Panasonic CU-2Z35 Series Manual

AIR CONDITIONER
Required tools for Installation Works
CAUTION
1 Phillips screw driver
2 Level gauge
R32
3 Electric drill, hole core drill (ø70 mm)
4 Hexagonal wrench (4 mm)
5 Spanner
REFRIGERANT
6 Pipe cutter
7 Reamer
This Air Conditioner contains and
8 Knife
operates with refrigerant R32.
9 Gas leak detector
THIS PRODUCT MUST ONLY BE INSTALLED OR SERVICED 10 Measuring tape
BY QUALIFIED PERSONNEL.
11 Thermometer
Refer to National, State, Territory and local legislation,
regulations, codes, installation & operation manuals, before
the installation, maintenance and/or service of this product.
SAFETY PRECAUTIONS
•
Read the following "SAFETY PRECAUTIONS" carefully before installation.
• Electrical work must be installed by a licensed electrician. Be sure to use the correct rating of the power plug and main circuit for the model to be installed.
• The caution items stated here must be followed because these important contents are related to safety. The meaning of each indication used is as below.
Incorrect installation due to ignoring of the instruction will cause harm or damage, and the seriousness is classifi ed by the following indications.
WARNING This indication shows the possibility of causing death or serious injury.
CAUTION This indication shows the possibility of causing injury or damage to properties only.
The items to be followed are classifi ed by the symbols:
Symbol with white background denotes item that is PROHIBITED.
Symbol with dark background denotes item that must be carried out.
• Carry out test running to confi rm that no abnormality occurs after the installation. Then, explain to user the operation, care and maintenance as stated in
instructions. Please remind the customer to keep the operating instructions for future reference.
•
This appliance is not intended for accessibility by the general public.
WARNING
Do not use means to accelerate the defrosting process or to clean, other than those recommended by the manufacturer. Any unfi t method or using incompatible
material may cause product damage, burst and serious injury.
Do not install outdoor unit near handrail of veranda. When installing air-conditioner unit on veranda of a high rise building, child may climb up to outdoor unit and
cross over the handrail causing an accident.
Do not use unspecifi ed cord, modifi ed cord, joint cord or extension cord for power supply cord. Do not share the single outlet with other electrical appliances. Poor
contact, poor insulation or over current will cause electrical shock or fi re.
The appliance shall be stored in a well ventilated room with indoor fl oor area larger than A (m²) [refer Table A] and without any continuously operating ignition
min
source. Keep away from open fl ames, any operating gas appliances or any operating electric heater. Else, it may explode and cause injury or death.
Do not tie up the power supply cord into a bundle by band. Abnormal temperature rise on power supply cord may happen.
Do not insert your fi ngers or other objects into the unit, high speed rotating fan may cause injury.
Do not sit or step on the unit, you may fall down accidentally.
The appliance shall be installed, and/or operated in a room with fl oor area larger than A (m²) [refer Table A] and keep away from ignition sources, such as heat/
min
sparks/open fl ame or hazardous areas such as gas appliances, gas cooking, reticulated gas supply systems or electric cooking appliances, etc.
Keep plastic bag (packaging material) away from small children, it may cling to nose and mouth and prevent breathing.
When installing or relocating air conditioner, do not let any substance other than the specifi ed refrigerant, eg. air etc mix into refrigeration cycle (piping).
Mixing of air etc. will cause abnormal high pressure in refrigeration cycle and result in explosion, injury etc.
Do not pierce or burn as the appliance is pressurized. Do not expose the appliance to heat, fl ame, sparks, or other sources of ignition.
Else, it may explode and cause injury or death.
Do not add or replace refrigerant other than specifi ed type. It may cause product damage, burst and injury etc.
Do not perform fl are connection inside a building or dwelling or room, when joining the heat exchanger of indoor unit with interconnecting piping. Refrigerant
connection inside a building or dwelling or room must be made by brazing or welding. Joint connection of indoor unit by fl aring method can only be made at outdoor or
at outside of a buidling or dwelling or room. Flare connection may cause gas leak and fl ammable atmosfere.
• For R32 model, use piping, fl are nut and tools which is specifi ed for R32 refrigerant. Using of existing (R22) piping, fl are nut and tools may cause abnormally high
pressure in the refrigerant cycle (piping), and possibly result in explosion and injury.
• Thickness for copper pipes used with R32 must be more than 0.8 mm. Never use copper pipes thinner than 0.8 mm.
• It is desirable that the amount of residual oil less than 40 mg/10 m.
Engage authorized dealer or specialist for installation. If installation done by the user is incorrect, it will cause water leakage, electrical shock or fi re.
For refrigeration system work, install according to this installation instructions strictly. If installation is defective, it will cause water leakage, electrical shock or fi re.
Use the attached accessories parts and specifi ed parts for installation. Otherwise, it will cause the set to fall, water leakage, fi re or electrical shock.
Install at a strong and fi rm location which is able to withstand weight of the set. If the strength is not enough or installation is not properly done, the set will drop and
cause injury.
For electrical work, follow the national regulation, legislation and this installation instructions. An independent circuit and single outlet must be used. If electrical circuit
capacity is not enough or defect found in the electrical work, it will cause electrical shock or fi re.
Do not use joint cable for indoor / outdoor connection cable. Use the specifi ed indoor/outdoor connection cable, refer to instruction 5 CONNECT THE CABLE TO
THE OUTDOOR UNIT and connect tightly for indoor/outdoor connection. Clamp the cable so that no external force will have impact on the terminal. If connection or
fi xing is not perfect, it will cause heat up or fi re at the connection.
Wire routing must be properly arranged so that control board cover is fi xed properly. If control board cover is not fi xed perfectly, it will cause fi re or electrical shock.
This equipment is strongly recommended to be installed with Earth Leakage Circuit Breaker (ELCB) or Residual Current Device (RCD), with sensitivity of 30mA at
0.1 sec or less. Otherwise, it may cause electrical shock and fi re in case of equipment breakdown or insulation breakdown.
During installation, install the refrigerant piping properly before running the compressor. Operation of compressor without fi xing refrigeration piping and valves at
opened position will cause suck-in of air, abnormal high pressure in refrigeration cycle and result in explosion, injury etc.
During pump down operation, stop the compressor before removing the refrigeration piping. Removal of refrigeration piping while compressor is operating and valves
are opened will cause suck-in of air, abnormal high pressure in refrigeration cycle and result in explosion, injury etc.
Tighten the fl are nut with torque wrench according to specifi ed method. If the fl are nut is over-tightened, after a long period, the fl are may break and cause refrigerant
gas leakage.
After completion of installation, confi rm there is no leakage of refrigerant gas. It may generate toxic gas when the refrigerant contacts with fi re.
Ventilate if there is refrigerant gas leakage during operation. It may cause toxic gas when the refrigerant contacts with fi re.
Be aware that refrigerants may not contain an odour.
This equipment must be properly earthed. Earth line must not be connected to gas pipe, water pipe, earth of lightning rod and telephone.
Otherwise, it may cause electrical shock in case of equipment breakdown or insulation breakdown.
CAUTION
Do not install the unit in a place where leakage of fl ammable gas may occur. In case gas leaks and accumulates at surrounding of the unit, it may cause fi re.
Prevent liquid or vapor from entering sumps or sewers since vapor is heavier than air and may form suffocating atmospheres.
Do not release refrigerant during piping work for installation, re-installation and during repairing refrigeration parts. Take care of the liquid refrigerant, it may cause
frostbite.
Do not install this appliance in a laundry room or other location where water may drip from the ceiling, etc.
Do not touch the sharp aluminium fi n, sharp parts may cause injury.
Carry out drainage piping as mentioned in installation instructions. If drainage is not perfect, water may enter the room and damage the furniture.
Select an installation location which is easy for maintenance.
Incorrect installation, service or repair of this air conditioner may increase the risk of rupture and this may result in loss damage or injury and/or property.
Power supply connection to the room air conditioner.
Use power supply cord 3 x 1.5 mm² type designation 60245 IEC 57 or heavier cord.
Connect the power supply cord of the air conditioner to the mains using one of the following method.
Power supply point should be in easily accessible place for power disconnection in case of emergency.
In some countries, permanent connection of this air conditioner to the power supply is prohibited.
1) Power supply connection to the receptacle using power plug.
Use an approved 16A power plug with earth pin for the connection to the socket.
2) Power supply connection to a circuit breaker for the permanent connection.
Use an approved 16A circuit breaker for the permanent connection.
It must be a double pole switch with a minimum 3.0 mm contact gap.
Installation work.
It may need two people to carry out the installation work.
PRECAUTION FOR USING R32 REFRIGERANT
• The basic installation work procedures are the same as conventional refrigerant (R410A, R22) models.
However, pay careful attention to the following points:
12 Megameter Since the working pressure is higher than that of refrigerant R22 models, some of the piping and installation and service tools are special.
Especially, when replacing a refrigerant R22 model with a new refrigerant R32 model, always replace the conventional piping and fl are nuts with the R32 and R410A
13 Multimeter
piping and fl are nuts on the outdoor unit side.
14 Torque wrench
For R32 and R410A, the same fl are nut on the outdoor unit side and pipe can be used.
18 N•m (1.8 kgf•m)
42 N•m (4.3 kgf•m)
Models that use refrigerant R32 and R410A have a different charging port thread diameter to prevent erroneous charging with refrigerant R22 and for safety.
55 N•m (5.6 kgf•m)
Therefore, check beforehand. [The charging port thread diameter for R32 and R410A is 12.7 mm (1/2 inch).]
65 N•m (6.6 kgf•m)
Be more careful than R22 so that foreign matter (oil, water, etc.) does not enter the piping.
100 N•m (10.2 kgf•m)
Also, when storing the piping, securely seal the opening by pinching, taping, etc. (Handling of R32 is similar to R410A.)
15 Vacuum pump
16 Gauge manifold
1. Installation (Space)
•
Must ensure the installation of pipe-work shall be kept to a minimum. Avoid use dented pipe and do not allow acute bending.
•
Must ensure that pipe-work shall be protected from physical damage.
• Must comply with national gas regulations, state municipal rules and legislation. Notify relevant authorities in accordance with all applicable regulations.
•
Must ensure mechanical connections be accessible for maintenance purposes.
•
In cases that require mechanical ventilation, ventilation openings shall be kept clear of obstruction.
• When disposal of the product, do follow to the precautions in #12 and comply with national regulations.
Always contact to local municipal offi ces for proper handling.
2. Servicing
2-1. Service personnel
• Any qualifi ed person who is involved with working on or breaking into a refrigerant circuit should hold a current valid certifi cate from an industry-accredited
assessment authority, which authorizes their competence to handle refrigerants safely in accordance with an industry recognized assessment specifi cation.
•
Servicing shall only be performed as recommended by the equipment manufacturer. Maintenance and repair requiring the assistance of other skilled personnel
shall be carried out under the supervision of the person competent in the use of fl ammable refrigerants.
• Servicing shall be performed only as recommended by the manufacturer.
2-2. Work
• Prior to beginning work on systems containing fl ammable refrigerants, safety checks are necessary to ensure that the risk of ignition is minimised.
For repair to the refrigerating system, the precautions in #2-2 to #2-8 must be followed before conducting work on the system.
•
Work shall be undertaken under a controlled procedure so as to minimize the risk of a fl ammable gas or vapour being present while the work is being performed.
• All maintenance staff and others working in the local area shall be instructed and supervised on the nature of work being carried out.
• Avoid working in confi ned spaces.
•
Wear appropriate protective equipment, including respiratory protection, as conditions warrant.
• Ensure that the conditions within the area have been made safe by limit of use of any fl ammable material. Keep all sources of ignition and hot metal surfaces
away.
2-3. Checking for presence of refrigerant
• The area shall be checked with an appropriate refrigerant detector prior to and during work, to ensure the technician is aware of potentially fl ammable
atmospheres.
•
Ensure that the leak detection equipment being used is suitable for use with fl ammable refrigerants, i.e. non sparking, adequately sealed or intrinsically safe.
•
In case of leakage/spillage happened, immediately ventilate area and stay upwind and away from spill/release.
• In case of leakage/spillage happened, do notify persons down wind of the leaking/spill, isolate immediate hazard area and keep unauthorized personnel out.
2-4. Presence of fi re extinguisher
• If any hot work is to be conducted on the refrigeration equipment or any associated parts, appropriate fi re extinguishing equipment shall be available at hand.
•
Have a dry powder or CO fi re extinguisher adjacent to the charging area.
2
2-5. No ignition sources
• No person carrying out work in relation to a refrigeration system which involves exposing any pipe work that contains or has contained fl ammable refrigerant shall
use any sources of ignition in such a manner that it may lead to the risk of fi re or explosion. He/She must not be smoking when carrying out such work.
•
All possible ignition sources, including cigarette smoking, should be kept suffi ciently far away from the site of installation, repairing, removing and disposal, during
which fl ammable refrigerant can possibly be released to the surrounding space.
• Prior to work taking place, the area around the equipment is to be surveyed to make sure that there are no fl ammable hazards or ignition risks.
• "No Smoking" signs shall be displayed.
2-6. Ventilated area
• Ensure that the area is in the open or that it is adequately ventilated before breaking into the system or conducting any hot work.
•
A degree of ventilation shall continue during the period that the work is carried out.
• The ventilation should safely disperse any released refrigerant and preferably expel it externally into the atmosphere.
2-7. Checks to the refrigeration equipment
•
Where electrical components are being changed, they shall be fi t for the purpose and to the correct specifi cation.
• At all times the manufacturer's maintenance and service guidelines shall be followed.
•
If in doubt consult the manufacturer's technical department for assistance.
•
The following checks shall be applied to installations using fl ammable refrigerants.
- The charge size is in accordance with the room size within which the refrigerant containing parts are installed.
- The ventilation machinery and outlets are operating adequately and are not obstructed.
- If an indirect refrigerating circuit is being used, the secondary circuit shall be checked for the presence of refrigerant.
- Marking to the equipment continues to be visible and legible. Markings and signs that are illegible shall be corrected.
- Refrigeration pipe or components are installed in a position where they are unlikely to be exposed to any substance which may corrode refrigerant containing
components, unless the components are constructed of materials which are inherently resistant to being corroded or are properly protected against being so corroded.
2-8. Checks to electrical devices
• Repair and maintenance to electrical components shall include initial safety checks and component inspection procedures.
•
Initial safety checks shall include but not limit to:-
- That capacitors are discharged: this shall be done in a safe manner to avoid possibility of sparking.
- That there is no live electrical components and wiring are exposed while charging, recovering or purging the system.
- That there is continuity of earth bonding.
• At all times the manufacturer's maintenance and service guidelines shall be followed.
•
If in doubt consult the manufacturer's technical department for assistance.
• If a fault exists that could compromise safety, then no electrical supply shall be connected to the circuit until it is satisfactorily dealt with.
• If the fault cannot be corrected immediately but it is necessary to continue operation, an adequate temporary solution shall be used.
•
The owner of the equipment must be informed or reported so all parties are advised thereinafter.
3. Repairs to sealed components
• During repairs to sealed components, all electrical supplies shall be disconnected from the equipment being worked upon prior to any removal of sealed covers,
etc.
• If it is absolutely necessary to have an electrical supply to equipment during servicing, then a permanently operating form of leak detection shall be located at the
most critical point to warn of a potentially hazardous situation.
•
Particular attention shall be paid to the following to ensure that by working on electrical components, the casing is not altered in such a way that the level of
protection is affected. This shall include damage to cables, excessive number of connections, terminals not made to original specifi cation, damage to seals,
incorrect fi tting of glands, etc.
•
Ensure that apparatus is mounted securely.
• Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing the ingress of fl ammable atmospheres.
•
Replacement parts shall be in accordance with the manufacturer's specifi cations.
NOTE: The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment.
Intrinsically safe components do not have to be isolated prior to working on them.
4. Repair to intrinsically safe components
• Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the permissible voltage and current permitted for
the equipment in use.
•
Intrinsically safe components are the only types that can be worked on while live in the presence of a fl ammable atmosphere.
• The test apparatus shall be at the correct rating.
• Replace components only with parts specifi ed by the manufacturer. Unspecifi ed parts by manufacturer may result ignition of refrigerant in the atmosphere from a leak.
5. Cabling
•
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or any other adverse environmental effects.
•
The check shall also take into account the effects of aging or continual vibration from sources such as compressors or fans.
6. Detection of fl ammable refrigerants
• Under no circumstances shall potential sources of ignition be used in the searching or detection of refrigerant leaks.
• A halide torch (or any other detector using a naked fl ame) shall not be used.
7. Leak detection methods
•
Electronic leak detectors shall be used to detect fl ammable refrigerants, but the sensitivity may not be adequate, or may need re-calibration.
(Detection equipment shall be calibrated in a refrigerant-free area.)
•
Ensure that the detector is not a potential source of ignition and is suitable for the refrigerant used.
• Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant employed and the appropriate
percentage of gas (25 % maximum) is confi rmed.
•
Leak detection fl uids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with the
refrigerant and corrode the copper pipe-work.
•
If a leak is suspected, all naked fl ames shall be removed/extinguished.
• If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves) in a
part of the system remote from the leak. Oxygen free nitrogen (OFN) shall then be purged through the system both before and during the brazing process.
8. Removal and evacuation
• When breaking into the refrigerant circuit to make repairs – or for any other purpose – conventional procedures shall be used.
However, it is important that best practice is followed since fl ammability is a consideration.
The following procedure shall be adhered to:
• remove refrigerant -> • purge the circuit with inert gas -> • evacuate -> • purge again with inert gas -> • open the circuit by cutting or brazing
• The refrigerant charge shall be recovered into the correct recovery cylinders.
•
The system shall be "fl ushed" with OFN to render the unit safe.
• This process may need to be repeated several times.
•
Compressed air or oxygen shall not be used for this task.
• Flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fi ll until the working pressure is achieved, then venting to atmosphere, and fi nally pulling down to a vacuum.
•
This process shall be repeated until no refrigerant is within the system.
• When the fi nal OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place.
•
WARNING This operation is absolutely vital if brazing operations on the pipe work are to take place.
• Ensure that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation available.
9. Charging procedures
• In addition to conventional charging procedures, the following requirements shall be followed.
- Ensure that contamination of different refrigerants does not occur when using charging equipment.
- Hoses or lines shall be as short as possible to minimize the amount of refrigerant contained in them.
- Cylinders shall be kept upright.
- Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
- Label the system when charging is complete (if not already).
- Extreme care shall be taken not to over fi ll the refrigeration system.
• Prior to recharging the system it shall be pressure tested with OFN (refer to #7).
CAUTION
•
The system shall be leak tested on completion of charging but prior to commissioning.
• A follow up leak test shall be carried out prior to leaving the site.
• Electrostatic charge may accumulate and create a hazardous condition when charging and discharging the refrigerant.
To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging.
10. Decommissioning
•
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its details.
•
It is recommended good practice that all refrigerants are recovered safely.
• Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required prior to re-use of reclaimed refrigerant.
•
It is essential that electrical power is available before the task is commenced.
a) Become familiar with the equipment and its operation.
b) Isolate system electrically.
c) Before attempting the procedure ensure that:
d) Pump down refrigerant system, if possible.
e) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various
parts of the system.
•
Electrostatic charge may accumulate and create a hazardous condition when charging or discharging the refrigerant.
To avoid fi re or explosion, dissipate static electricity during transfer by grounding and bonding containers and equipment before charging/discharging.
Labelling
11.
•
Equipment shall be labelled stating that it has been de-commissioned and emptied of refrigerant.
• The label shall be dated and signed.
• Ensure that there are labels on the equipment stating the equipment contains fl ammable refrigerant.
Recovery
12.
•
When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
• When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed.
• Ensure that the correct number of cylinders for holding the total system charge are available.
•
All cylinders to be used are designated for the recovered refrigerant and labelled for that refrigerant (i.e. special cylinders for the recovery of refrigerant).
• Cylinders shall be complete with pressure relief valve and associated shut-off valves in good working order.
• Recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
•
The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the recovery of fl ammable refrigerants.
• In addition, a set of calibrated weighing scales shall be available and in good working order.
• Hoses shall be complete with leak-free disconnect couplings and in good condition.
•
Before using the recovery machine, check that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event of a
refrigerant release.
Consult manufacturer if in doubt.
• The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant Waste Transfer Note arranged.
• Do not mix refrigerants in recovery units and especially not in cylinders.
•
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that fl ammable refrigerant does not remain within the lubricant.
• The evacuation process shall be carried out prior to returning the compressor to the suppliers.
• Only electric heating to the compressor body shall be employed to accelerate this process.
•
When oil is drained from a system, it shall be carried out safely.
1. Please cut using pipe cutter and then remove the burrs.
2. Remove the burrs by using reamer. If burrs is not removed, gas leakage may be caused.
Turn the piping end down to avoid the metal powder entering the pipe.
3. Please make fl are after inserting the fl are nut onto the copper pipes.
f) Make sure that cylinder is situated on the scales before recovery takes place.
g) Start the recovery machine and operate in accordance with manufacturer's instructions.
h) Do not over fi ll cylinders. (No more than 80 % volume liquid charge).
i) Do not exceed the maximum working pressure of the cylinder, even temporarily.
• mechanical handling equipment is available, if required, for handling refrigerant
j) When the cylinders have been fi lled correctly and the process completed, make sure that the cylinders
cylinders;
and the equipment are removed from site promptly and all isolation valves on the equipment are closed
• all personal protective equipment is available and being used correctly;
off.
• the recovery process is supervised at all times by a competent person;
k) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned
• recovery equipment and cylinders conform to the appropriate standards. and checked.
CUTTING AND FLARING THE PIPING
Pipe
Point down
1. To cut 2. To remove burrs
 Improper flaring 
Handle
0 – 0.5 mm
Reamer
Bar Bar
Yoke
Core
Inclined Surface Cracked Uneven
damaged thickness
Clamp
Copper pipe
Red arrow mark
handle When properly flared, the internal
surface of the flare will evenly shine and
3. To flare
be of even thickness. Since the flare part
comes into contact with the connections,
carefully check the flare finish.
ENGLISH
ACXF60-06550 1/2
PRINTED IN MALAYSIA