Sanyo R410A Installation Instructions Manual

W-3way eco-i system air conditioner

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Installation and operation manual (36 pages)

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R410A Models

Indoor Units

Class

4-Way Air Discharge

Semi-Concealed

4-Way Air Discharge

Mini Semi-Concealed

1-Way Air Discharge

AHX0752

Semi-Concealed

U Concealed-Duct

UHX0762

UM Slim Concealed-Duct UMHX0762

Concealed-Duct High

Static Pressure

T Ceiling-Mounted

K Wall-Mounted

KHX0752

F Floor-Standing

FHX0762

Concealed-Floor

FMHX0762

Standing

Outdoor Units

Class

Eco-i W-3WAY

Refrigerant R410A is used in the outdoor units.

Optional Controllers

Timer Wired Remote Controller

Wireless Remote Controller (For U, UM, D, F, FM Types)

Wireless Remote Controller (For X Type)

Wireless Remote Controller (For XM Type)

Wireless Remote Controller (For A, T Types)

Wireless Remote Controller (For K Type)

Simplified Remote Controller

System Controller

Schedule Timer

Intelligent Controller

Communication Adaptor

Remote Sensor

LonWorks Interface

85464369236000 ©SANYO 2009

INSTALLATION INSTRUCTIONS

– W-3WAY ECO-i System Air Conditioner –

for Refrigerant R410A

This air conditioner uses the new refrigerant R410A.

External diameter of service port R410A: 5/16"

NOTE

XHX1252

XMHX1252

AHX0952

AHX1252

UHX0962

UHX1262

UMHX0962

UMHX1262

THX1252

KHX0952

KHX1252

FHX0962

FHX1262

FMHX0962

FMHX1262

CHDZ07263

CHDZ09663

CHDZR07263

CHDZR09663

XHX1852

XMHX1852

UHX1562 UHX1862

UMHX1562 UMHX1862

THX1852

KHX1862 KHX1962 KHX2452

FHX1562

FHX1862

FMHX1562 FMHX1862

RCS-TM80BG

RCS-BH80AAB.WL

RCS-SH80AAB.WL

RCS-XM18AAB.WL

RCS-TRP80AAB.WL

RCS-SH1AAB

RCS-KR1EG

SHA-KC64UG

SHA-TM64AGB

SHA-KT256EA

SHA-KA128AAB

ART-K45AGB

SHA-LN16UAB

SANYO North America Corporation

Commercial Solutions Division

2055 Sanyo Ave., San Diego

CA 92154, U.S.A.

XHX2452 XHX3652

UHX2462 UHX3662 UHX4862 UHX5462

DHX3652 DHX4852

THX2452

FHX2462

FMHX2462

In Canada

SANYO Canada Inc.

201 Creditview Road, Woodbridge

Ontario, L4L 9T1, Canada

Table of Contents

Summary of Contents for Sanyo R410A

Page 1 INSTALLATION INSTRUCTIONS – W-3WAY ECO-i System Air Conditioner – for Refrigerant R410A This air conditioner uses the new refrigerant R410A. External diameter of service port R410A: 5/16" NOTE R410A Models Indoor Units Class 4-Way Air Discharge XHX1252 XHX1852 XHX2452 XHX3652...
Page 2: Important
IMPORTANT! Please Read Before Starting This air conditioning system meets strict safety and oper- When Installing… ating standards. As the installer or service person, it is an …In a Room important part of your job to install or service the system so Properly insulate any tubing run inside a room to prevent it operates safely and efficiently.
Page 3: Check Of Density Limit
The refrigerant (R410A), which is used in the air condition- er, is safe, without the toxicity or combustibility of ammonia, and is not restricted by laws imposed to protect the ozone layer.
Page 4: Precautions For Installation Using New Refrigerant
2. Be sure to recharge the refrigerant only in liquid form. 2-1. Since R410A is a non-azeotrope, recharging the refrigerant in gas form can lower performance and cause defects in the unit.
Page 5: New Refrigerant R410A Cannot Be Used For Earlier Models
New refrigerant R410A cannot be used for earlier models 1. Compressor specifications are different. If recharging a R22 or R407C compressor with R410A, durability will significantly decrease since some of the materials used for compressor parts are different. 2. Existing tubing cannot be used (especially R22).
Page 6: Table Of Contents
Check of Density Limit 5-2. Connecting Tubing Between Indoor and Precautions for Installation Using New Refrigerant Outdoor Units New refrigerant R410A cannot be used for earlier models 5-3. Insulating the Refrigerant Tubing 5-4. Taping the Tubes 1. GENERAL ............... 7 5-5.
Page 7: General
1. GENERAL This booklet briefly outlines where and how to install the air conditioning system. Please read over the entire set of instructions for the outdoor unit and make sure all accessory parts listed are with the system before beginning. 1-1.
Page 8: Tubing Length
Note: Do not use commercially available T-joints for the liquid tubing parts. APR-RZP224BAB (for indoor unit) * Be sure to use special R410A distribution joints (APR: purchased separately) for outdoor APR-RZP680BAB (for indoor unit) unit connections and tubing branches. APR-RZP1350BAB (for indoor unit)
Page 9: Tubing Size
1-6. Tubing Size Table 1-3 Main Tubing Size (LA) Unit: in. (mm) BTU/h 72,000 96,000 144,000 168,000 192,000 216,000 240,000 264,000 288,000 (kW) (21.1) (28.1) (42.2) (49.2) (56.2) (63.3) (70.3) (77.3) (84.3) Total system horsepower Combined outdoor units o7/8" o1-1/8" o1-3/8"...
Page 10: Straight Equivalent Length Of Joints
Table 1-6 Refrigerant Charge Amount at Shipment (for outdoor unit) CHDZ07263 CHDZ09663 CHDZR07263 CHDZR09663 (oz) Table 1-7 Indoor Unit Tubing Connection Size ( – Unit: in. (mm) Indoor unit type Total system horsepower Suction tubing o5/8" (o15.88) Distribution joint-solenoid Discharge tubing o1/2"...
Page 11: System Limitations
Table 1-10-2 Necessary Amount of Refrigerant Charge Per Outdoor Unit Further charge a certain amount listed below in addition to the amount of refrigerant charge. CHDZ07263 CHDZ09663 CHDZR07263 CHDZR09663 42 oz/unit 42 oz/unit 1-9. System Limitations Table 1-11 System Limitations Max.
Page 12: Check Of Limit Density
Always check the gas density Tube branching methods (horizontal use) limit for the room in which the WARNING unit is installed. 1-11. Check of Limit Density When installing an air conditioner in a room, it is necessary to ensure that even if the refrigerant gas accidentally leaks Horizontal line out, its density does not exceed the limit level for that room.
Page 13: Optional Distribution Joint Kits
1-13. Optional Distribution Joint Kits See the installation instructions packaged with the distribution joint kit for the installation procedure. Table 1-12 Model name Cooling capacity after distribution Remarks 1. APR-CHRZP900BAB 307.100 BTU/h or less For outdoor unit 2. APR-RZP224BAB 76.400 BTU/h or less For indoor unit 3.
Page 14 Table 1-14 Dimensions for connections of each part Unit: in. Position Dimension ø1-1/2" ø1-1/4" ø1-1/8" ø1" ø7/8" ø3/4" ø5/8" ø1/2" ø3/8" – 2. APR-RZP224BAB Use: For indoor unit (Capacity after distribution joint is 76.400 BTU/h or less.) Example: (F below indicates inner diameter. below indicates outer diameter.) Discharge tubing Liquid tubing...
Page 15: Optional Solenoid Valve Kit
1-14. Optional Solenoid Valve Kit Precautions on Installation of Solenoid Valve Kit (1) Clean base metals thoroughly. (2) Use proper ventilation to carry fumes away from the work area. (3) Use a high quality silver based solder of at least 15 % silver. (4) Heat the base materials broadly and uniformly.
Page 16 Specifications ATK-RZP160BAWB Types and specifications of Part ATK-RZP160BAWB tubing connections Number Gas tube: ID5/8" Compatibility 19.000 Total capacity of indoor units (BTU/h) < 54.600 Liquid tube : ID3/8" Power source Single-phase AC 208–230V 60Hz (supplied by indoor unit) Suspension hook Power input 40 W max.
Page 17 Installation of Solenoid Valve Kit 1. Install the relay kit into the indoor unit. Refer to the Installation Manual for the solenoid valve kit. 2. Connect the solenoid valve kit and the relay kit in the field. Suspension hook Gas tube Liquid tube Top surface Connect with...
Page 18: Example Of Tubing Size Selection And Refrigerant Charge Amount
However if only one outdoor unit is installed, a balance tube is not used. Therefore, leave the valves fully closed.) Charge with R410A refrigerant in liquid form. With R410A refrigerant, charge while adjusting the amount being fed a little at a time in order to prevent liquid refrigerant from backing up.
Page 19: Refrigerant Charge Amount
● Obtain liquid tubing size from Tables 1-3, 4, 5 and 9. Main tubing LA = ø5/8 (ft.) (Total capacity of indoor unit is 179,400 BTU/h) The longest tubing length in this example LB = ø1/2 (ft.) (Total capacity of indoor unit is 131,600 BTU/h) (LA = 131 ft.) LC = ø3/8 (ft.) (Total capacity of indoor unit is 83,800 BTU/h) Distribution joint tubing...
Page 20: Selecting The Installation Site
2. SELECTING THE INSTALLATION SITE Exhaust fan 2-1. Outdoor Unit Hot air AVOID: Heat source ● heat sources, exhaust fans, etc. Out- door ● damp, humid or uneven locations unit ● indoors (no-ventilation location) Fig. 2-1 ● choose a place as cool as possible. ●...
Page 21: Precautions When Installing In Heavy Snow Areas
2-2. Precautions When Installing in Heavy Snow Areas AVOID a) The platform should be higher than the maximum snow depth. (Fig. 2-4) b) The 2 anchoring feet of the outdoor unit should be used for the platform, and the platform should be installed beneath the air-intake side of the outdoor unit.
Page 22: Dimensions Of Wind Ducting
2-3. Dimensions of Wind Ducting Reference diagram for air-discharge chamber (field supply) unit: in. Ceiling panel Ceiling panel Air direction: Front direction Air direction: Right direction 33-3/16 (Ceiling panel dimensions) (Ceiling panel dimensions) (Ceiling panel dimensions) 35-1/4 (Maximum bracket dimensions) Front view Right side view Front view...
Page 23: Dimensions Of Snow Ducting
2-4. Dimensions of Snow Ducting Reference diagram for snow-proof ducting (field supply) 31-1/2 Air direction: Air direction: Front direction Right direction Ceiling panel Ceiling panel 31-1/2 31-1/2 (Air intake duct) unit: in. 33-3/16 (Air outlet duct) 9-1/2 9-1/2 9-1/2 9-1/2 9-1/2 9-1/2 (Ceiling panel dimensions)
Page 24: How To Install The Outdoor Unit
3. HOW TO INSTALL THE OUTDOOR UNIT 3-1. Transporting When transporting the unit, have it delivered as close to the installation site as possible without unpacking. Use a hook for suspending the unit. (Fig. 3-1) CAUTION ● When hoisting the outdoor unit, pass ropes or straps under the bottom plate as shown in the figure at right.
Page 25: Remove The Brackets Used For Transport
3-3. Remove the Brackets Used for Transport ● After installing the unit, remove the 2 transport brackets from the front and rear (4 brackets total). (Fig. 3-5) Remove the 2 screws (8 screws total) Remove the 2 transport brackets from the front and rear (4 brackets total) Fig.
Page 26: Prepare The Tubing
3-5. Prepare the Tubing ● Material: Use C1220 phosphorous deoxidized copper as described in JIS H3300, “Copper and Copper Alloy Seamless Pipes and Tubes.” (For tubes that are ø1" (ø25.4 mm) or larger, use 1/2H material or H material. For all others use O material.) ●...
Page 27 (This unit utilizes R410A refrigerant, and the refrigerant oil is ether oil (synthetic oil). However, hub oil (synthetic oil) can also be used.) ●...
Page 28: Electrical Wiring
4. ELECTRICAL WIRING 4-1. General Precautions on Wiring (1) Before wiring, confirm the rated voltage of the unit (7) Regulations on wire diameters differ from locality as shown on its nameplate, then carry out the wiring to locality. For field wiring rules, please refer to your closely following the wiring diagram.
Page 29: Wiring System Diagram
4-3. Wiring System Diagram Indoor unit (No. 1) Outdoor unit Power supply 208 / 230V, 1ø, ~60Hz INV unit Power supply 208 / 230V, 3ø, ~60Hz Ground Remote controller Ground Indoor unit (No. 2) Inter-outdoor unit control wiring Outdoor unit Power supply INV unit 208 / 230V, 1ø, ~60Hz...
Page 30 CAUTION (1) When linking outdoor units in a network (S-net link system), disconnect the terminal extended from the short plug (CN003, 2P Black, location: right bottom on the outdoor main control PCB) from all outdoor units except any one of the outdoor units.
Page 31 Loose wiring may cause the terminal to overheat or result WARNING in unit malfunction. A fire hazard may also exist. Therefore, ensure that all wir- ing is tightly connected. When connecting each power wire to the terminal, fol- low the instructions on “How to connect wiring to the terminal”...
Page 32: How To Process Tubing
5. HOW TO PROCESS TUBING Deburring The liquid tubing side is connected by a flare nut, and the gas Before After tubing side is connected by brazing. 5-1. Connecting the Refrigerant Tubing Use of the Flaring Method Many of conventional split system air conditioners employ the flaring method to connect refrigerant tubes which run between indoor and outdoor units.
Page 33: Connecting Tubing Between Indoor And Outdoor Units
R410A (type 2). The refrigerant as a guide when tightening. tubing that is used must be of the correct wall thick- ●...
Page 34: Insulating The Refrigerant Tubing
5-3. Insulating the Refrigerant Tubing Two tubes arranged together Liquid tubing Gas tubing Tubing Insulation ● Thermal insulation must be applied to all unit tubing, including the distribution joint (purchased separately). (Fig. 5-7) Insulation * For gas tubing, the insulation material must be heat Three tubes arranged together resistant to 248°F or above.
Page 35: Taping The Tubes
5-4. Taping the Tubes (1) At this time, the refrigerant tubes (and electrical wir- ing if local codes permit) should be taped together with armoring tape in 1 bundle. To prevent the con- densation from overflowing the drain pan, keep the drain hose separate from the refrigerant tubing.
Page 36: Air Purging
6. AIR PURGING Vacuum pump Manifold gauge Outlet Air and moisture in the refrigerant system may have Inlet undesirable effects as indicated below. ● pressure in the system rises ● operating current rises ● cooling (or heating) efficiency drops ● moisture in the refrigerant circuit may freeze and block capillary tubing ●...
Page 37 (3) Do a leak test of all joints of the tubing (both indoor Manifold valve and outdoor) and all service valves. Bubbles indicate a leak. Wipe off the soap with a clean cloth after a Pressure leak test. gauge (4) After the system is found to be free of leaks, relieve the nitrogen pressure by loosening the charge hose connector at the nitrogen cylinder.
Page 38: Test Run.
Close with the system in Cooling mode at the time of test run. (Fig. 6-6) Close ● Close the valve on the cylinder containing R410A. Balance tube Close Finishing the job Fig. 6-5 (1) With a flathead screwdriver, turn the liquid tube ser- vice valve counter-clockwise to fully open the valve.
Page 39: Test Run
7. TEST RUN 7-1. Preparing for Test Run ● Before attempting to start the air conditioner, check the following. (1) The control wiring is correctly connected and all electrical connections are tight. (Power must be turned ON at least 5 hours before (2) The transportation pads for the indoor fan have attempting test run) been removed.
Page 40: Test Run Procedure
7-2. Test Run Procedure Items to Check Before the Test Run Recheck the items to check before the test run. Turn the remote power switch on at least 5 hours before the test, in order to energize the crankcase heater. Turn the outdoor service valves (4 locations) Have the outdoor sub units been connected? to the full-open positions.
Page 41 Examples of the No. of indoor units settings (S005, S004) Indoor unit setting (S005) Indoor unit setting (S004) No. of indoor units (3P DIP switch, blue) (Rotary switch, red) 10 20 30 1 unit (factory setting) All OFF Set to 1 11 units 1 ON Set to 1...
Page 42: Main Outdoor Unit Pcb Setting
7-3. Main Outdoor Unit PCB Setting CN003 CN101 CN100 S007 S006 S005 S004 S003 S002 Fig. 7-4...
Page 43: Auto Address Setting
7-4. Auto Address Setting Basic wiring diagram: Example (1) • If link wiring is not used (The inter-unit control wires are not connected to multiple refrigerant systems.) Indoor unit addresses can be set without operating the compressors. No. 1 (main unit) settings No.
Page 44 Basic wiring diagram: Example (2) • If link wiring is used * When multiple outdoor main units exist, remove the socket that is used to short-circuit the terminal plug (CN003) from all outdoor main unit PCBs except for 1. No. 1 (main unit) settings Alternatively, move the sockets to the “OPEN”...
Page 45 Case 1 Automatic Address Setting (no compressor operation) ● Indoor and outdoor unit power can be turned ON for each system separately. Indoor unit addresses can be set without operating the compressors. Automatic Address Setting from Outdoor Unit 1. On the outdoor main unit control PCB, check that the system address rotary switch (S002) is set to “1” and that the DIP switch (S003) is set to “0”...
Page 46 Case 2 Automatic Address Setting in Heating Mode ● Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating. Therefore perform this process only after completing all refrigerant tubing work.
Page 47 Case 3 Automatic Address Setting in Cooling Mode ● Indoor and outdoor unit power cannot be turned ON for each system separately. In the following, automatic setting of indoor unit addresses is not possible if the compressors are not operating. Therefore perform this process only after completing all refrigerant tubing work.
Page 48 Display during automatic address setting ● On outdoor main unit PCB * Do not short-circuit the automatic address setting pin (CN100) again while automatic address set- ting is in progress. Doing so will cancel the setting operation and will cause LEDs 1 and 2 to turn OFF.
Page 49: Remote Controller Test Run Settings
Request concerning recording the indoor/outdoor unit combination Nos. After automatic address setting has been completed, be sure to record them for future reference. List the outdoor main unit system address and the addresses of the indoor units in that system in an easily visible loca- tion (next to the nameplate), using a permanent marking pen or similar means that cannot be abraded easily.
Page 50: Meaning Of Alarm Messages
7-7. Meaning of Alarm Messages Table of Self-Diagnostics Functions and Description of Alarm Displays Alarm messages are indicated by the blinking of LED 1 and 2 (D72, D75) on the outdoor unit PCB. They are also displayed on the wired remote controller. ●...
Page 51 Alarm Possible cause of malfunction message Activation of <<P01>> Protective device in indoor unit Thermal protector in indoor unit fan motor is activated. protective is activated. Improper wiring connections of ceiling panel. <<P09>> device <<P10>> Float switch is activated. sensor (detects low oxygen level) activated Protective device in outdoor Incorrect discharge temperature.
Page 52 Alarm messages displayed on system controller Indoor or main outdoor unit is not operating correctly. Serial Error in transmitting serial communication signal Mis-wiring of control wiring between indoor unit, main outdoor unit communication and system controller. errors Mis-setting Indoor or main outdoor unit is not operating correctly. Error in receiving serial Mis-wiring of control wiring between indoor unit, main outdoor unit communication signal...
Page 54 SANYO Electric Co., Ltd. Gunma, Japan...

Sanyo R410A Installation Instructions Manual

Important

1 General

2 Selecting the Installation Site

3 How to Install the Outdoor Unit

4 Electrical Wiring

5 How to Process Tubing

6 Air Purging

7 Test Run

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