Sanyo Mini ECO-i SPW-ASR74GXH56(A/B) Installation Instructions Manual

System air conditioner

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05-194

5/27/05

5:06 PM

R410A Models

Indoor Units

Indoor Unit Type

1-Way Air Discharge SPW-

Semi-Concealed

ASR74GXH56(A/B) ASR94GXH56(A/B) ASR124GXH56(A/B)

1-Way Air Discharge

Semi-Concealed Slim

2-Way Air Discharge SPW-

Semi-Concealed

SR74GXH56(A/B)

4-Way Air Discharge SPW-

Semi-Concealed*

XDR74GXH56(A/B) XDR94GXH56(A/B) XDR124GXH56(A/B) XDR164GXH56(A/B) XDR184GXH56(A/B) XDR254GXH56(A/B) XDR364GXH56(A/B) XDR484GXH56(A/B)

Wall-Mounted

SPW-

KR74GXH56(A/B)

Ceiling-Mounted

Concealed-Duct

SPW-

UR74GXH56(A/B)

Concealed-Duct

High Static Pressure*

Floor-Standing

SPW-

FR74GXH56(A/B)

Concealed-Floor-

SPW-

Standing

FMR74GXH56(A/B) FMR94GXH56(A/B) FMR124GXH56(A/B) FMR164GXH56(A/B) FMR184GXH56(A/B) FMR254GXH56(A/B)

* SPW-XDR604GXH56(A/B) is also available.

* SPW-DR764GXH56(A/B) and DR964GXH56(A/B) are also available.

Outdoor Units

Heat Pump Unit

Cooling Unit

* Refrigerant R410A is used in the outdoor units.

Optional Controllers

Remote Controller

Wireless Remote Controller (For X type)

Wireless Remote Controller (For S, LD type)

Wireless Remote Controller (For T type)

RC Wireless Remote Controller (For AS, U, D, F, FM type) RCS-BH80AG.WL

Wireless Remote Controller (For K type)

Simplified Remote Controller

Remote Sensor

System Controller

Schedule Timer

85464359780000 ©SANYO 2005

Page a

INSTALLATION INSTRUCTIONS

– Mini ECO-i System Air Conditioner –

for Refrigerant R410A

SPW-

LDR94GXH56(A/B) LDR124GXH56(A/B)

SPW-

SR94GXH56(A/B)

SR124GXH56(A/B)

SPW-

KR94GXH56(A/B)

KR124GXH56(A/B)

SPW-

TDR124GXH56(A/B) TDR164GXH56(A/B) TDR184GXH56(A/B) TDR254GXH56(A/B) TDR364GXH56(A/B) TDR484GXH56(A/B)

SPW-

UR94GXH56(A/B)

UR124GXH56(A/B)

SPW-

FR94GXH56(A/B)

FR124GXH56(A/B)

SPW-

SPW-CR365GXH56, SPW-CR485GXH56, SPW-CR605GXH56

SPW-CR365GX56, SPW-CR485GX56, SPW-CR605GX56

RCS-SH80AG

RCS-SH80AG.WL

RCS-TH80AG.WL

RCS-TRP80ANG.WL

RCS-SH1AG

RCS-KR1AG

ART-K45AG

SHA-KC64AG

SHA-TM64AG

SPW-

LDR184GXH56(A/B) LDR254GXH56(A/B)

SPW-

SR164GXH56(A/B) SR184GXH56(A/B)

SR254GXH56(A/B)

SPW-

KR164GXH56(A/B) KR184GXH56(A/B)

KR254GXH56(A/B)

SPW-

UR164GXH56(A/B) UR184GXH56(A/B) UR254GXH56(A/B) UR364GXH56(A/B) UR484GXH56(A/B)

SPW-

DR254GXH56(A/B) DR364GXH56(A/B) DR484GXH56(A/B)

SPW-

FR164GXH56(A/B)

FR184GXH56(A/B)

FR254GXH56(A/B)

SPW-

SANYO Electric Co., Ltd.

Gunma, Japan

Table of Contents

Summary of Contents for Sanyo Mini ECO-i SPW-ASR74GXH56(A/B)

Page 1 RC Wireless Remote Controller (For AS, U, D, F, FM type) RCS-BH80AG.WL Wireless Remote Controller (For K type) RCS-SH1AG Simplified Remote Controller RCS-KR1AG Remote Sensor ART-K45AG System Controller SHA-KC64AG Schedule Timer SHA-TM64AG SANYO Electric Co., Ltd. 85464359780000 ©SANYO 2005 Gunma, Japan...
Page 2: Important
05-194 5/27/05 5:06 PM Page 2 IMPORTANT! Please Read Before Starting When Installing… …In a Room This air conditioning system meets strict safety and operat- ing standards. As the installer or service person, it is an Properly insulate any tubing run inside a room to prevent important part of your job to install or service the system so it “sweating”...
Page 3: Check Of Density Limit
05-194 5/27/05 5:06 PM Page 3 Check of Density Limit 2. The standards for minimum room volume are as follows. The room in which the air conditioner is to be (1) No partition (shaded portion) installed requires a design that in the event of refrigerant gas leaking out, its density will not exceed a set limit.
Page 4: Precautions For Installation Using New Refrigerant
05-194 5/27/05 5:06 PM Page 4 Precautions for Installation Using New Refrigerant 1. Care regarding tubing 1-1. Process tubing Material: Use C1220 phosphorous deoxidized copper specified in JIS H3300 “Copper and Copper Alloy Seam- less Pipes and Tubes.” Tubing size: Be sure to use the sizes indicated in the table below. Use a tube cutter when cutting the tubing, and be sure to remove any flash.
Page 5 05-194 5/27/05 5:06 PM Page 5 3-2. Use R410A exclusive cylinder only. Valve Single-outlet valve (with siphon tube) Liquid refrigerant should be recharged with the cylinder standing on end as shown. Liquid...
Page 6: Table Of Contents
05-194 5/27/05 5:06 PM Page 6 CONTENTS Page Page IMPORTANT ......2 6.
Page 7: General
05-194 5/27/05 5:06 PM Page 7 1. GENERAL This booklet briefly outlines where and how to install 1-4. Additional Materials Required for Installation the air conditioning system. Please read over the 1. Refrigeration (armored) tape entire set of instructions for the outdoor unit and make 2.
Page 8: Tubing Size
05-194 5/27/05 5:06 PM Page 8 Table 1-1 (Outdoor Unit) Q ty Part name Figure 365 Model 485 Model 605 Model (4 hp) (5 hp) (6 hp) Tube Discharge Assy paper Instruction manual hp = horsepower 1-5. Tubing Size Table 1-2 Main Tubing Size (LA) 11.2 14.0 15.5...
Page 9: Straight Equivalent Length Of Joints
05-194 5/27/05 5:06 PM Page 9 1-6. Straight Equivalent Length of Joints Design the tubing system by referring to the following table for the straight equivalent length of joints. Table 1-5 Straight Equivalent Length of Joints Gas tubing size (mm) 12.7 15.88 19.05...
Page 10: Tubing Length
05-194 5/27/05 5:06 PM Page 10 1-9. Tubing Length Select the installation location so that the length and size of refrigerant tubing are within the allowable range shown in the figure below. Main tube of unit 1st branch Unit distribution tube Note: Do not use commercially available T-joints for the liquid tubing.
Page 11: Check Of Limit Density
Indoor unit (1) added to that distribution joint. (When adding the ball valve, locate it within 40 cm of the distribution joint.) (When not using ball valve) (Consult with SANYO separately concerning the ball valve.) Main tubing Horizontal If a trap or ball valve is not added, do not operate...
Page 12: Optional Distribution Joint Kit
05-194 5/27/05 5:06 PM Page 12 1-12. Optional Distribution Joint Kit See the installation instructions packaged with the distribution joint kit for the installation procedure. Table 1-11 Model name Cooling capacity after distribution Remarks APR-RP160AG 22.4 kW or less For indoor unit APR-RP160AG Use: For indoor unit (Capacity after distribution joint is 22.4 kW or less.) Example: (F below indicates inner diameter.
Page 13 05-194 5/27/05 5:06 PM Page 13 Ball Valve Installation (for refrigerant R410A only) Check the size of the ball valve set you separately purchased. Model name Size φ 6.35 • φ 12.7 BV-RXP56AG φ 9.52 • φ 15.88 BV-RXP160AG 1. Installing the ball valve (1) If the ball valve is to be installed for indoor unit Outdoor unit extension, or near an indoor unit, install it so that...
Page 14: Recommended Location Of Ball Valves
05-194 5/27/05 5:06 PM Page 14 3. Opening and closing the valve This valve is open at the time of shipment from the factory. If the valve is used for extension, be sure to close it. Valve opened Valve closed Spindle Spindle 4.
Page 15: Example Of Tubing Size Selection And Refrigerant Charge Amount
05-194 5/27/05 5:06 PM Page 15 1-15. Example of Tubing Size Selection and Refrigerant Charge Amount Additional refrigerant charging Based on the values in Tables 1-2, 1-3, 1-4 and 1-7, use the liquid tubing size and length, and calculate the amount of additional refrigerant charge using the formula below.
Page 16 05-194 5/27/05 5:06 PM Page 16 Example: Main tube of unit 1st branch model 184 n–1 Unit distribution tube model 74 model 94 model 124 model 164 Example of each tubing length Main tubing Distribution joint tubing LA = 40 m Indoor side LB = 5 m 1 = 5 m...
Page 17: Selecting The Installation Site
05-194 5/27/05 5:06 PM Page 17 Ceiling-Mounted Type 2. SELECTING THE INSTALLATION SITE Ceiling 2-1. Indoor Unit Wall AVOID: areas where leakage of flammable gas may be min. 25 cm min. 25 cm expected. Front view places where large amounts of oil mist exist. NOTE direct sunlight.
Page 18: Outdoor Unit
05-194 5/27/05 5:06 PM Page 18 2-2. Outdoor Unit Exhaust fan AVOID: Hot air heat sources, exhaust fans, etc. (Fig. 2-6) damp, humid or uneven locations Heat source Out- door unit choose a place as cool as possible. choose a place that is well ventilated and outside air temperature does not exceed maximum 45°C constantly.
Page 19: Air-Discharge Chamber For Top Discharge
05-194 5/27/05 5:06 PM Page 19 2-3. Air Discharge Chamber for Top Discharge Be sure to install an air discharge chamber in the Air discharge field when: it is difficult to keep a space of min. 50 cm between the air discharge outlet and an obstacle. the air discharge outlet is facing a sidewalk and discharged hot air may annoy passers-by.
Page 20: Dimensions Of Air-Discharge Chamber
05-194 5/27/05 5:06 PM Page 20 2-6. Dimensions of Air-Discharge Chamber Reference diagram for air-discharge chamber (field supply) STK-DRE140A for SPW-CR365/485/605GX(H)56 Unit front, air discharge chamber Unit left side, air discharge chamber Unit light side, air discharge chamber Reinforcement brackets, 4 locations 29.5 29.5 Rectangular...
Page 21 05-194 5/27/05 5:06 PM Page 21 Reference for air-discharge chamber (field supply) Required space around outdoor unit SPW-CR365/485/605GX(H)56 with STK-DRE140A Required space around outdoor unit If an air discharge chamber is used, the space shown below must be secured around the outdoor unit. If the unit is used without the required space, a protective device may activate, preventing the unit from operating.
Page 22: Dimensions Of Snow Ducting
05-194 5/27/05 5:06 PM Page 22 2-8. Dimensions of Snow Ducting Reference diagram for snow-proof vents (field supply) STK-BDR140U for SPW-CR365/485/605GX(H)56 Fastened by screws at 13 locations Unit top, snow-proof vent Unit left side Unit right side Unit reverse side Unit reverse side Unit sides, reinforcement brackets for snow-proof vent Unit: mm...
Page 23 05-194 5/27/05 5:06 PM Page 23 Reference diagram for snow-proof vents – 1 Space requirements for setting – (1) SPW-CR365/485/605GX(H)56 with STK-BDR140U [Obstacle to the front of unit] [Obstacle to the rear of unit] • Top is open: • Top is open: (1) Single-unit installation (2) Obstacles on both sides (1) Single-unit installation...
Page 24 05-194 5/27/05 5:06 PM Page 24 Reference diagram for snow-proof vents – 2 Space requirements for setting – (2) SPW-CR365/485/605GX(H)56 with STK-BDR140U [Obstacles to the front and rear of unit] • The top and both sides must remain open. Either the obstacle to the front or the obstacle to the rear must be no taller than the height of the outdoor unit.
Page 25: How To Install The Outdoor Unit
05-194 5/27/05 5:06 PM Page 25 3. HOW TO INSTALL THE OUTDOOR UNIT 3-1. Installing the Outdoor Unit Use concrete or a similar material to create the base, and ensure good drainage. Ordinarily, ensure a base height of 5 cm or more. If a drain pipe is used, or for use in cold-weather regions, ensure a height of 15 cm or more at the feet on both sides of the unit.
Page 26: Electrical Wiring
05-194 5/27/05 5:06 PM Page 26 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 to locality.
Page 27: Wiring System Diagrams
05-194 5/27/05 5:06 PM Page 27 4-3. Wiring System Diagram Indoor unit (No. 1) Power supply Outdoor unit 220-240V 50Hz INV unit Ground Power supply 380-415V-3N 50Hz Remote controller Ground Ground Ground Indoor Ground unit (No. 2) Inter-outdoor-unit control wiring Power supply 220-240V 50Hz...
Page 28 05-194 5/27/05 5:06 PM Page 28 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 29 05-194 5/27/05 5:06 PM Page 29 (5) Use shielded wires for inter-unit control wiring (c) and ground the shield on both sides, other- wise misoperation from noise may occur. (Fig. 4-4) Connect wiring as shown in Section “4-3. Shielded wire Wiring System Diagram.”...
Page 30: How To Process Tubing
05-194 5/27/05 5:06 PM Page 30 5. HOW TO PROCESS TUBING Deburring Before After 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. In this method, the copper tubes are flared at each end and connected with flare nuts.
Page 31: Connecting Tubing Between Indoor And Outdoor Units
05-194 5/27/05 5:06 PM Page 31 Caution Before Connecting Tubes Tightly (1) Apply a sealing cap or water-proof tape to prevent dust or water from entering the tubes before they are used. Apply refrigerant lubricant here and here (2) Be sure to apply refrigerant lubricant to the match- ing surfaces of the flare and union before connect- Fig.
Page 32: Insulating The Refrigerant Tubing
05-194 5/27/05 5:06 PM Page 32 5-3. Insulating the Refrigerant Tubing Two tubes arranged together Tubing Insulation Liquid tubing Gas tubing Thermal insulation must be applied to all unit tub- ing, including distribution joint (purchased sepa- rately). * For gas tubing, the insulation material must be heat resistant to 120°C or above.
Page 33: Taping The Tubes
05-194 5/27/05 5:06 PM Page 33 5-4. Taping the Tubes (1) At this time, the refrigerant tubes (and electrical wiring if local codes permit) should be taped together with armoring tape in 1 bundle. To pre- vent the condensation from overflowing the drain pan, keep the drain hose separate from the refrigerant tubing.
Page 34: Air Purging
05-194 5/27/05 5:06 PM Page 34 6. AIR PURGING Manifold gauge Air and moisture in the refrigerant system may have 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 water may lead to corrosion of parts in the refriger- Fig.
Page 35 05-194 5/27/05 5:06 PM Page 35 (3) Do a leak test of all joints of the tubing (both indoor and outdoor) and both gas tube and liquid tube service valves. Bubbles indicate a leak. Wipe Manifold valve off the soap with a clean cloth after the leak test. (4) After the system is found to be free of leaks, Pressure relieve the nitrogen pressure by loosening the...
Page 36 05-194 5/27/05 5:06 PM Page 36 Use a cylinder designed for CAUTION Manifold valve use with R410A respectively. Pressure Charging additional refrigerant gauge Charging additional refrigerant (calculated from the liquid tube length as shown in Section 1-7 “Addi- Valve tional Refrigerant Charge”) using the liquid tube service valve.
Page 37: Test Run
05-194 5/27/05 5:06 PM Page 37 7. TEST RUN 7-1. Preparing for Test Run Before attempting to start the air conditioner, check the following. (1) All loose matter is removed from the cabinet, especially steel filings, bits of wire, and clips. (Power must be turned ON at least 5 hours before (2) The control wiring is correctly connected and all...
Page 38: Test Run Procedure
05-194 5/27/05 5:06 PM Page 38 7-2. Test Run Procedure Items to Check Before the Test Run Recheck the items to check before the test run. 1. Turn the remote power switch on at least 5 hours before the test, in order to energize the crank case heater.
Page 39 05-194 5/27/05 5:06 PM Page 39 7-3. Outdoor Unit PCB Setting CN33 S003 CN51 CN50 S002 D043 S004 (LED2) D042 (LED1) Fig. 7-4...
Page 40 05-194 5/27/05 5:06 PM Page 40 Examples of the No. of indoor units settings Indoor unit setting (S004) No. of indoor units (Rotary switch, red) 1 unit (factory setting) Set to 1 2 units Set to 2 9 units Set to 9 Examples of refrigerant circuit (R.C.) address settings (required when link wiring is used) System address (S003) System address (S002)
Page 41: Auto Address Setting
05-194 5/27/05 5:06 PM Page 41 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.
Page 42 05-194 5/27/05 5:06 PM Page 42 Basic wiring diagram: Example (2) ¥ If link wiring is used * When multiple outdoor units exist, remove the socket that is used to short-circuit the terminal plug (CN33) from all outdoor unit PCBs except for 1. Alternatively, move the sockets to the OPEN side .
Page 43 05-194 5/27/05 5:06 PM Page 43 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.
Page 44 05-194 5/27/05 5:06 PM Page 44 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 45 05-194 5/27/05 5:06 PM Page 45 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 46 05-194 5/27/05 5:06 PM Page 46 Display during automatic address setting On outdoor unit PCB * Do not short-circuit the automatic address setting pin (CN51) again while automatic address setting is in progress. Doing so will cancel the setting operation and will cause LEDs 1 and 2 to turn OFF.
Page 47 05-194 5/27/05 5:06 PM Page 47 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 unit system address and the addresses of the indoor units in that system in an easily visible location (next to the nameplate), using a permanent marking pen or similar means that cannot be erased easily.
Page 48: Caution For Pump Down
05-194 5/27/05 5:06 PM Page 48 7-5. Caution for Pump Down Pump down means refrigerant gas in the system is returned to the outdoor unit. Pump down is used when the unit is to be moved, or before servicing the refrigerant circuit.
Page 49 05-194 5/27/05 5:06 PM Page 49 Alarm Possible cause of malfunction message This alarm message shows when the indoor unit for multiple-use Improper setting. Serial commu- is not connected to the outdoor unit. nication errors Duplication of main indoor unit address setting in group control. <L03>...

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Sanyo Mini ECO-i SPW-ASR74GXH56(A/B) Installation Instructions Manual

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