Mitsubishi Electric PUHY-EP450YLM-A [29/56] 7 thermal insulation for pipes

The outdoor unit described in this manual is air conditioning equipment that is designed only for human comfort the numeric values in the unit model name e g puhy ep ylm a indicate the capacity index of the unit this unit uses r410a refrigerant 10

Specifications 11

Package contents 12

The table below lists all the parts and their quantities included in the package 12

Always use two slings to lift up the unit each sling must be at least 8 m 26 ft long and must be able to support the weight of the unit put protective pads between slings and the unit where the slings touch the unit at the base to protect the unit from being scratched put 50 mm 2 in or thicker protective pads between slings and the unit where the slings touch the unit at the top of the unit to protect the unit from being scratched and to avoid contact with the slings and the fan guard make sure that the angles between slings at the top are less than 40 degrees 13

Transporting the unit 13

When lifting the unit pass the slings through the four designated sling holes improper lifting will cause the unit to topple or fall resulting in serious injury 13

1 single unit installation 14

1 when all walls are within their height limits 14

2 when one or more walls exceed their height limits 14

Add the dimension that exceeds the height limit shown as h1 through h3 in the figures to l1 l2 and l3 as shown in the table below 14

Do not install the unit where combustible gas may leak if combustible gas accumulates around the unit fire or explosion may result 14

Installation location 14

Provide sufficient space around the unit for effective operation efficient air movement and ease of access for maintenance note that refrigerant gas is heavier than air and will therefore tend to collect in low spots such as basements when an indoor unit that draws in outside air exits near the outdoor unit be careful not to affect the normal operation of the indoor unit 14

When the wall at the rear exceeds its height limit when all walls exceed their height limits 14

When the wall s at the front and or the right left exceed s their height limits 14

1 side by side installation 15

2 face to face installation 15

2 multiple unit installation 15

3 when there are overhead obstacles 15

Required minimum distance mm in l1 front l2 rear l4 between 450 17 3 4 h1 100 3 15 16 h2 100 3 15 16 15

Required minimum distance mm in l1 front l2 rear l4 between 450 17 3 4 h1 100 3 15 16 h2 450 17 3 4 15

Required minimum distance mm in l1 front l2 rear l4 between 450 17 3 4 h1 300 11 13 16 h2 30 1 3 16 15

Required minimum distance mm in l3 right left l4 between 15 5 8 h3 450 17 3 4 15

When installing multiple units make sure to take into consideration factors such as providing enough space for people to pass through ample space between blocks of units and sufficient space for airflow the areas marked with in the figures below must be left open in the same way as with the single unit installation add the dimension that exceeds the height limit shown as h1 through h3 in the figures to l1 l2 and l3 as shown in the tables below if there are walls in the front and rear of the block of units up to six units three units for units ep400 through ep500 can be installed consecutively side by side and a space of 1000 mm 39 3 8 in or more must be left between each block of six units 15

When the distances between the units l4 need to be small when the distance behind the block of units l2 needs to be small 15

When there are walls in the front and rear of the block of units when there is a wall on either the right or left side of the block of units 15

3 combination of face to face and side by side installations 16

When there are walls in the front and rear of the block of units when there are two walls in an l shape 16

Foundation work 17

Install the unit in accordance with the instructions to minimize the risk of damage from earthquakes and strong winds improper installation will cause the unit to topple resulting in serious injury 17

The unit must be securely installed on a structure that can sustain its weight failure to do so will cause the unit to fall resulting in serious injury 17

1 restrictions 19

Refrigerant piping work 19

1 the pipe from the outdoor units must be inclined downward to the indoor unit side in the figure on the right because the pipe is inclined upward the oil in the pipe accumulates when unit 1 is in operation and unit 3 is stopped 20

2 the distance between the unit bottom and the pipe h must be 0 m 7 7 8 in or below in the figure on the right because the distance is more than 0 m 7 7 8 in the oil accumulates in units 1 and 2 when unit 3 is in operation and units 1 and 2 are stopped 20

3 the vertical separation between units h must be 0 m 3 15 16 in or below in the figure on the right because the distance is more than 0 m 3 15 16 in the oil accumulates in unit 1 when unit 3 is in operation and unit 1 is stopped 20

4 the vertical separation between units h must be 0 m 3 15 16 in or below in the figure on the right because the distance is more than 0 m 3 15 16 in the oil accumulates in unit 3 when unit 1 is in operation and unit 3 is stopped 20

Make sure that the inclination tolerance of the twinning kit is 15 to the ground to avoid unit damage 20

Small dots in the figures indicate branching points to indoor units 20

The pipe from multiple outdoor units must be installed so that oil will not accumulate in the pipe under certain conditions refer to the figures below for details 20

Twinning kit 20

2 pipe selection 21

If the length of the pipe between the branching point and the outdoor unit exceeds 2 m 6 ft provide a trap within 2 m 6 ft from the branching point the trap must be at least 200 mm 7 7 8 in in height gas pipe only if there is no trap oil can accumulate inside the pipe causing a shortage of oil and may damage the compressor 21

Use refrigerant pipes for use with r410a refrigerant system piping for systems for use with other types of refrigerants may not be able to be used use refrigerant pipes with the thicknesses specified in the table below 21

Use refrigerant piping made of phosphorus deoxidized copper copper and copper alloy seamless pipes that meets local requirements pipe joints should also meet local requirements keep the inner and outer surfaces of the pipes clean and free of sulphur oxides dust dirt shaving particles oils moisture or any other contaminants contaminants on the inside of the refrigerant piping will cause the refrigerant oil to deteriorate and cause the compressor to malfunction 21

3 1 indoor unit twinning kit 22

3 2 outdoor unit twinning kit 22

3 twinning kit selection 22

4 pipe connection example 22

Example of pipe connection between outdoor units 22

Select a proper indoor unit twinning kit sold separately based on the total capacity of the downstream indoor units using the table below as a reference 22

Select a proper outdoor unit twinning kit sold separately based on the total capacity of the outdoor units using the table below as a reference 22

Ep200 to ep500ylm a 23

Ep500 to ep600yslm a 23

Ep650 to ep1350yslm a 23

Example of pipe connection between outdoor units and indoor units 23

Outdoor unit 1st branching indoor unit cap outdoor unit twinning kit header branching the total length of a1 a2 a3 and a4 is less than 10 m 32 ft 23

5 1 removing the pinched connecting pipes 25

5 piping connections and valve operations 25

Before heating the brazed sections remove the gas and oil that are trapped in the pipes failure to do so may generate fire resulting in serious injury 25

Braze the pipes with a nitrogen purge to avoid oxidation oxidized flux inside the refrigerant pipes will cause the refrigerant oil to deteriorate and cause the compressor to malfunction 25

Keep the flame out of contact with the cables and metal sheet when brazing the pipes failure to do so may result in burnout or malfunction 25

Keep the service valves closed until refrigerant charging is completed failure to do so will damage the unit 25

Place a wet towel on the service valves before brazing the pipes to keep the temperature of the valves from rising above 120ºc 248ºf failure to do so may result in equipment damage 25

Store pipes indoors and keep both ends of the pipes sealed until just before making a flare connection or brazing store elbows and other joints in plastic bags if dust dirt or water enters the refrigerant lines the refrigerant oil will deteriorate and the compressor will malfunction 25

The unit is shipped with the pinched connecting pipes attached to the liquid and gas side service valves to prevent gas leakage take the following steps ① through ③ to remove the pinched connecting pipes before connecting refrigerant pipes to the outdoor unit ① check that the service valves are fully closed turned clockwise all the way ② remove the gas in the pinched connecting pipes and drain out all the refrigerant oil see below ③ remove the pinched connecting pipes see below 25

Ventilate the room while servicing the unit if the refrigerant leaks oxygen deficiency may result if the leaked refrigerant comes in contact with a heat source toxic gas will be generated 25

5 2 connecting pipes 26

Refer to section 5 package contents for details about the supplied connecting pipes when connecting pipes make sure the service valves are completely closed commercially available pipes often contain dust or debris always blow them clean with a dry inert gas take care to prevent dust water or other contaminants from entering the pipes during installation reduce the number of bending portions as much as possible and make the bending radius as big as possible do not use any commercially available anti oxidizing agents since they may cause pipe corrosion and degrading of the refrigerant oil please contact mitsubishi electric for more details make sure that the pipes are not in contact with each other unit panels or base plates 1 when routing the pipes through the front of the unit 2 when routing the pipes through the bottom of the unit 26

The refrigerant pipe from the outdoor unit is branched at the pipe end and each branch is then connected to an indoor unit 26

Connecting the on site piping and the service valve piping when routing the pipes through the front of the unit 27

Severed section 27

Size of refrigerant pipes 27

When routing the pipes through the bottom of the unit 27

5 3 sealing the openings around the pipes 28

6 air tightness test 28

After refrigerant pipe installation is completed check the system for leaks by conducting an air tightness test if there is a leak the composition of the refrigerant will change and the performance will drop 28

Do not use oxygen flammable gas or a refrigerant containing chlorine for air tightness testing doing so may result in an explosion chlorine will deteriorate the refrigerant oil 28

Seal all openings around pipes and wires to keep out small animals rainwater or snow failure to do so may result in current leakage electric shock or damage to the unit 28

When expanding the on site piping satisfy the minimum insertion depth requirement as follows 28

① make sure the service valves are closed ② add pressure to the refrigerant pipes through the service ports of the liquid and gas pipes 28

③ if the pressure holds for one day and does not decrease the pipes have passed the test and there are no leaks if the pressure decreases there is a leak look for the source of the leak by spraying a bubbling agent e g gupoflex on the flared or brazed sections ④ wipe off the bubbling agent 28

7 1 insulation material 29

7 thermal insulation for pipes 29

Check that the insulation materials meet the standards in the table below 29

Do not insulate the electric wires 29

Insulate pipes to prevent condensation condensation may collect and drip from the unit onto the ceiling or floor 29

Insulate the liquid and gas pipes separately with polyethylene foam insulation materials inadequate insulation may cause condensation to drip pipes in the ceiling are especially vulnerable to condensation and require adequate insulation 29

Make sure that the pipe connections all the way from the indoor unit are properly insulated 29

1 inner wall concealed 2 outer wall 3 outer wall exposed 30

4 floor waterproof 5 rooftop pipe shaft 6 protecting the penetrating parts in a fire limit zone or through a parting wall 30

7 2 insulation for the section of the pipe that goes through a wall 30

When caulking the gaps with mortar cover the section of the pipe that goes through the wall with a metal sheet to prevent the insulation material from sagging for this section use nonflammable insulation and covering materials vinyl tape should not be used 30

8 evacuation of the system 31

Do not purge the air using refrigerant use a vacuum pump to evacuate the system residual gas in the refrigerant lines will cause bursting of the pipes or an explosion 31

Use a scale that can measure down to 0 kg 0 oz recommended vacuum gauge robinair 14830a thermistor vacuum gauge or micron gauge do not use a gauge manifold to measure the vacuum pressure use a vacuum pump capable of attaining a vacuum of 65 pa abs within five minutes of operation 31

Use a vacuum pump with a check valve if the vacuum pump oil flows back into the refrigerant lines the refrigerant oil may deteriorate and the compressor may malfunction 31

① evacuate the system from both service ports using a vacuum pump with the service valves closed ② after the vacuum reaches 650 pa continue evacuation for at least one hour ③ stop the vacuum pump and leave it for an hour ④ verify that the vacuum has not increased by more than 130 pa ⑤ if the vacuum has increased by more than 130 pa water infiltration is suspected pressurize the system with dry nitrogen gas up to 0 5 mpa repeat ① though ⑤ until the vacuum is increased by 130 pa or below if the results persist then perform the triple evacuation below 31

① evacuate the system to 533 pa from both service ports using a vacuum pump ② pressurize the system with dry nitrogen gas up to 0 pa from the discharge service port ③ evacuate the system to 200 pa from the suction service port using a vacuum pump ④ pressurize the system with dry nitrogen gas up to 0 pa from the discharge service port ⑤ evacuate the system from both service ports using a vacuum pump ⑥ after the vacuum reaches 66 pa stop the vacuum pump and leave it for an hour a vacuum of 66 pa must be maintained for at least one hour ⑦ verify that the vacuum has not increased for at least 30 minutes 31

9 1 calculation of the amount of additional refrigerant 32

9 additional refrigerant charge 32

Both refrigerant overcharge and undercharge will cause problems charge the system with the proper amount of refrigerant record the added refrigerant amount on the label attached to the control box panel for future servicing 32

Charge refrigerant in a liquid state charging refrigerant in the gaseous state will change the composition of the refrigerant and lead to a performance drop 32

Do not use a charging cylinder when charging refrigerant the use of a charging cylinder may change the composition of the refrigerant and lead to a performance drop 32

The amount of refrigerant that is shown in the table below is factory charged in the outdoor units the amount necessary for extended piping is not included and needs to be added on site 32

The amount of refrigerant that is shown in the table below is the maximum amount to be added on site 32

The amount of refrigerant to be added depends on the size and the total length of the liquid piping calculate the amount of refrigerant to be charged according to the formula below round up the calculation result to the nearest 0 kg 0 oz 32

A ø12 40 m b ø9 2 10 m c ø9 2 15 m d ø9 2 10 m a ø9 2 10 m b ø9 2 5 m c ø6 5 10 m d ø6 5 10 m e ø9 2 10 m 33

Amount of additional charge 40 0 1 60 0 54 20 0 21 0 3 11 kg fractions are rounded up 33

Outdoor unit model ep300 total capacity of connected indoor units 361 33

The total length of each liquid piping is as follows ø12 total length 40 a ø9 2 total length 10 b 15 c 10 d 10 a 5 b 10 e 60 ø6 5 total length 10 c 10 d 20 33

Therefore when the piping length from the outdoor unit to the farthest indoor unit is longer than 30 m 100 ft 33

When the piping length from the outdoor unit to the farthest indoor unit is 30 m 100 ft or shorter 33

When the piping length from the outdoor unit to the farthest indoor unit is longer than 30 m 100 ft 33

A ø1 2 131 ft b ø3 8 32 ft c ø3 8 49 ft d ø3 8 32 ft a ø3 8 32 ft b ø3 8 16 ft c ø1 4 32 ft d ø1 4 32 ft e ø3 8 32 ft 34

Amount of additional charge 131 1 9 193 0 8 64 0 3 0 124 406 oz fractions are rounded up 34

Outdoor unit model ep300 total capacity of connected indoor units 361 34

The total length of each liquid piping is as follows ø1 2 total length 131 a ø3 8 total length 32 b 49 c 32 d 32 a 16 b 32 e 193 ø1 4 total length 32 c 32 d 64 34

Therefore when the piping length from the outdoor unit to the farthest indoor unit is longer than 30 m 100 ft 34

When the piping length from the outdoor unit to the farthest indoor unit is 30 m 100 ft or shorter 34

When the piping length from the outdoor unit to the farthest indoor unit is longer than 30 m 100 ft 34

9 2 charging additional refrigerant 35

After evacuation and refrigerant charging ensure that the service valves are fully open do not operate the unit with the service valves closed 35

Charge the calculated amount of refrigerant in the liquid state to the unit through the service port after the completion of piping work upon completion of all work securely tighten all service port caps and shaft caps to prevent refrigerant leakage 35

Do not vent the refrigerant into the atmosphere refer to the table below for the appropriate tightening torque 35

If the refrigerant tank does not have a siphon pipe charge the liquid refrigerant with the tank upside down as shown in the figure below 35

1 before electrical work 36

2 power cables and device capacity 36

Electrical work 36

Be sure to use the appropriate type of overcurrent breaker note that generated overcurrent may include some amount of direct current select the type of breaker for an inverter circuit as an earth leakage breaker mitsubishi electric nv s series or its equivalent the earth leakage breaker should be used in combination with a local switch use a local switch with at least 3 mm 1 8 in contact separation in each pole do not connect the power cables l1 l2 and l3 to n ensure the correct phase sequence if the power cable is damaged it must be replaced by the manufacturer its service agent or similarly qualified persons in order to avoid a hazard use dedicated power cables for the outdoor unit and indoor unit ensure oc and os are wired individually power cable size device capacity and system impedance if local regulations do not specify the minimum power cable size or device capacity follow the values in the table below 37

Wiring example 37

At the interface point between the user s supply and the public system it is the responsibility of the installer or user of the equipment to ensure by consultation with the distribution network operator if necessary that the equipment is connected only to a supply with a short circuit power ssc greater than or equal to ssc 38

Sample chart 38

The wire size is the minimum value for metal conduit wiring if the voltage drops use a wire that is one size thicker in diameter make sure the power supply voltage does not drop more than 10 make sure that the voltage imbalance between the phases is 2 or less power supply cords of parts of appliances for outdoor use shall not be lighter than polychloroprene sheathed flexible cord design 60245 iec57 for example use wiring such as yzw this unit is intended for the connection to a power supply system with a maximum permissible system impedance shown in the above table at the interface point power service box of the user s supply the user must ensure that this unit is connected only to a power supply system which fulfils the requirement above if necessary the user can ask the public power supply company for the system impedance at the interface point this unit complies with iec 61000 3 12 provided that the short circuit power ssc is greater than or equal to ssc 38

3 control cable specifications 39

4 system configuration 39

Remote controller cable 39

Transmission cable 39

Unit code and the maximum number of connectable units 39

1 when me remote controllers are connected 40

Maximum allowable length of control cables 40

System configuration example 40

2 when ma remote controllers are connected 41

3 when a transmission booster unit is connected 41

Maximum allowable length of control cables 41

5 1 threading power cable through the knockout hole 42

5 wiring connections in the control box 42

Connections must be made securely and without tension on the terminals improperly connected cables may break overheat or cause smoke or fire 42

If there are any gaps around the power cable please be sure to fill these in with a suitable material when putting the power cable through the knockout hole without using a conduit tube deburr the hole and protect the power cable with protective tape use a conduit tube to narrow down the opening if there is a possibility of small animals entering the unit when taking the conduit tube out from the bottom part of the unit caulk around the tube opening to prevent water infiltration 42

Punch out the knockout holes at the bottom of the front panel with a hammer use the appropriate knockout hole according to the size of the power cable referring to the table below 42

1 make sure the cables are not coming out of the rubber bushing cut 43

2 when threading the wiring through the rubber bushing make sure the rubber bushing will not come off the sheet metal on the control box guard 43

3 when tying the supplied tie band around the rubber bushing make sure to leave no gap between the ends 43

5 2 fixing the cables in place 43

Below ② thread the unit wiring sensor wiring and the transmission cable through the rubber bushing on the right side see 43

Below ③ hold the power cable and the transmission cable in place respectively with the cable straps ④ secure each rubber bushing with the supplied tie band see 43

① thread the power cable through the rubber bushing on the left side see 43

5 3 connecting the cables 44

6 address setting 45

Set the address setting switch as follows 45

1 before a test run 46

After the wiring work has been completed measure the insulation resistance and make sure that it reads at least 1 mω failure to do so may result in electric leakage malfunction or fire 46

Test run 46

Turn on the power at least 12 hours before starting operation keep the power turned on throughout the operating season insufficient energizing will result in malfunction 46

2 function setting 47

3 operation characteristics in relation to the refrigerant charge 47

It is important to have a clear understanding of the characteristics of refrigerant and the operation characteristics of air conditioners before attempting to adjust the refrigerant charge in a given system during cooling operation the amount of refrigerant in the accumulator is the smallest when all indoor units are in operation during heating operation the amount of refrigerant in the accumulator is the largest when all indoor units are in operation refrigerant undercharge creates a tendency for the discharge temperature to rise changing the amount of refrigerant in the system while there is refrigerant in the accumulator has little effect on the discharge temperature the higher the high pressure level the more likely it is for the discharge temperature to rise the lower the low pressure level the more likely it is for the discharge temperature to rise when the amount of refrigerant in the system is adequate the compressor shell temperature is 10 to 60ºc 50 to 140ºf higher than the l 47

Make function settings by setting the dipswitches sw4 sw6 and swp1 on the main board write down the switch settings on the electrical wiring diagram label on the control box front panel for future reference when the control box needs to be replaced take the following steps to make snow sensor settings snow sensor control will not function when the outdoor temperature sensor th7 reading is 6ºc 43ºf or above 47

Make various function settings by setting sw6 referring to the table below 47

① set the 10th bit of sw6 to on ② set sw4 as shown in the table below to select the setting item no 33 or 934 the setting item no will be displayed on led1 ③ press swp1 for two seconds or longer to change the settings the settings can be checked on led3 47

4 operation check 48

The following symptoms are normal and do not indicate a problem 48

Inspection and maintenance 49

Only qualified personnel must relocate or repair the unit do not attempt to disassemble or alter the unit failure to do so will result in refrigerant leakage water leakage serious injury electric shock or fire 49

Rating plate information 50

Mitsubishi Electric PUHY-EP450YLM-A [29/56] 7 thermal insulation for pipes

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