Booster Unit INSTALLATION MANUAL
Contents
1. 6 1 Example of Wiring Entire System Note 1 For Remote switch use non voltage contact for microcurrent not more than 1mA 12VDC Note 2 Total capacity for warning alarm 0 5A or less at AC 220 to 240V Capacity for operation output 0 5A or less at AC 220 to 240V Note 3 In case of the malfunction Constant a contact output TI Timer for refrigeration 52H Electromagnetic contactor SIT Thermostat for inner temperature adjustment T2 Timer for freezer Defrost heater 52T Defrost completion thermostat Ry0 Ry3 Relay HIP Defrost lamp Y15 Solenoid valve Earth leakage circuit breaker Integrated heat control board Field suppl Freezer showci For earth fault overload ae as SUPP ES short circuit protection KM y 1 phase 380 415V Remote switch Earth leakage circuit breaker LA Sa High frequency type T 2 For earth fault overload and short circuit protection Outdoor unit SIT m3 Alarm panel ruts ME R ETT E i 3 o oC Warning output 0 Ow Caution output LT Aimer for freezer Refrigeration IR Ead Note 3 eH a efrigeration unit cooler 12 Refrigeration operating output AC220 24 V XIN AIP s a XM In Out Out Out oz loc t ma Timer for refrigeration Mita AC220 240 V2. 1 1945 ye ueejVie Jepun epueAGuuou 1 se enpredsal LL 910 pjoyuay sepueue essip je jespnuoj sa uewnyop 181 QL avri dion INMMBH weidetrue1o Wimorftieuo 1016191981009 60 sessou se opiooe ep wefas epsep s oaeuuou s ojueunoop 5 no 5 s ajunbas sje woo epepruuojuoo 08158 80 ejsesoe as aseo e euorjipuoo Jae ap ajajesede arepundse eudoid ad GB gy efoejejyop ezsfeiuiu yogy ez osoujerzperwodpo buzobj eu efnueprep Gd 21 e tjusjefhy ueqeyepn abassojaja CH 91 Isoupo eao es aloy eu efepaun eui ns ep wojyseja ongnlys pod GA 9 juesejuoid ojo as Zulu y eoezgeuuri az ysouparodpo aujd
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7. soir ue eti cde 11 1 FIRST OF ALL This document is an installation manual for the Daikin Booster Unit Before installing the unit read this manual thoroughly and following the instructions contained in it After installation do a test run to make sure the unit runs properly and then explain how to operate and take care of the unit to the customer using the operation manual Lastly make sure the customer keeps this manual along with the operation manual in a safe place This manual does not describe how to install the indoor unit and out door unit Refer to the installation manual included with the indoor unit and outdoor unit for that 1 1 Safety Precautions Please read these Safety precautions carefully before installing the booster unit and be sure to install it correctly After completing installation conduct a trial operation to check for faults and explain to the customer how to operate the booster unit and take care of it with the aid of the operation manual Ask the cus tomer to store the installation manual along with the operation man ual for future reference Meaning of WARNING and CAUTION notices result in personal injury or loss of life A CAUTION Failure to observe these instructions properly may result in property damage or personal injury which may be serious depending on the circumstances N WARNING Ask your dealer or qualified personnel to carry o
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11. English 4 2 Installation the Unit Make sure the unit is installed level on a sufficiently strong base to prevent vibration and noise Secure the unit to its base using foundation bolts Use four com mercially available M8 type foundation bolts nuts and washers The foundation bolts should be inserted 20 mm Foundation bolt allowance e N 680 650 4 m Dimension of booster unit and foundation bolt position Unit mm Note When installing on a roof make sure the roof floor is strong enough and be sure to water proof all work Make sure the area around the machine drains properly by setting up drainage grooves around the foundation Drain water is sometimes discharged from the booster unit when itis running f the booster unit is of brine damage Resin resistant type use nuts provided with washers resin washers to secure the product to phones the foundation bolts see the illustra tion on the right hand side The rustproof effect of the nut will be lost if the coatings on the tightening portions of the nuts come off Use the drain pan kit when using indoors Model BWC63A2 Ensure that sufficient drainage is supplied by following the guide lines below as necessary when using outdoors 4 3 Draining the Unit For drainage work of the unit install piping to ensure complete drainage Condensation may for
12. Remove the valve cover and turn the shaft anticlockwise with a hexagon wrench 2 Turn the shaft until the shaft stops 3 Tighten the valve cover securely Refer to the above table for the tightening torque according to the size English Closing method 1 Remove the valve cover and turn the shaft clockwise with a hexa gon wrench 2 Tighten the shaft until the shaft comes in contact with the sealing part of the valve 3 Tighten the valve cover securely Refer to the above table for the tightening torque according to the size Handling Precautions for Valve Cover Becareful not to damage the sealing part Atthe time of mounting the valve cover apply a screw lock agent to the screw thread Do not apply a screw lock agent for flare nut use to the sealing part Be sure to tighten the valve cover securely after operating the valve Refer to Operation Method of Shutoff Valves for the tightening torque of the valve Screw thread Apply a screw lock agent Valve cover Shutoff valve Part of mounting the Sealing part valve cover Not apply a screw lock agent Handling Precautions for Service Port e Work on the service port with a charge hose provided with a push ing rod Atthe time of mounting the cap apply a screw lock agent to the Screw thread Do not apply a screw lock agent for flare nut use to the sealing part Besureto tighten the cap securely after the work Ref
13. current from lightning or other sources may cause damage to the booster unit Be sure to install an earth leakage breaker Failure to install an earth leakage breaker may result in electric shocks or fire N CAUTION While following the instructions in this installation manual install drain piping to ensure proper drainage and insulate piping to pre vent condensation Improper drain piping may result in indoor water leakage and property damage English Install the indoor and outdoor units power cord and connecting wires at least 1 meter away from televisions or radios to prevent picture interference and noise Depending on the incoming signal strength a distance of 1 meter may not be sufficient to eliminate noise Do not install the booster unit in the following locations 1 Where there is a high concentration of mineral oil spray or vapour e g a kitchen Plastic parts will deteriorate parts may fall off and water leak age could result 2 Where corrosive gas such as sulphurous acid gas is produced Corroding of copper pipes or soldered parts may result in refrigerant leakage 3 Near machinery emitting electromagnetic radiation Electromagnetic radiation may disturb the operation of the control system and result in a malfunction of the unit 4 Where flammable gas may leak where there is carbon fiber or ignitable dust suspensions in the air or where volatile flamma bles such as paint thinner or
14. gasoline are handled Operating the unit in such conditions may result in fire 5 Vehicles ships or other places that generate vibration or cause the booster unit to move The booster unit may malfunction or cause oxygen deficiency accidents as a result of refrigerant leakage 6 Places with excessive voltage fluctuations The booster unit may malfunction Places where fallen leaves accumulate or weeds grow thick Places that become small animals shelter Small animals coming in contact with electrical parts can cause malfunctions smoke or ignition The booster unit is not intended for use in a potentially explosive atmosphere 1 2 Special Notice of Product This booster unit comes under the term appliances not acces sible to the general public CLASSIFICATION This booster unit comes under the term appliances not accessi ble to the general public Follow the showcase to be connected for the climate class EMC CHARACTERISTICS This System is a class A product In a domestic environment this product may cause radio interference in which case the user may be required to take adequate measures REFRIGERANT Important information regarding the refrigerant used This product is factory charged with N2 The refrigerant system will be charged with fluorinated greenhouse gases covered by the Kyoto Protocol Do not vent gases into the atmosphere Refrigerant type R410A GWP value 19
15. improper electrical con struction may lead to electric shocks or fire Make sure that all wiring is secured the specified wires are used and that there is no strain on the terminal connections or wires Improper connections or securing of wires may result in abnormal heat build up or fire When wiring the power supply and connecting transmission wir ing position the wires so that the control box lid can be securely fastened Improper positioning of the control box lid may result in electric shocks fire or the terminals overheating If refrigerant gas leaks during installation ventilate the area immediately Toxic gas may be produced if the refrigerant gas comes into con tact with fire After completing installation check for refrigerant gas leakage Toxic gas may be produced if the refrigerant gas leaks into the room and comes into contact with a source of fire such as a fan heater stove or cooker Be sure to switch off the unit before touching any electrical parts Do not directly touch refrigerant that has leaked from refrigerant pipes or other areas as there is a danger of frostbite Do not allow children to climb on the outside unit and avoid plac ing objects on the unit Injury may result if the unit becomes loose and falls Be sure to earth the booster unit Do not earth the unit to a utility pipe lightning conductor or CD telephone earth lead Imperfect earthing may result in electric shocks or fire A high surge
16. 75 GWP global warming potential Values are indicated in F gas regulations EC No 842 2006 Annex l Parts 1 and 2 Therefrigerant R410A requires strict cautions for keeping the sys tem clean dry and tight Read the chapter REFRIGERANT PIPING carefully and follow these procedures correctly A Clean and dry Foreign materials including mineral oils such as SUNISO oil or moisture should be prevented from getting mixed into the system B Tight Take care to keep the system tight when installing R410A does not contain any chlorine does not destroy the ozone layer and does not reduce the earth s protection against harmful ultraviolet radiation R410A can contribute slightly to the greenhouse effect if it is released Since R410A is a mixed refrigerant the required additional refrig erant must be charged in its liquid state If the refrigerant is charged in a state of gas its composition changes and the system will not work properly DESIGN PRESSURE Since design pressure is 3 8MPa or 38bar for R407C units 3 3MPa or 33bar the wall thickness of pipes should be more carefully selected in accordance with the relevant local and national regula tions 1 3 Disposal Requirements Dismantling of the unit treatment of the refrigerant oil and eventual other parts should be done in accordance with the relevant local and national regulations 2 BEFORE INSTALLATION N CAUTION When installing the indo
17. DAIKIN INSTALLATION MANUAL Installation manual Booster Unit Installationsanleitung Zusatzger t Manuel d installation Unit d acc l ration Manual de instalaci n Unidad booster Manuale di installazione Compressore ausiliario Booster Unit u LCBKQ3AV1 E Installatiehandleiding Boostereenheid Manual de instalac o Booster ueder Z 8 0 9 exeso IUSIN PIeZeXEN 21 CALTSTITLSNANI NIMIVA npunjo lt g gt 9106 9 aA 106 ep ev 62 lt D gt s opens A lt B gt gt A guapeAn HZ 01 02 Arenuer jo jueunjedeq Areno 9 appeeyyruas yeneyseA Buel pmepiny sxeay el v sipueuunyop pnyepreu uo nBeu 02 9 s B s V A ouogojop af Oy 3P263176 1 lt 09 gt ewaid lt g gt euis po ouelualoo ouAnzod gt n ef OEY Q 5 _A lt g gt ougigifz guapzod e V ouapaan ef py 2 1e eueyses ueunfgugn g 8018 0 UN v suipelou BY tz lt Q gt tibus ebed viebdsnu reweibiay dey 41 vr eVAjeysnu diey zz
18. IO 39 QVGIWHO3NOO 30 NOIOVuY 1030 39 DAIKIN LCBKQ3AV1 E Booster Unit Installation manual Maintenance personnel of the manufacturer or equivalent skilled CONTENTS personnel should install this unit T FIRSTOF ALE oriol er ei c datus 1 1 Safety Precautions 1 2 Special Notice of Product 1 3 Disposal Requirements 2 BEFORE INSTALLATION ccc 2 1 Standard Supplied Accessories 2 2 Example of System Configuration 2 3 Indoor Unit Constraints 3 SELECTION OF LOCATION 4 PLACING THE 4 1 Handling The 4 2 Installation the Unit 4 3 Draining the Unit 4 4 Installation Procedure 5 REFRIGERANT 5 1 Selection of Piping Material 5 2 Protection against Contamination when Installing Pipes tentent 5 3 teatro red 5 4 Connecting the Refrigerant Piping 5 5 Air Tight Test Vacuum Drying 5 6 Thermal Insulation for Piping 6 FIELD WIRING 6 1 Example of Wiring Entire 6 2 Procedure for Incoming Wiring 6 3 Wiring 6 4 Checking of Device and Installation Conditions 7 CHECKS AFTER WORK COMPLETION e 8 REFRIGERANT 11 9
19. No Refrigeration showcase AC220 240V CR Branch switch freezer L IP Overcurrent For refrigerator SIT circuit breaker DO box Remote tot mi FE Indoor FFY controller I unit Refrigeration showcase IP SIT AC 220 240V Booster unit a HE mE 1 E mal Earth leakage circuit XIM orem 1 breaker B p High frequency type For earth fault Freezer pereon rM 2 overload and short OM circuit protection 20 pd 1 2381 controller o Warning Sensor 1 E 6 input input Remote switch E8 291 Showcase interface x Note 1 eun rl 9 ACI00V Note 6 2 Procedure for Incoming Wiring Use conduit for power supply wiring Make sure the weak electric wiring i e for the remote controller between units etc and the power wiring do not pass near each other keeping them at least 50 mm apart Proximity may cause electrical interference malfunctions and breakage Be sure to connect the power wiring to the power wiring terminal block and secure it as described in 6 2 Procedure for Incoming Wiring Do not connect the power supply to the terminal block for the transmission wiring for warning alarm operation output and remote operation switch Otherwise the entire system will be dam aged Transmission wiring should be secured as described in 6 3 Wir ing Connection Secure wiring with clamp such as insulation lock ties to avoid con tact with piping Shape t
20. Service Manual for the checking method L4 The air passage 15 blocked obstacles blocking the air passage U1 Reverse phase of the power Exchange two wires out of supply three power supply wires U2 Voltage drop Check the voltage drop Check the connection of U4 UF Wrong wiring of transmis transmission lines between sion lines between units the outdoor unit and the air conditioner In the case of system dis Check if the air conditioner is UA connected as should be crepancy assembled E2 Electric leak See 1 Set the operating switch to the OFF position to reset the power sup ply and then return the switch to the ON position to restart the unit If the problem persists refer to the Service Manual N CAUTION Do not disconnect the power supply for 1 minute after setting the operating switch to ON Electric leak detection is performed for several seconds after the operating switch is set to ON and each compressor starts oper ating so disconnecting the power supply during that time will result in a false detection AN For dealers e After the test run is finished check that the piping cover and front panel are mounted e Atthe time of delivery to the customer use the Operation Manual and fully explain the handling of the equipment For precautions at the time of delivery refer to the provided Instal lation Manual for each unit as well English 11 3P248411 5B
21. door unit and the remote controller 3 Has the fuse on PCB melted f you have changed the power wire and the transmission line keep the power of the indoor unit air conditioner refrigeration showcase refrigeration unit cooler and the integrated heat con trol board turned on turn off the operation switch of the outdoor units and never fail to press the push button switch BS5 on PCB A1P in the electric accessory box right of the outdoor unit for at least 10 seconds Open the inspection door right on the upper right portion of the electric accessory box and operate the push button switch BS5 using an insulating rod See the right figure O O RESET 855 Inspection door right Upper right portion of the electric accessory box Refer to the Service Manual for other malfunction codes Take the following action if you find a malfunction code on the remote controller during the test run Defect installation Action to be taken code E3 E4 Shutoff valves closed shutot valves Check the transmission wire between the booster and the outdoor unit Wiring error or booster mal If the malfunction code EJ function of the transmission sists check the LED on the wire between the booster print board A2P in the elec and the outdoor unit tric accessory box of the booster unit Refer to the
22. e pipes no grounding effect is possible if hard plastic pip ing is used Telephone ground wires and lightning rods dangerous when struck by lightning due to abnormal rise in electrical potential in the grounding Be sure to install an earth leakage circuit breaker This unit uses an inverter so install the earth leakage circuit breaker that be capable of handling high harmonics in order to prevent malfunctioning of the earth leakage circuit breaker itself Earth leakage circuit breaker which are especially for protecting ground faults should be used in conjunction with main switch or fuse for use with wiring Electrical wiring must be done in accordance with the wiring dia grams and the description herein Do not operate until refrigerant piping work is completed If operated before complete the piping work the compressor may be broken down Never remove thermistor sensor or etc when connecting power wiring and transmission wiring If operated with thermistor sensor or etc removed the compres sor may be broken down This product have reversed phase protection detector that only works when the power is turned on If there exists black out or the power goes on and off which the product is operating attach a reversed phase protection circuit Running the product in reversed phase may break the compressor and other parts Attach the power wire securely Introducing power with a missing N phase or with a mista
23. er to Oper ation Method of Shutoff Valves for the tightening torque of the cap Cap Sealing part Not apply a screw lock agent Screw thread Apply a screw lock agent N CAUTION Apply a screw lock agent to the valve cover mount and the screw thread of the service port Otherwise dew condensation water will intrude inside and freeze Therefore refrigerant gas leakage or a compressor malfunction may result from the cap deformation or damage 5 5 Air Tight Test Vacuum Drying Ensure the following tests have been conducted after piping Check that the gas side and liquid side shutoff valves are open e Air tight test Always use the nitrogen gas Pressurize the high pressure side liquid side to the design pres sure 3 8MPa of the outdoor unit and pressurize the low pressure side suction side to the design pressure 2 5MPa of the indoor unit field supplied In this case they shall be accepted if no pressure drop is found for 24 hours through pressurization at least 5 minutes from the port and the liquid shutoff port shown in the right figure Check if there are any leakage areas in the case of pressure drop Vacuum drying Refer to the installation manual of the outdoor unit Liquid side shutoff valve port Port A 5 6 Thermal Insulation for Piping Always insulate connection pipes and branch pipes on the dis charge suction and liquid sides The liquid and gas pipe tem
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25. gth actual length b f lt 30m g x d is d1 d2 or e whichever is longer b c d lt 30m Between booster unit and refrigeration showcase equivalent length i lt 30m Max difference in height between booster unit and refrigeration showcase refer to the right figure Example of piping connection Gm v A Outdoor unit Indoor unit Air conditioning T a showcase L Refrigeration ER Unit cooler Refrigeration 0 lt H lt 10m Refer to the right figure Floor No of connection of booster unit LRYEQ16AY1 Max no of connection of booster unit Booster Booster unit unit PEEL Em Freezer Freezer showcase showcase d1 d2 English 5 2 Protection against Contamination when Installing Pipes Protect the piping to prevent moisture dirt dust etc from entering the piping Place Installation period Protection method More than a month Pinch the pipe Outdoor Less than a month Pinch or tape the pipe Indoor Regardless of the period Note Exercise special caution to prevent dirt or dust when passing piping through holes in walls and when passing pipe edges to the exterior 5 3 Pipe Connection Be sure to perform nitrogen permutation or nitrogen blow whe
26. h a minimum diameter of 19 1 mm Therefore be sure to use 1 2 H type with a minimum thickness of 1 0 mm If O type is used for piping with a minimum diameter of 19 1 mm a minimum thickness of 1 2 mm will be required In that case be sure to perform the blazing of each joint Be sure to perform piping work within the range specified in the following table lt Refrigerant piping size Piping size O D x min thickness mm Note 1 Liquid piping inlet outlet Note 1 Note 2 Liquid piping inlet Main liquid piping between booster unit and outdoor 6 4x0 8 O type unit Note 2 Suction piping Note 1 15 9 1 0 0 type Liquid piping outlet Between booster unit and refrigeration showcase Suction piping Between booster unit and refrigeration showcase LCBKQ3AV1 E Note 1 Discharge piping 9 5 0 8 0 type Discharge piping Main gas piping between booster unit and outdoor unit Note 2 If the size of the connection pipe of the refrigerating showcase exceeds that of the branch pipe shown in the table on the left install piping near the refrigerating showcase Refrigerant piping length and permissible difference in height Refer to the installation manual of the outdoor unit for the indoor unit Max permissible one way piping length equivalent length a b c d lt 130m dis di 92 or e whichever is longer Booster Unit Max branch piping len
27. he wires to prevent the structure such as the control box lid deforming And close the cover firmly Route high voltage wiring power supply wire earth wire and refrigeration operation output wiring through the wiring openings located on the side of the unit through holes on the left side Wiring diagram label back of the cover of the electric accessory box Electric wiring earth wire high voltage Transmission wire low voltage Route low voltage wiring transmission wire refrigeration opera tion input wiring and remote switch wire through the wiring open ings located on the side of the unit through holes on the right side English Block the gap shaded area shown in the figure below with seal ing material such as putty if an intrusion by small creatures is pos sible Do not touch the high pressure piping in the shaded area SENS during wiring Sus Gap Block with sealing material 6 3 Wiring Connection High voltage wiring Power supply wiring Refrigeration opera tion output wiring and earth wire Power supply 1 phase 220 240V Overcurrent circuit breaker Earth leakage S P ci
28. iring REMOTE OFF ON Outdoor unit Booster unit OR uH 1 0 2 2 2 T1T2F1F2 4 12 15 ejpjejp Transmission gn re 4 Never connect power supply wire Refrigeration operation e input wiring p 50mm or more Refrigeration operation input wiring High voltage wiring Low voltage wiring Transmission wire voltage wing with the attached clamp lt Connection for remote switch wire gt Setthe operation switch to Remote as shown in the figure below to remotely start up and shut down Use a remote switch that has a contact assuring the minimum applicable load of DC12V 1mA REMOTE OFF ON AUFS FINIS Remote switch Constant a contact input between 1 and 2 6 4 Checking of Device and Installation Conditions Be sure to check the followings lt For those doing electrical work gt See 6 2 Procedure for Incoming Wiring 1 Make sure there 15 no faulty power wiring or loosing of a nut See 6 3 Wiring Connection 2 Has the insulation of the main power circuit deteriorated Measure the insulation and check the insulation is above regular value in accordance with relevant local a
29. ken N phase will break the unit Never connect the power supply in reversed phase The unit can not operate normally in reversed phase If you connect in reversed phase replace two of the three phases Make sure the electrical unbalance ratio is no greater than 2 If it is larger than this the unit s lifespan will be reduced If the ratio exceeds 4 the unit will shut down and an malfunction code will be displayed on the indoor remote controller Connect the wire securely using designated wire and fix it with attached clamp without applying external pressure on the termi nal parts terminal for power wiring terminal for transmission wir ing and earth terminal 8 English
30. l an R410A solenoid valve on the primary side of the mechanical thermostatic expansion valve Max operating differ ential pressure of 3 5 MPa 35 bars or over described above for each indoor unit Install a filter on the primary side of the solenoid valve described above for each indoor unit Determine the filter mesh count based on the size specified by the solenoid valve and mechanical ther mostatic expansion valve being used Route the path to the indoor unit heat exchanger so that the flow of refrigerant is from top to bottom When installing a number of indoor units be sure to install them at the same level Use the electric heater defrosting as the defrosting type Hot gas defrosting models cannot be used 3 SELECTION OF LOCATION Select a location for installation that meets the following conditions Get the customer s permission 1 There is no danger of fire due to leakage of inflammable gas 2 Select the location of the unit in such a way that the sound gener ated by the unit disturb anyone 3 The foundation is strong enough to support the weight of the unit and the floor is flat to prevent vibration and noise generation 4 The piping length between the booster unit and outdoor unit or between the booster unit and indoor unit may not exceed the allowable piping length Refer to REFRIGERANT PIPING 5 When installing the unit outdoors install it preferably in a location that is not exposed to rai
31. m on the bottom frame depending on the condition of the installation location If the unit is installed in a poorly drained location install an addi tional drain pan optional accessory Check drainage of the drain pan after completing the installation work and make sure that the water runs smoothly 4 4 Installation Procedure 1 Fit the drain holder to the top of the drain socket prong 2 Fit the drain socket in drain hole A of the bottom frame C of the unit and turn it about 40 degrees clockwise E Drain hole position 3 Plug hole caps in other drain Drain socket ES holes B E from the under ey 222 side to prevent water from a Drain receiver leaking 4 Connect the hose to the 3 Hole cap drain socket using a com mercial plastic hose 25 mm and a hose band If the hose is long and hangs be careful not to bend it halfway through Booster unit 4 Drain socket Drain hose Take it out down 2300mm Ifinstalling a drain hose directly to the booster unit reserve the space described above 5 REFRIGERANT PIPING To Piping Work Contractors Do not use flux at the time of brazing and connecting refrigerant pipes Use phosphorous copper brazing filler metal BCuP 2 which does not require flux Chlorine based flux causes piping corrosion Furthermore if fluoride is contained the flux will have adverse influences on the refrigerant piping line s
32. n 6 The space around the unit is adequate for servicing and the min imum space for air inlet and air outlet is available See the Installation Space Examples for the minimum space requirements Installation Space Examples During installation install the units using the most appropriate of the patterns shown in the following figure for the location in ques tion taking into consideration human traffic and wind Asregards space in front of the unit consider the space needed for the local refrigerant piping when installing the units f the work conditions in the following figure do not apply contact your dealer or Daikin directly When installed as a single unit 1 When installed in serial gt 2500mm 2500mm Piping slot 2500mm 2500mm Front side Front side 2500mm 2200mm 2500mm 2500mm 200mm h 2500mm V P Booster unit CAUTION Power supply y Unit cooler Control Power supply oono 3 panel panel pone Vaid Power supply 54 45 1 5m or more 1 5m or more y 4 5m or more o Showcase 1 An inverter booster unit may cause electronic noise generated from AM broadcasting Examine where to install the main booster unit and electric wires keeping proper distances away fr
33. n brazing Refrigerant pipe Location to Regulator be brazed 11 Q Nitrogen 3 Taping Nitrogen Brazing without performing nitrogen permutation or nitrogen blow into the piping will create large quantities of oxidized film on the inside of the pipes adversely affecting valves and compressors in the refrigerating system and preventing normal operation The pressure regulator for the nitrogen released when doing the brazing should be set to 0 02 MPa about 0 2kg cm Enough to feel a slight breeze on your cheek Note Do not use anti oxidants when brazing the pipe joints Residue can clog pipes and break equipment 5 4 Connecting the Refrigerant Piping N CAUTION Do not connect an onsite piping to an incorrect one Wrong con nection will cause a malfunction Remove the piping slot cap before connecting the pipe A Liquid piping inlet Connect the pipe to the liquid pipe refrigeration of the outdoor unit Set the piping such Refrigeration of a that it slants vain gas piping of showcase SHOWCASE a downward oor unit Liquid 27 re mier B Liquid piping outlet piping Connect from the upper part of the main pipe fs prevent the unit from oil 9 outlet Suction Booster piping unit Piping length shall be 30 m or less D Discharge piping and liquid refrigerant fl
34. nd national regulations lt For those doing pipe work gt 1 Make sure piping size is correct See 5 1 Selection of Piping Material 2 Make sure insulation work is done See 5 6 Thermal Insulation for Piping 3 Make sure there is no faulty refrigerant piping See 5 REFRIGERANT PIPING 7 CHECKS AFTER WORK COMPLETION Make sure the following works are complete in accordance with the installation manual Piping work W Wiring work Air tight test Vacuum drying W Installation work for indoor unit Refrigeration unit cooler refrigeration showcase freezer showcase air conditioner Installation work for outdoor unit Drainage water 10 English 8 REFRIGERANT REPLENISHMENT Operation the booster is not needed to replenish refrigerant Follow the installation manual of the outdoor unit for the replenish ment procedure 9 TEST RUN A For test run operators Do not operate the outdoor unit alone on a trial basis Use the following procedure to perform a test run after installation work is complete for the entire system Test run procedure 1 Fully open the shutoff valves on the gas and liquid side of the out door unit and the booster unit 2 Check that the electric accessory box lids of the outdoor unit the booster unit and the indoor unit air conditioner refrigeration showcase refrigeration unit cooler and the piping cover of the outdoor unit and the booster unit are closed Then
35. om ste reo equipment personal computers etc Particularly for locations with weak reception ensure there is a distance of at least 3 meters for indoor remote controllers place power wiring and transmission wiring in conduits and ground the conduits 2 If condensate may drip on downstairs or walkway depending on the floor condition take a measure such as the installation of drain pan kit sold separately 3 The refrigerant R410A itself is nontoxic nonflammable and is safe If the refrigerant should leak however its concentration may exceed the allowable limit depending on room size Due to this it could be necessary to take measures against leakage See Engineering Data for details 4 PLACING THE UNIT 4 1 Handling the Unit 1 Decide on the transportation route 2 If hanging the unit use a cloth sling to prevent damaging the unit Keeping the following points in mind hang the unit following the procedure shown in the following figure Use the slings bearing product mass enough Lift the unit with 2 belts of the at least 4m long Put cushion cloth where the slings contact the casing Lift the product with cave at the product center of gravity posi tion If using the handle of unit carry the unit slowly with having the handle Belt sling Belt sling Cushion cloth gt LL NAM s AL M i Handle Hang on the edge of the bottom plate
36. or unit and the outdoor unit refer to the installation manual provided for the indoor unit and the outdoor unit Optional accessories are required for the installation of the prod uct Refer to the information on optional accessory 2 1 Standard Supplied Accessories The following accessories are included The storage location of the accessories is shown in the figure Note Do not throw away any of the accessories until installation is complete Name Clamp Manual Drain socket Quantity 3 pcs 1 pc 1 pc AD 2 Installation 2 Shape a Manual i Name Drain receiver Hole cap Quantity 1 pc 4 pcs Shape lt gt 2 2 Example of System Configuration Name Outdoor unit Booster unit Shape Indoor unit Name 7 Refrigeration Air conditioner Blower coil Showcase Shape Indoor unit Remote con caol Warning troller for Name Freezer panel 9 Defrost panel air Blower coil Showcase 06 conditioner Shape English 1 Installation manual 2 Clamps 2 3 Indoor Unit Constraints The design pressure for the indoor unit is 2 5 MPa or more Install an R410A mechanical thermostatic expansion valve on each indoor unit Insulate the feeler block of the mechanical thermostatic expan sion valve Instal
37. owin in from the main pipe while the booster unit is stopped Createa trap on the gas pipe at 5 m intervals if the outdoor unit is located above the booster unit to ensure the smooth return of oil in the riser pipe Refer to Figure below Create a trap on the gas pipe at 5 m intervals if the booster unit is located below the outdoor unit to ensure the smooth return of oil in the riser pipe Refer to Figure 2 below CD When the refrigeration showcase is below the booster unit 2 When the outdoor unit is above the booster unit Create a trap Create a trap Booster Refrigeration showcase unit 9 Booster unit About 5m Operation Method of Shutoff Valves Follow the instructions below when operating each shutoff valve N CAUTION Do not open the shutoff valve until the steps specified in 6 4 Checking of Device and Installation Conditions is com pleted Do not leave the shutoff valve opened without turning the power on otherwise refrigerant may be condensed in the compressor and the insulation of the main power supply circuit may be degraded Be sure to use an exclusive tool to handle the shutoff valve The shutoff valve is not of back sheet type Excessive force imposed may break the valve Usea charge hose when using the service port Make sure that there is no refrigerant gas leakage after the valve cover and cap are securely tightened Tightening
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39. perature are as follows Liquid pipe arrival minimum temperature 5 C For outdoor unit 10 C To indoor unit Gas pipe arrival minimum temperature 45 C For indoor unit 100 C To outdoor unit Max temperature Use a discharge pipe whose heat resistance is 120 C or more as its maximum temperature reaches about 100 C Use a suction pipe and liquid pipe whose heat resistance is 80 C as the stan dard specification Refertothe installation manual attached to the outdoor unit for the outdoor unit side Insulation field supply Liquid piping inlet between booster unit and main liquid pipe Liquid piping outlet between booster unit and refrigeration showcase Insulation field supply Discharge pipe Connect piping up to the joint so that piping may not be exposed Heat resistance 120 C or more N CAUTION Always insulate the pipe joint for onsite piping An exposed pipe can cause dew condensation and burn by con tact English 6 FIELD WIRING A switch that allows all poles to be switched on and off from the main power supply must be installed To Electric Engineering Contractors This switch must have a contact gap of at least 3 mm Be sure to install an earth leakage breaker The product incorpo rates inverter equipment In order to prevent the malfunctioning of the earth leakage breaker make sure that the earth leakage breaker withstands harmonic interfe
40. r unit Gas pipe arrival minimum temperature 45 C For indoor unit 100 C To outdoor unit Max temperature In the case of thickness insufficiency add additional insulation material or renew the existing insulation material Renew the insulation material if the insulation material is degraded Keep the following points in mind for the reuse of existing heat exchangers Units with insufficient design pressure since this product is an R410A unit require a lower stage design pressure of 2 5 MPa 25 bars Units for which the path to the heat exchanger has been routed so that the flow of refrigerant is from bottom to top Units with copper tubing or fan corrosion Units that may be contaminated with foreign matter such as rub bish or other dirt English 5 1 Selection of Piping Material Make sure that the inner side and outer side of the piping used is clean and free of contaminants such as sulphur oxide dust chips oil and fat and water It is desirable that the maximum oil adhesion in the piping is 30 mg per 10 m Use the following type of refrigerant piping Material Seamless phosphorus deoxidized copper tube C1220T O for a maximum outer diameter of 15 9 mm and C1220T 1 2H for a mini mum outer diameter of 19 1 mm Refrigerant piping size and wall thickness Decide the size and thickness from the following table This product uses R410A The withstand pressure of O type may be insufficient if it is used for piping wit
41. rcuit breaker 4 O Earth wire AL Power supply Y terminal block poo rp Attach the insulation sleeve Refrigeration operation 2 output wirin Power supply wire Earth terminal Fix refrigeration operation Tv output wiring 51 S2 with g DO RS the attached clamp Fix power supply wiring Y L N phases with the attached clamp When two wires are connected to a single terminal connect them so that the rear sides of the crimp contacts face each other Also make sure the thinner wire is on top securing the two wires simultaneously to the resin hook using the accessory clamp 1 Clamp 1 Terminal block Crip style terminal Wire narrow Wire thick CE AA Resin hook Power circuit safety device and cable requirements A power circuit see the following table must be provided for con nection of the unit This circuit must be protected with the required safety devices i e a main switch a slow blow fuse on each phase and an earth leakage circuit breaker Use copper conductors only Use insulated wire for the power cord Select the power supply cable type and size in accordance with relevant local and national regulations Specifications for local wiring are in compliance with IEC60245 Use wire type HO5VV when protected pipes are used Use wire type HO7RN F when protec
42. rence Do not operate the booster unit until refrigerant piping work is completed or otherwise the compressor will malfunction Do not remove any electrical components such as thermistors or sensors when connecting power supply wires or transmission wires The compressor may malfunction if the booster unit is oper ated with such electrical components removed N CAUTION All field wiring and components must be installed by a licensed electrician and must comply with relevant local and national reg ulations Be sure to use a dedicated power circuit Never use a power sup ply shared by another appliance Neverinstall a phase advancing capacitor As this unit is equipped with an inverter installing a phase advancing capacitor will not only deteriorate power factor improvement effect but also may cause capacitor abnormal heating accident due to high frequency waves Only proceed with wiring work after blocking off all power Always ground wires in accordance with relevant local and national regulations This machine includes an inverter device Connect earth and leave charge to eliminate the impact on other devices by reducing noise generated from the inverter device and to prevent leaked current from being charged in the outer hull of the product Donot connect the ground wire to gas pipes sewage pipes light ning rods or telephone ground wires Gas pipes can explode or catch fire if there is a gas leak Sewag
43. ted pipes are not used Minimum Recom Phase and Aen Voltage circuit mended frequency amp fuses LCBKQ3AV1 41 50Hz 220 240 15A 20A Refrigeration operation output wire specifications Electric wire thickness 0 75 1 25mm Max wiring length 130m N CAUTION Refer to the 6 1 Example of Wiring Entire System by all means when connecting the operation output wiring A compressor failure may result if the operating output wiring is not connected Low voltage wiring transmission wire refrigeration operation input wiring and remote switch wire Connect low voltage wiring between the booster unit and the outdoor unit the booster unit and the integrated heat control board and the remote switch by referring to the figure below Precautions for low voltage wiring Never connect the 220 240V power supply to the terminal block of low voltage wiring The entire system could be damaged Isolate low voltage wiring from high voltage wiring power supply wire refrigeration operation output wiring and earth wire by at least 50 mm Always install low voltage wiring using vinyl cord with a 0 75 1 25 mm sheath or cable duplex Install low voltage wiring within the limit described below Exceed ing the limit can cause transmission problems Distance between the booster unit and the outdoor unit 100 m Connection for transmission wire and refrigeration operation input w
44. torque Check with the following table the sizes of shutoff valves incorporated by each model and the tightening torque values of the respective shutoff valves Shutoff valve sizes B Liquid piping outle Connect the pipe to the liquid pipe of the refrigeration showcase C Suction pipe Connect the pipe to the gas pipe of the refrigeration showcase D Discharge pipe Connect the pipe to the gas pipe refrigeration of the outdoor unit Donotletthe onsite piping contact other piping the bottom frame and the side panel of the product Precautions for piping Always connect the piping within the range of the max permissi ble piping length and the permissible difference in height Bendthe pipe allowing for a possibly large diameter Do not bend the pipe repeatedly Install a gauge joint to install the pressure sensor on the inlet and outlet pipes of the booster unit when connecting the AIRNET sys tem Refer to the Service Manual for details Liquid side shutoff valve 9 5 Gas side shutoff valve 9 5 Service port 185 Valve cover E 4 Hexagon hole Sealing part Shaft D Shutoff Tightening torque Nem closes clockwise valve sizes Shaft valve body Valve cover Service port 9 5 5 4 6 5 Hexagon 135 165 11 5 13 9 wrench 4mm FETO method
45. turn on the outdoor the booster unit and indoor units air conditioner refrigeration showcase refrigeration unit cooler 3 Turn on the operation switch from the inspection door of the out door unit and the booster unit The outdoor fan rotates in about 10 minutes after the operation switch is turned on and the com pressor starts 4 Push the ON OFF button on the remote controller of the outdoor unit air conditioner to operate the unit 5 Check the sealing condition through the sight glass of the outdoor unit In case of shortage of refrigerant check if the refrigerant is charged to the specified level 6 Check the following on each unit Cold air should be blowing and the temper ature should decrease to the preset level Refrigeration showcase The unit should start defrosting operation by the time set on the timer Cold air should be blowing and the temper ature should decrease to the preset level Refrigeration unit cooler The unit should start defrosting operation by the time set on the timer Air conditioner Cold air or hot air should be blowing 7 Be sure to turn off the operation switch before turning off the power Error diagnosis Checkthe following if nothing is displayed on the remote controller during the test run Indoor unit air conditioner gt 1 Is the power turned on 2 Is the wire broken or incorrectly wired between the power the in
46. uch as the dete rioration of refrigerating machine oil CAUTION All field piping must be installed by a licensed refrigeration tech nician and must comply with relevant local and national regula tions Precautions for reuse of existing refrigerant piping heat exchangers Keep the following points in mind for the reuse of existing refrig erant piping heat exchangers A malfunction may result if there is deficiency Donotuse the existing piping in the following cases Perform new piping instead The piping is different in size The strength of the piping is insufficient The compressor of the booster unit previously used caused a malfunction An adverse influence of residual substances such as the oxi dation of refrigerant oil and the generation of scale is consid ered fthe indoor unit or outdoor unit is disconnected from the piping for a long time The intrusion of water and dust into the piping is considered The copper pipe is corroded The refrigerant of the booster unit previously used was other than R410A e g R404A R507 or R407C The contamination of the refrigerant with heterogeneity is con sidered fthere are welded connections midway on the local piping make gas leakage checks on the welded connections Be sure to insulate the connection piping The liquid and gas pipe temperatures are as follows Liquid pipe arrival minimum temperature 5 C For outdoor unit 10 C To indoo
47. ut installation Work Do not attempt to install the booster unit yourself Improper installation may result in water leakage electric shocks or fire Install the booster unit in accordance with the instructions in this installation manual Improper installation may result in water leakage electric shocks or fire When installing the unit in a small room take measures against to keep refrigerant concentration from exceeding allowable safety limits in the event of refrigerant leakage Contact the place of purchase for more information Excessive refrigerant in a closed ambient can lead to oxygen deficiency Be sure to use only the specified accessories and parts for instal lation work Failure to use the specified parts may result in the unit falling water leakage electric shocks or fire Install the booster unit on a foundation strong enough to withstand the weight of the unit A foundation of insufficient strength may result in the equipment falling and causing injury Carry out the specified installation work after taking into account strong winds typhoons or earthquakes Failure to do so during installation work may result in the unit fall ing and causing accidents Make sure that a separate power supply circuit is provided for this unit and that all electrical work is carried out by qualified person nel according to local laws and regulations and this installation manual An insufficient power supply capacity or
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