Mitsubishi Electric PUHZ-SW75VHA Air to Water Heat Pump Installation Guide

MITSUBISHI ELECTRIC PUHZ-SW75VHA Air to Water Heat Pump

Caution:

• Do not vent R410A into the Atmosphere:
• R410A is a Fluorinated Greenhouse gas, covered by the Kyoto Protocol, with a Global Warming Potential (GWP)=1975.
  Heat pumps certification
  The mark “NF Heat pumps” is an independent certification program proving that heat pumps’ performances and production quality of the factory are conformed with the certification reference NF-414. The combinations of indoor units and outdoor units, and their applications allowed to use of the NF PAC mark can be consulted on the website www.marque-nf.com

Safety precautions

• Before installing the unit, make sure you read all the “Safety precautions”. Please report to or take consent by the supply authority before connection to the system.
• Equipment complying with IEC/EN 61000-3-12 (PUHZ-SW100/120VHA)
• PUHZ-SW160, 200YKA
  “This equipment complies with IEC 61000-3-12 provided that the short-circuit power Ssc is greater than or equal to Ssc (*1) 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 (*1)” Ssc (*1)

Warning:

• The unit must not be installed by the user. Ask a dealer or an authorized technician to install the unit. If the unit is installed incorrectly, water leakage, electric shock, or  re may result.
• For installation work, follow the instructions in the Installation Manual and use tools and pipe components specifcally made for use with R410A refrigerant. The R410A refrigerant in the HFC system is pressurized 1.6 times the pressure of usual refrigerants. If pipe components not designed for R410A refrigerant are used and the unit is not installed correctly, the pipes may burst and cause damage or injuries. In addition, water leakage, electric shock, or  re may result.
• The unit must be installed according to the instructions in order to minimize the risk of damage from earthquakes, typhoons, or strong winds. An incorrectly installed unit may fall down and cause damage or injuries.
• The unit must be securely installed on a structure that can sustain its weight. If the unit is mounted on an unstable structure, it may fall down and cause damage or injuries.
• If the outdoor unit is installed in a small room, measures must be taken to prevent the refrigerant concentration in the room from exceeding the safety limit in the event of refrigerant leakage. Consult a dealer regarding the appropriate measures to prevent the allowable concentration from being exceeded. Should the refrigerant leak and cause the concentration limit to be exceeded, hazards due to lack of oxygen in the room may result.
• Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released.
• All electric work must be performed by a qualified technician according to local regulations and the instructions given in this manual. The units must be powered by dedicated power lines and the correct voltage and circuit breakers must be used. Power lines with insufficient capacity or incorrect electrical work may result in electric shock or re.
• Use C1220 copper phosphorus, for copper and copper alloy seamless pipes, to connect the refrigerant pipes. If the pipes are not connected correctly, the unit will not be properly grounded and an electric shock may result.

Before installation

Caution:

• Do not use the unit in an unusual environment. If the outdoor unit is installed in areas exposed to steam, volatile oil (including machine oil), or sulfuric gas, areas exposed to high salt content such as the seaside, or areas where the unit will be covered by snow, the performance can be
  significantly reduced and the internal parts can be damaged.
• Do not install the unit where combustible gases may leak, be produced,• Use only specialed cables for wiring. The wiring connections must be made securely with no tension applied on the terminal connections. Also, never splice the cables for wiring (unless otherwise indicated in this document). Failure to observe these instructions may result in overheating or are.
• The terminal block cover panel of the outdoor unit must be firmly attached. If the cover panel is mounted incorrectly and dust and moisture enter the unit, electric shock or re may result.
• When installing or relocating, or servicing the outdoor unit, use only the specif ed refrigerant (R410A) to charge the refrigerant lines. Do not mix it with any other refrigerant and do not allow air to remain in the lines.
  If air is mixed with the refrigerant, then it can be the cause of abnormally high pressure in the refrigerant line, and may result in an explosion and other hazards.
• The use of any refrigerant other than that specified for the system will cause mechanical failure or system malfunction or unit breakdown. In the worst case, this could lead to a serious impediment to securing product safety.
• Use only accessories authorized by Mitsubishi Electric and ask a dealer or an authorized technician to install them. If accessories are incorrectly installed, water leakage, electric shock, or re may result.
• Do not alter the unit. Consult a dealer for repairs. If alterations or repairs are not performed correctly, water leakage, electric shock, or re may result.
• The user should never attempt to repair the unit or transfer it to another location. If the unit is installed incorrectly, water leakage, electric shock, or re may result. If the outdoor unit must be repaired or moved, ask a dealer or an authorized technician.
• After installation has been completed, check for refrigerant leaks. If refrigerant leaks into the room and comes into contact with the name of a heater or portable cooking range, poisonous gases will be released.
• The outdoor unit produces condensation during the heating operation. Make sure to provide drainage around the outdoor unit if such condensation is likely to cause damage.
• When installing the unit in a hospital or communications office, be prepared for noise and electronic interference. Inverters, home appliances, high-frequency medical equipment, and radio communications equipment

Safety precautions

Before installation (relocation)

• Be extremely careful when transporting or installing the units. Two or more persons are needed to handle the unit, as it weighs 20 kg or more. Do not grasp the packaging bands. Wear protective gloves to remove the unit from the packaging and to move it, as you can injure your hands on the ns or the edge of other parts.
• Be sure to safely dispose of the packaging materials. Packaging materials, such as nails and other metal or wooden parts may cause stabs or other injuries.

Before electric work

Caution:

• Be sure to install circuit breakers. If not installed, an electric shock may result.
• For the power lines, use standard cables of sufficient capacity. Otherwise, a short circuit, overheating or may result.
• When installing the power lines, do not apply tension to the cables. If the connections are loosened, the cables can snap or break, and overheating or re may result.

 Before starting the test run

Caution:

• Turn on the main power switch more than 12 hours before starting operation. Starting operation just after turning on the power switch can severely damage the internal parts. Keep the main power switch turned on during the operation season.
• Before starting operation, check that all panels, guards and other protective parts are correctly installed. Rotating, hot, or high voltage parts can cause injuries.
• Do not touch any switch with wet hands. Electric shock may result.

Using R410A refrigerant outdoor units

Caution:

• Use C1220 copper phosphorus, for copper and copper alloy seamless pipes, to connect the refrigerant pipes. Make sure the insides of the pipes are clean and do not contain any harmful contaminants such as sulfuric compounds, oxidants, debris, or dust. Use pipes with the special ed thickness. (Refer to 4.1.) Note the following if reusing existing pipes that carried R22 refrigerant.
• Replace the existing nuts and the red sections again.
• Do not use thin pipes. (Refer to 4.1.)
• Store the pipes to be used during installation indoors and keep both ends of the pipes sealed until just before brazing. (Leave elbow joints, etc. in their packaging.) If dust, debris, or moisture enters the refrigerant lines, oil deterioration or compressor breakdown may result.
• Use ester oil, ether oil, and alkylbenzene oil (small amount) as the refrigeration oil applied to the area sections. If mineral oil is mixed in the refrigeration oil, oil deterioration may result.
• Do not use refrigerant other than R410A refrigerant. If another refrigerant is used, the chlorine will cause the oil to deteriorate.
  Use the following tools specially designed for use with R410A refrigerant. The following tools are necessary to use R410A refrigerant. Contact your nearest dealer for any questions.

• Tools (for R410A)
  Gauge manifold	Flare tool
  Charge hose	Size adjustment gauge
  Gas leak detector	Vacuum pump adapter
  Torque wrench	Electronic refrigerant charging scale

• Be sure to use the correct tools. If dust, debris, or moisture enters the refrigerant lines, refrigeration oil deterioration may result.
• Do not use a charging cylinder. If a charging cylinder is used, the composition of the refrigerant will change and the efficiency will be lowered.

 Accessories of an outdoor unit (Fig. 1-1) (SW160, 200)

The parts shown in the left are the accessories of this unit, which are affixed to the inside of the service panel.

1. Put are nut which is removed from the Ball Valve on the Joint Pipe accessory and carry out are work.
2. The Joint Pipe accessory and the pipe which is prepared on-site must be brazed in non-oxidation status.
3. After the pipes are brazed, connect the Joint Pipe accessory to the Ball Valve which locates within the unit by are connection.
   * Never connect the Joint Pipe accessory to the Ball Valve before brazing. Some parts may be burnt and it may cause refrigerant leakage.

Installation location

Refrigerant pipe
Check that the difference between the heights of the indoor and outdoor units, the length of refrigerant pipe, and the number of bends in the pipe
are within the limits shown below.

Choosing the outdoor unit installation location

• Avoid locations exposed to direct sunlight or other sources of heat.
• Select a location from which noise emitted by the unit will not inconvenience neighbors.
• Select a location permitting easy wiring and pipe access to the power source and indoor unit.
• Avoid locations where combustible gases may leak, be produced,  ow, or accumulate.
• Note that water may drain from the unit during operation.
•  Select a level location that can bear the weight and vibration of the unit.
•  Avoid locations where the unit can be covered by snow. In areas where heavy snowfall is anticipated, special precautions such as raising the installation location or installing a hood on the air intake must be taken to prevent the snow from blocking the air intake or blowing directly against it. This can reduce the air ow and a malfunction may result.
• Avoid locations exposed to oil, steam, or sulfuric gas.
• Use the transportation handles of the outdoor unit to transport the unit. If the unit
  is carried from the bottom, hands or fingers may be pinched.

Outline dimensions (Outdoor unit)

Ventilation and service space
Windy location installation

When installing the outdoor unit on a rooftop or other location unprotected from the wind, situate the air outlet of the unit so that it is not directly exposed to strong winds. Strong wind entering the air outlet may impede the normal airflow and a malfunction may result.

The following shows three examples of precautions against strong winds.

1. Face the air outlet towards the nearest available wall about 50 cm away from the wall.
2. Install an optional air guide if the unit is installed in a location where strong winds from a typhoon, etc. may directly enter the air outlet. (Fig. 2-4) Air outlet guide
3. Position the unit so that the air outlet blows perpendicularly to the seasonal wind direction, if possible. (Fig. 2-5) Wind direction

When installing a single outdoor unit (Refer to the last page)
Minimum dimensions are as follows, except for Max., meaning Maximum dimensions, indicated.

The figures in parentheses are for SW100-200 models. Refer to figures for each case.

• Obstacles at rear only (Fig. 2-6)
• Obstacles at the rear and above only (Fig. 2-7)
• Obstacles at rear and sides only (Fig. 2-8)
  • 350 for SW40, 50.
• Obstacles at the front only (Fig. 2-9)
  • When using an optional air outlet guide, the clearance for SW100-200 models is 500 mm or more.
• Obstacles at front and rear only (Fig. 2-10)
  • When using an optional air outlet guide, the clearance for SW100-200 models is 500 mm or more.
• Obstacles at the rear, sides, and above only (Fig. 2-11)
  • 350 for SW40, 50.
• Do not install the optional air outlet guides for upward air ow.

When installing multiple outdoor units (Refer to the last page)
Leave 350 mm for SW40, 50 and 10 mm for SW75-120 and 50 mm for SW160, with 200 space or more between the units.

The figures in parentheses are for SW100-200 models. Obstacles at rear only (Fig. 2-12)

1. Obstacles at the rear and above only (Fig. 2-13)
2. No more than 3 units must be installed side by side. In addition, leave space as shown.
3. Do not install the optional air outlet guides for upward air ow.
4. Obstacles at the front only (Fig. 2-14)
   • When using an optional air outlet guide, the clearance for SW100-200 models is 1000 mm or more.
5. Obstacles at front and rear only (Fig. 2-15)
   • When using an optional air outlet guide, the clearance for SW100-200 models is 1000 mm or more.
6. Single parallel unit arrangement (Fig. 2-16)
   • When using an optional air outlet guide installed for the upward arrow, the clearance is
     500 (1000) mm or more.
7. Multiple parallel unit arrangement (Fig. 2-17)
   • When using an optional air outlet guide installed for upward air ow, the clearance is 1000 (1500) mm or more.
8. Stacked unit arrangement (Fig. 2-18)
   • The units can be stacked up to two units high.
   • No more than 2 stacked units must be installed side by side. In addition, leave space as shown.

Installing the outdoor unit

• Make sure that the length of the foundation bolt is within 30 mm of the bottom surface of the base.
• Secure the base of the unit only with four-M10 foundation bolts in sturdy locations.

Installing the outdoor unit

• Do not block the vent. If the vent is blocked, the operation will be hindered and breakdown may result.
• In addition to the unit base, use the installation holes on the back of the unit to attach wires, etc., if necessary to install the unit. Use self-tapping screws (ø5 × 15 mm or less) and install them on-site.

Warning:

• The unit must be securely installed on a structure that can sustain its weight. If the unit is mounted on an unstable structure, it may fall down
  and cause damage or injuries.
• The unit must be installed according to the instructions in order to minimize the risk of damage from earthquakes, typhoons, or strong winds. An
  the incorrectly installed unit may fall down and cause damage or injuries.

Installing the refrigerant piping

Precautions for devices that use R410A refrigerant

• Refer to 1.5. for precautions not included below on using outdoor units with R410A refrigerant.
• Use ester oil, ether oil, and alkylbenzene oil (small amount) as the refrigeration oil applied to the sections.
• Use C1220 copper phosphorus, for copper and copper alloy seamless pipes, to connect the refrigerant pipes. Use refrigerant pipes with the thicknesses specified in the table to below. Make sure the insides of the pipes are clean and do not contain any harmful contaminants such as sulfuric compounds, oxidants, debris, or dust. Always apply no-oxidation brazing when brazing the pipes, otherwise, the compressor will be damaged.

Warning:
When installing or relocating, or servicing the outdoor unit, use only the specialed refrigerant (R410A) to charge the refrigerant lines. Do not mix it with any other refrigerant and do not allow air to remain in the lines. If air is mixed with the refrigerant, then it can be the cause of abnormally high
pressure in the refrigerant line and may result in an explosion and other hazards. The use of any refrigerant other than that special ed for the system will cause mechanical failure or system malfunction or unit breakdown. In the worst case, this could lead to a serious impediment to securing product safety.

 

• A: Stop valve
• B: Seal section
• C: Local piping
• D: double spanner section
• E: Joint pipe
• F: Pipe cover

 

• A: Cover panel front
• B: Cover panel rear
• C: Stop valve
• D: Service panel
• E: Bend radius: 100 mm – 150 mm

Connecting pipes

• When commercially available copper pipes are used, wrap liquid and gas pipes with commercially available insulation materials (heat-resistant to 100 °C or more, the thickness of 12 mm or more). Direct contact with the bare piping may result in burns on frostbite.
• The indoor parts of the drainpipe should be wrapped with polyethylene foam insulation materials (specific gravity of 0.03, thickness of 9 mm or more).
• Apply a thin layer of refrigerant oil to the pipe and joint seating surface before tightening are a nut.
• Use two wrenches to tighten piping connections.
• Use a leak detector or soapy water to check for gas leaks after connections are completed.
• Apply refrigerating machine oil over the entire seat surface.
• Use the are nuts for the following pipe size.
• When bending the pipes, be careful not to break them. Bend radii of 100 mm to 150 mm are sufficient.
• Make sure the pipes do not contact the compressor. Abnormal noise or vibration may result.
• Pipes must be connected starting from the indoor unit.
• Flare nuts must be tightened with a torque wrench.
• Flare the liquid pipes and gas pipes and apply a thin layer of refrigeration oil (Applied on-site).
• When usual pipe sealing is used, refer to Table 1 for  aring of R410A refrigerant pipes.
• The size adjustment gauge can be used to con rm A measurements.
• Use the following procedure for connecting the gas-side piping. (Fig.4-3) (SW160/200)
  1. Braze the Joint pipe provided to the outdoor unit using locally procured brazing materials and Local piping without oxygen.
  2. Connect the Joint pipe to the gas-side Stop valve. Use 2 wrenches to tighten the are a nut.
• If an order is reversed, a refrigerant leak occurs because of the part damaged by brazing re.

• A: Stop valve <Liquid side>
• B: Stop valve <Gas side>
• C: Service port
• D: Open/Close section
• E: Local pipe
• F: Sealed, same way for the gas side
• G: Pipe cover

• A: Valve
• B: Unit side
• C: Handle
• D: Cap
• E: Local pipe side
• F: Pipe cover
• G: Service port
• H: Wrench hole
• I: Double spanner section
  (Do not apply a spanner other than to this section. Doing so would cause coolant leaks.)
• J: Seal section (Seal the end of the heat insulation material at the pipe connection section with whatever seal material you have on hand so that water does not in ltrate the heat insulation material.
• The figure to the left is an example only.
• The stop valve shape, service port position, etc., may vary according to the model.
  Turn section only. (Do not further tighten sections together.)

Refrigerant pipe airtight testing method (Fig. 4-5)

1. Connect the testing tools.
   • Make sure the stop valves are closed and do not open them.
   • Add pressure to the refrigerant lines through the service port of the liquid stop valve.
2. Do not add pressure to the special ed pressure all at once; add pressure little by little.
   1. Pressurize to 0.5 MPa (5 kg/cm2G), wait five minutes, and make sure the pressure does not decrease.
   2. Pressurize to 1.5 MPa (15 kg/cm2G), wait  ve minutes, and make sure the
   3. pressure does not decrease. Pressurize to 4.15 MPa (41.5 kg/cm2G) and measure the surrounding temperature and refrigerant pressure.
3. If the special ed pressure holds for about one day and does not decrease, the pipes have passed the test and there are no leaks.
   • If the surrounding temperature changes by 1 °C, the pressure will change by about 0.01 MPa (0.1 kgf/cm2G). Make the necessary corrections.
4. If the pressure decreases in steps (2) or (3), there is a gas leak. Look for the source of the gas leak.

Stop valve opening method
The stop valve opening method varies according to the outdoor unit model. Use the appropriate method to open the stop valves.

1. The gas side of SW75 (Fig. 4-6)
   Remove the cap and turn the valve rod counter clockwise as far as it will go with the use of a 5 mm hexagonal wrench. Stop turning when it hits the stopper. (ø 15.88: Approximately 13 revolutions.) Make sure that the stop valve is open completely and rotate the cap back to its
   original position.
2. The gas side of SW100-200 (Fig. 4-7)
   Remove the cap, pull the handle toward you and rotate 1/4 turn in a counterclockwise direction to open.
   Make sure that the stop valve is open completely, push in the handle, and rotate the cap back to its original position.
3. Liquid side of SW75-200 and Gas/Liquid side of SW40-75 (Fig. 4-8) Remove the cap and turn the valve rod counterclockwise as far as it will go with the use of a 4 mm hexagonal wrench. Stop turning when it hits the stopper. (ø9.52: Approximately 10 revolutions) Make sure that the stop valve is open completely, push in the handle, and rotate the cap back to its original position.

Refrigerant pipes are protectively wrapped for SW75-200
The pipes can be protectively wrapped up to a diameter of ø90 before or after connecting the pipes. Cut out the knockout in the pipe cover following the groove and wrap the pipes.

Precautions when using the charge valve (Fig. 4-9)
Do not tighten the service port too much when installing it, otherwise, the valve core could be deformed and become loose, causing a gas leak.
After positioning the section in the desired direction, turn the section only and tighten it.
Do not further tighten sections together after the tightening section.

Addition of refrigerant

• Additional charging is not necessary if the pipe length does not exceed 10 m (SW40-120), 30 m (SW160, 200).
• If the pipe length exceeds 10 m (SW40-120), 30 m (SW160, 200), charge the unit with additional R410A refrigerant according to the permitted pipe lengths in the chart below.
• When the unit is stopped, charge the unit with the additional refrigerant through the liquid stop valve after the pipe extensions and indoor unit have been vacuumized.
  When the unit is operating, add refrigerant to the gas check valve using a safety charger. Do not add liquid refrigerant directly to the check valve.

Precautions when reusing existing R22 refrigerant pipes

• Refer to the flowchart below to determine if the existing pipes can be used and if it is necessary to use a  lter dryer.
• If the diameter of the existing pipes is different from the speci ed diameter, refer to technological data materials to con rm if the pipes can be used.

Drainage piping work

Outdoor unit drainage pipe connection
When drain piping is necessary, use the drain socket or the drain pan (option).

Water piping work

Minimum water quantity
Following water quantity is required in the water circuit.

Electrical work

Outdoor unit

1. Remove the service panel.
2. Wire the cables referring to Fig. 7-1 and Fig. 7-2.

Field electrical wiring

Electrical work

1. Wiring size must comply with the applicable local and national codes.
2. Power supply cables and the cables between Interface unit/Flow temp. controller and outdoor unit shall not be lighter than polychloroprene sheathed flexible cables. (Design 60245 IEC 57)
3. Be sure to connect the cables between the Interface unit/Flow temp. controller and the outdoor unit directly to the units (no intermediate connections are allowed). Intermediate connections may result in communication errors. If water enters at the intermediate connection point, it may cause insufficient insulation to ground or poor electrical contact.
   (If an intermediate connection is necessary, be sure to take measures to prevent water from entering the cables.)
4. Install earth longer than other cables.
5. Do not construct a system with a power supply that is turned ON and OFF frequently.

Warning:

• In the case of A-control wiring, there is high voltage potential on the S3 terminal caused by an electrical circuit design that has no electrical insulation between the power line and the communication signal line. Therefore, please turn off the main power supply when servicing. And do not touch the S1, S2, S3 terminals when the power is energized. If an isolator should be used between the indoor unit and outdoor unit, please use the 3-pole type.

Breaker size setting (only for SW75)

Special Functions

• A: Circuit diagram example (low noise mode) On-site arrangement
• B: External input adapter (PAC-SC36NA-E)
• C: X: Relay
• D: Outdoor unit control board
• E: Max. 10 m
• F: Power supply for relay

Refrigerant collecting (pump down)
Perform the following procedures to collect the refrigerant when moving the indoor unit or the outdoor unit.
Supply power (circuit breaker).

• When power is supplied, make sure that CENTRALLY CONTROLLED  is not displayed on the remote controller. If  CENTRALLY CONTROLLED  is displayed,
  the refrigerant collecting (pump down) cannot be completed normally.
• Start-up of the indoor-outdoor communication takes about 3 minutes after the power (circuit breaker) is turned on. Start the pump-down operation 3 to 4 minutes after the power (circuit breaker) is turned ON.
• In the case of multi-units control, before powering on, disconnect the wiring between the master indoor unit and the slave indoor unit. For more details refer to the installation manual for the indoor unit. After the liquid stop valve is closed, set the SWP switch on the control board of
  the outdoor unit to ON. The compressor (outdoor unit) and ventilators (indoor and outdoor units) start operating and refrigerant collecting operation begins. LED1 and LED2 on the control board of the outdoor unit are lit.
• Only set the SWP switch (push-button type) to ON if the unit is stopped. However, even if the unit is stopped and the SWP switch is set to ON less than 3 minutes after the compressor stops, the refrigerant collecting operation cannot be performed. Wait until the compressor has been stopped for 3 minutes and then set the SWP switch to ON again.

Low noise mode (on-site mod cation) (Fig. 8-1)

By performing the following Modi cation, the operation noise of the outdoor unit can be reduced by about 3-4 dB.
The low noise mode will be activated when a commercially available timer or the contact input of an ON/OFF switch is added to the CNDM connector (option) on the control board of the outdoor unit.
The ability varies according to the outdoor temperature and conditions, etc.

1. Complete the circuit as shown when using the external input adapter (PAC-SC36NA-E). (Option)
2. SW7-1 (Outdoor unit control board): OFF
3. SW1 ON: Low noise mode
4. SW1 OFF: Normal operation

System control

Specifications