas Piping Installation
5. Fuel Gas Piping Installation Fuel Gas Piping Installation Warning � Use only the fuel gas indicated on the name plate. Using wrong type of fuel gas could cause incomplete combustion or could damage the out- door unit. � Always perform a gas leakage test after connecting the piping. If there should be a gas leakage, a fire or an explosion could occur.
Page 38: Drain Piping Installation
Drain Piping Installation 1) Exhaust Water Drain Piping Installation Warning � Never connect the exhaust drain and the indoor unit condensation line together. If exhaust gas flows into the building, it could cause gas poisoning or an accident due to lack of oxygen.
Page 39 6. Drain Piping Installation Rear side of outdoor unit Exhaust water Breather Breather drain hose Size at the end of the exhaust Exhaust water drain pipe water drain pipe: Downward gradient must be 1/50 or more Catch basin Hard PVC pipe VP30 (VP50 for cold district specification) Enlarged view Released to...
Page 40 2) Condensation water drain piping installation � Condensation water on the surface of the accumulator will drain from the condensation water drain port. Connect a hose on the market to the condensation water drain port and install the drain piping if there is a prob- lem due to condensation water dripping.
Page 41: How To Extend Exhaust Pipe
7. How to Extend Exhaust Pipe How to Extend Exhaust Pipe � Use Exhaust pipe (required locally) with a diameter of 100 mm for exhaust pipe extension. � Ask an authorized dealer about KP. 1) Precautions for exhaust pipe extension Warning �...
Page 42 2) Exhaust pipe extension � Extended the exhaust pipe according to the following procedure by referring to the figure below. 1. Remove the exhaust top from the outdoor unit exhaust port. 2. Connect the Exhaust pipe (required locally) sequentially from the outdoor unit side, and extend the exhaust pipe to the desired position following the restriction below.
Page 43: Summary Of Electric Wire Installation
8. Summary of Electric Wiring Installation Summary of Electric Wiring Installation Warning � Use a dedicated branch circuit. Never use the outdoor unit with other appliances on the same circuit. If the outdoor unit and other appliances are used on the same circuit, secondary damage could occur due to breaker tripping.
Page 44: Wiring Example
8-2. Wiring example [Combined installation] Single-phase 230 VAC or 208 VAC Electric leakage breaker Over-current (Master unit) (Sub unit) breaker In･Out Out･Out Out･Out In･Out ＋ − ＋ − Optional connector, Optional not used connector, Important reminder not used Connect the centralized ●...
Page 45: Electric Wire Specifications And Precautions
9. Electric Wire Specifications and Precautions Electric Wire Specifications and Precautions 9-1. Power supply wire Warning � The specifications for the electrical wiring and the selection of the appropriate size must be in accordance with the relevant local and national regulations and technical standards.
Page 46: Signal Wire Between Indoor/Outdoor Units, Outdoor/Outdoor Units, And Between Combined Outdoor Units
9-2. Signal wire between indoor/outdoor units, outdoor/outdoor units, and between combined outdoor units Important reminder � Never mix signal and power supply (230 V) wires in a multiple core cord. This will cause malfunc- tion. In addition, provide 2 in (50 mm) or more clearance between wires to prevent electrical noise influence.
Page 47: Remote Control Wire
9. Electric Wire Specifications and Precautions 9-3. Remote control wire � Connect terminals of the remote control wire (P1, P2) to the indoor unit terminals (P1, P2) (P1 and P2 terminals have no polarity). Wire specifications Type of wire Vinyl sheath code or cable Thickness AWG #18 to #16 (0.75 to 1.25 mm �...
Page 48: Power Supply Wiring Procedure
Power Supply Wiring Procedure 10-1. Wiring instruction [Combined installation] Point ⑤ : In ● In Combination Multi, O : Out the master unit RC: Remote controller controls the Single-phase sub unit. 230 VAC Connect the indoor/ or 208 VAC Outdoor unit B Outdoor unit A outdoor and outdoor/ Power supply...
Page 49 10. Power Supply Wiring Procedure [Stand-alone installation] Single-phase : In 230 VAC Outdoor unit A or 208 VAC O : Out (Master unit) Power supply RC: Remote controller Point All of indoor/outdoor and Power supply outdoor/outdoor unit signal wires must be non-polarity 2 core cable.
Page 50: 10-2.Wiring Length
10-2. Wiring length The wiring length of indoor-outdoor and outdoor-outdoor signal wires except the wiring of the remote controller must not exceed the following restriction: • Longest wiring length: 3281ft (1000 m) • Total wiring length: 6562ft (2000 m) (When using shielded wires, the total wire length is restricted up to 4921 ft (1500) meters.) �...
Page 51: 10-3.Branch Wiring
10. Power Supply Wiring Procedure 10-3. Branch wiring The following 3 wiring methods are acceptable. � Series wiring Series wiring Centralized controller � Bus wiring (Up to 10 branches, re-branching after the branch is not possible) Centralized controller First branch Bus wiring Second branch Third branch...
Page 52: After Installation 11. Check After Installation
Check after Installation � The installation check must be performed according to the check list on page 71.
Page 53: Test Operation 12. Various Function Settings
Various Function Settings 12. Various Function Settings All function settings of the outdoor unit in this model are performed by board maintenance function. 12-1. Address setting method of the indoor and outdoor units � The address setting of the outdoor and indoor units is performed automatically. �...
Page 54 List of EEP dip switch settings dip switch Periodic inspection display OFF: Not available / ON: Available — — — — Setting can be e l i changed with check code Combination Multi OFF: Backup starts after error reset No.80 Depends on models backup function *2 On: Automatic backup...
Page 55 Various Function Settings EEP dip switch setting is set in the “check mode“. Disconnect the personal computer, and then, select the check mode. 1) How to change the current mode to the check mode 1. Press the MODE SELECT switch. The mode LED (LED15) lights up in green. (Proceeding to the monitoring mode) 2.
Page 56: 12-3.Gas Type Setting
12-3. Gas type setting Gas type setting is set in the “check mode“. Disconnect the personal computer, and then, select the check mode. To select the check mode, refer to “12-2. 1) How to change the current mode to the check mode” on the previous page.
Page 57: 12-4.Cool/Heat Collective Address Setting
Various Function Settings 12-4. Cool/heat collective address setting This address is set when cooling and heating is switched by using the cool/heat selector. This setting is required only when the optional outdoor external control adapter is used. This setting sets 5 bits (5 pins) of cool/heat address. Refer to the installation manual attached to the external control adaptor for the details of the address setting.
Page 58 2. Each time you press the INDOOR SELECT switch, the pin number changes as “#1 pin” “#2 pin” “#5 pin” ”#1 pin”. Select the pin number you would like to change. (The following figure shows #5 pin is selected.) When #5 pin of cool/heat collective address is OFF...
Page 59: 12-5.Low-Noise Address Setting
Various Function Settings 12-5. Low-noise address setting This setting is required only when the optional outdoor external control adapter is used. This setting sets 5 bits (5 pins) of low-noise address (demand address). Refer to the installation manual attached to the external control adaptor for the details of the address setting. The relationship between the demand address (cool/heat address) of the external control adapter and this low- noise address is as follows: Upper 2 bits...
Page 60 3. Press the SET switch. LED2 and LED1 start to flash to show the system is ready to accept the command. Select ON or OFF by pressing the CODE No. UP or CODE No. DOWN switch. When #5 pin of low-noise address is ON ＳＷ２...
Page 61: 12-6.Field Settings With The Remote Controller
Various Function Settings 12-6. Field settings with the remote controller � Master control setting � What is master control? Only master remote controller can select “cooling”, “heating”, and “dry”. � How to set master control A remote controller you press the “OPERATION CHANGE / MIN-MAX” button first after installation of the indoor /outdoor unit is the master controller.
Page 62: 12-7.List Of Setting Contents And Mode Numbers
Press and hold Cancel button for <Basic screen> 4 seconds or more. Service settings menu will be displayed. Set temperature °C Select Field Settings in the Service Settings menu by using Return Press the menu button (Up/Down) button, and press Menu/OK button.
Page 63 Various Function Settings Press Menu/OK button. Setting conﬁ rmation screen will be displayed. <Setting conﬁ rmation screen> Select and press Menu/OK Field Settings button. Changes will be Save the settings? applied to the settings and the display will be returned to “Field setting” screen. While changing multiple setting Setting changes, repeat “...
Page 64: 13. Remote Control
13. Remote Control 13-1. Remote control with 2 remote controllers � 1 indoor unit control with 2 remote controllers at 2 locations From other To other indoor units indoor units External input Single-phase 230 VAC or 208VAC power supply Remote control wiring length is up to 1640 ft (500m). Main Main Main...
Page 65: Test Operation
Test Operation 14. Test Operation Caution � Do not touch the moving parts. You could be injured. The fans or engine may automatically start running to protect the device to maintain perfor- mance even if the GHP is stopped. Be sure to turn OFF the power breaker when you need to touch the moving parts. 14-1.
Page 66 1) Model information display After turning ON the power, the model information is displayed for about 10 seconds (shown below) and after that, it proceeds to “2) Connection check.“ 2) Connection check This step checks indoor and outdoor unit connection condition. Display during the connection check is as follows: ＳＷ２...
Page 67 Test Operation 3) Connection condition check Check if the wiring between outdoor and indoor units are connected correctly with the display indicated on the mas- ter and the sub outdoor units. The display is as follows. � In the case of Combination Multi master unit, or single outdoor unit ...
Page 68 4) Connection condition display Connection condition is displayed (shown below) for about 10 seconds. After that, the display automatically changes to normal operation mode (running hour display). � In the case of Combination Multi master unit, or single outdoor unit ＳＷ２...
Page 69: 14-3.When Installing Additional Indoor/Outdoor Units Or Replacing The Indoor/Outdoor Unit Pcbs
Test Operation 14-3. When installing additional indoor/outdoor units or replacing the indoor/ outdoor unit PCBs � When changing the number of indoor units or replacing the indoor unit PCB Perform re-wiring recognition of the indoor units. � When changing the number of outdoor units or replacing the outdoor unit PCB Perform re-wiring recognition of the outdoor units.
Page 70 4. Press the SET switch again for 2 seconds or longer while the above-mentioned display (step 3) is shown. Selected re-wiring is recognized and the display is as follows: ＳＷ２ＳＷ３ＳＷ４ＳＷ５ＳＷ６ＣＯＤＥＮｏ．ＩＮＤＯＯＲ...
Page 71: Installation Check List
15. Installation Check List Installation Check List Are there any problems with the exterior and interior of the outdoor unit? Is there any possibility that a short circuit operation could occur due to outdoor unit exhaust heat? Is there specified space for air flow and servicing? Is there any possibility that discharged air from the outdoor unit or engine exhaust gas accumulates inside the room or flows into the room? Is there proper drainage from the outdoor unit?
Page 72: (Reference) Troubleshooting
(Reference) Troubleshooting Perform inspections in accordance with the error displays on the remote controller and the outdoor unit circuit board. 1. Error code display Remote controller Outdoor unit Description of breakdown error code error code � Indoor unit: External protective device activation 63 - �...
Page 73 (Reference) Troubleshooting Remote controller Outdoor unit Description of breakdown error code error code 40 - 0 � Outdoor unit EEPROM failure � Outdoor unit model code failure 40 - 1 � Outdoor unit programs do not match between main microcomputer and engine microcomputer 40 - 2 84 - 3 �...
Page 74: Cancelling The Error Codes
Remote controller Outdoor unit Description of breakdown error code error code 65 - 0 � Disconnected outdoor heat exchanger liquid temperature sensor 65 - 2 � Short-circuited outdoor heat exchanger liquid temperature sensor 85 - 0 � Disconnected outdoor heat exchanger vapor temperature sensor 85 - 2 �...
Page 76 Distributor: Manufacturer: AISIN WORLD CORP. OF AMERICA 46501 Commerce Center Drive 2-1 Asahi-machi, Kariya, Aichi, Plymouth, MI 48170 JAPAN 448-8650...

Aisin AWGP180E1NHS Installation Instructions Manual

Main Unit and Piping

5 Fuel Gas Piping Installatio N

Electrical

After Installation 11. Check after Installation

Test Operation 12. Various Function Settings

13. Remote Control

Test Operation

Reference

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