MULTI–SPLIT SYSTEM AIR CONDITIONER TECHNICAL
Contents
1. 1 i E F DI 60600 BLK SOLENOID VALVE C SOLENOID VALVE D YELI 851 2 5253 205 04 4 Outdoor Unit DKR8585C TERMINAL 1 NORMAL2 NORMAL 1 n GRN GRY GRY x D I ELECTRIC WIRING SYSTEMS WIRING SYSTEM DIAGRAM POWER SUPPLY OUTDOOR UNIT si DE TERMINAL 3P M D sE UNIT A Go D P end 8P One D OtHeot He UNIT B a d 2 ov Or D o eh 8 OF ol ro amp LL el Deel 6 INSTALLATION INSTRUCTIONS 6 1 Installation Site Selection Maximum Allowable Tubing Length and Elevation Difference H The Multi Split System outdoor unit should be installed as close to the indoor units as possible Maximum allowable length of the refrigerant tubing and elevation difference between outdoor and 3 indoor units are shown in Table 6 1 and Fig 6 2 while outdoor and 4 indoor units are shown in Table 6 2 and Fig 6 3 INDOOR UNIT Less than elevation difference H between OUTDOOR the 2 units UNIT Fig 6 1 Table 6 1 3 indoor unit s combination Combination Max allowable SEN 3 Limit of elevation Required amount of E tubing length at S ter 9 difference H additional Outdoor Unit Indoor Unit shipment m gin m refrigerant g m A AWR2. oO Power relay PR2 35uF Fan Motor Capacitor C1 Relay R4 Fan Motor Capacitor C2 Relay R3 gi Relay R2 S Relay R1 Power relay PR1 e Parts Layout in Unit Heat exchenger coil pe Compressor 2 CM2 5 Indoor Unit A and B J 80807045E 1 700W 40u Compressor 1 CM1 o Indoor Unit C Dual System Kit 80805045C 1 500W 35uF Fan motor Upper KFC6T 91C5P FM1 5uF Lower KFC6T 91C5P FM2 5uF 39 Dual System Kit DKR8585C Terminal Plate Terminal Plate 3 4P To Indoor Unit C2 el Terminal Plate 2 4P To Indoor Unit C1 m Terminal Plate 1 5P To Outdoor Unit Electric Parts PCB Ass y Solenoid coil SVC 1 H ged Solenoid coil SVC 2 3 E 40 12 CHECKING ELECTRICAL COMPONENTS 12 1 Measurement of Insulation Resistance The insulation is in good condition if the resistance exceeds 1MQ 12 1 1 Power Supply Wires Clamp the ground wire of the power supply wires with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on either of the power wires Fig 12 1 Then measure the resistance between the ground wire and
3. 393 425 444 148 177 213 Unit mm 4 REFRIGERANT FLOW DIAGRAM AER534QC Outdoor Unit 3 Indoor Unit s Combination Wide tube O D Outdoor Unit NE Indoor Unit A an AERS34QC SH AWR609 A 12 7mm 7 H Compressor 2 Compressor 1 127 Indoor Unit C Accumulator Accumulator C AWR518 B O O Kk Q 8 ES SVC SVD o Lo Gerd fre 5 Hp 2 put Indoor Unit B 5 Narrow tube AWR609 Si i A SEH Capillary for Capillary for go Jomm 7 gd A SVA liguid injection liguid injection Capi box 1 4 E uu E Strainer Strainer E FM J L Y p SVB D lt n gt i Ut pe Narrow tube O D 26 35mm 1 4 S m Narrow tube service valve Wide tube service valve Mw Capillary tube with DKR8585C AER534QC Outdoor Unit 4 Indoor Unit s Combination with Dual System Kit Wide tube Wide tube O D Outdoor Unit Dual System Kit O D Indoor Unit A eT AER534QC DKR8585C
4. 9 4 6 With both the Lo and Hi knobs of the manifold valve open run the vacuum pump The operation time varies with the capacity of the pump Run the pump at least 30 minutes Evacuation is successful if the vacuum gauge reading remains 75 cmHg or more for at least 10 seconds after closing both the Lo and Hi knobs of the manifold valve 9 4 7 With the vacuum pump still running turn both the narrow and wide service valves all the way in to close the valves position a Then stop the pump 9 4 8 After removing the vacuum hoses from the service valves replace the flare nuts and bonnets on the valves The refrigerant circuit is now ready for charging 9 5 Refrigerant charging 9 5 1 After evacuation is completed charge the circuit with the proper amount of refrigerant SA Disconnect switch Field supply NOTE NE hov gt Power The proper amount of refrigerant is specified on LEN L sl Supply the nameplate of the outdoor unit and in Section H gt 2 1 Unit Specifications in the service manual i 9 5 2 Use a hose to connect the narrow tube service O H ovirdnth valve to the liquid port of the charging cylinder Fig 9 3 Charging cylinder SS 9 5 3 Purge air from the hose Do this by opening the charging cylinder valve then slightly loosening the connection to the narrow tube service valve Wait a few momen
5. cylinder Fig 6 37 10 7 Charging additional refrigerant 10 7 1 When tubes are extended Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came with the indoor unit Charge additional refrigerant in liquid state Never charge additional refrigerant if refrigerant is leaking from the unit Follow Ne instructions given in 10 6 In case refrigerant is leaking and completely carry out repairs Only then should you recharge the refrigerant 10 8 Retro fitting existing systems 10 8 1 Use of existing units Never use new refrigerant R407C for existing units which use R22 This will cause the air conditioner to operate improperly and may result in a hazardous condition 10 8 2 Use of existing tubing If replacing an older unit that used refrigerant R22 with a R407C unit do not use its existing tubing Instead completely new tubing must be used 38 11 ARRANGEMENT OF ELECTRICAL COMPONENTS Outdoor Unit AER534QC e Terminal Plate Terminal Plate 8P m d To Indoor Unit A and B olololololololo ooroo Terminal Plate 5P OI To either Indoor Unit C QI OL or Dual System Kit ele ele Ollo X Terminal Plate 3P ele po i To Power supply ele Electric Parts Compressor Motor Capacitor C3 Compressor Motor Capacitor C4 Timer T
6. 8 2 3 Only outdoor unit does not run Check power relay in outdoor unit Measure coil resistance of power relay PR1 PR2 Check connectors in outdoor unit Are green green connectors attached Circuit breaker is tripped Power failure gt Reset breaker Wait for recovery or contact power company together in outdoor unit NOTE gt Reattach GRN GRN connectors Refer to 9 6 Reattaching green connectors for operation 8 3 Some part of air conditioner does not operate 8 3 1 Only outdoor fan does not run Fan cannot Check fan rotation be turned Turn fan gently once or twice by hand e Measure resistance of outdoor fan motor winding Check fan motor capacitor C1 or C2 gt 23 e Check fan casing for foreign matter on inside gt Fan motor burnout or foreign matter in bearings gt Remove foreign matter or repair Repair or replace 8 3 2 Only compressor does not run Check compressor motor Overload relay is working capacitor 62 C3 or 03 64 OLR 1 to 4 YES Measure resistance of Temperature of compressor is compressor motor winding abnormally high YES Y YES Refrigerant gas shortage Charge refrigerant gas R22 NO Y Rotor may be locked up Check Timer in outdoor unit O
7. 89 Indoor Unit C1 AWR609 A AWR609 EE Compressor 2 Compressor 1 mm T Accumulator Accumulator 7 8 B O Os H I 3 o o 1 3 DRY SVC SVD m i VZ 8 Lu I d S I S Indoor Unit B 5 Indoor Unit C2 AWR609 E AWR609 Capillary for Capillary for i 7 H A SVA liguid injection liguid injection SVC1 H S 3 ut Sy At EN 5 Strainer Strainer Strainer cm 5 i S CTH zd TH g p SVB HD MED y HL T SVC2 tL 4 pa ment St Narrow tube gt L Check port 2 Narrow tube O D O D 6 35mm 6 35mm 1 4 1 4 gt lt Narrow tube service valve RI Wide tube service valve Mw Capillary tube 10 5 ELECTRICAL DATA 5 1 Electrical Characteristics The values in the table below indicate the sum of indoor units which are in running condition Outdoor Unit AER534QC 230V Single phase 50 Hz 3 Units 4 Uni Number of indoor unit spis A B C A B C1 C2 Running amp A 19 0 19 0 Rating Conditions Power input kW 4 05 4 08 Running amp A 22 1 23 0 Full Load Conditions Power input 4 77 4 97 Rating Conditions Indoor Air Temperature 27 C D B 19 C W B Outdoor Air Temperature 35 C D B Full Load Conditions Indoor Air Temperature 32 C D B 23 C W B Outdoor Air Temperature 43 C D B 5 2 Electric Wiring Diagram AER534QC Outdoor Unit TERMINAL PLATE 2 NDOOR UNIT 12 ua pen RR zm LT e p
8. 1160 T Shipping volume m3 0 59 Remarks Rating conditions are DATA SUBJECT TO CHANGE WITHOUT NOTICE Indoor air temperature 27 C D B 19 W B Outdoor air temperature 35 C D B 24 C W B Outdoor Unit AER534QC with DKR8585C Option Symbol of indoor unit A B C1 C2 AWR609 Power Source 220 240 V 50 Hz MEME Lit DT ami 8 Me wady wl ma 0 AA rs e 36 200 d AR c n sc S C1 C2 B CA eenn Nad TN EE KE E ne Voltage rating N 290 ii ira Z Avalablevollagerangs ui ass SI Running amperes Al V 22 EE ieee in EE x S re cog I I mw oa E 77 Compressor locked rotor amperes 43 Fansped n CMM ERE Ee Rotary Hermetic Refrigerant Amount charged at shipment 91 R4070 A B 1 300 C1 02 1200 h Refrigerant control jl Gapillary tube Operation sound gt EN en S Refrigerant tubing connections NNN NN Max allowable tubing length at shipment MU NET NO ene Refrigerant tube Narrow tube mmn Un A B C1 C2 635 14 EE Wide tube mm n n AB C2 9 52 9 8 7 eee Refrigerant tube kit Optional s PO i ee AERS34QC IMMANE DKR8585C 7 i Pee T E ue vomit SE bo gt Width mm 940 213 zc Depth nl NM mm MONY SE S Width mm 1 036 340 Depth ml nee LE E M i i i m C E o n LONE M Shipping volume m3 0 59 0 031 DATA SUBJECT TO CHANGE WITHOUT NOTICE Remarks Rating conditions are Indoor air temperature 27 C D B 19 W B Ou
9. 3 Tools specifically for R407C For servicing use the following tools for R407C Tool Distinction Gauge manifold Charging hose Gas leak detector Refrigerant cylinder Charging cylinder Tools specifically for R407C Refrigerant recovery unit e Vacuum pump with anti reverse flow 1 Solenoid valve installed type which prevents oil from flowing back into the unit when the power is off is recommended Vacuum pump 2 can be used if the following adapter is attached e Vacuum pump adapter reverse flow prevention adapter 3 Solenoid valve installed adapter attached to a conventional vacuum pump Electronic scale for charging refrigerant Flare tool Bender Tools which can be commonly Torque wrench used for R22 and R407C Cutter Reamer Welding machine nitrogen gas cylinder The above tools specifically for R407C must not be used for R22 Doing so will cause malfunction of the unit For the above vacuum pump 1 2 and vacuum pump adapter 3 those for R22 type units can be used for R407C type However they must be used exclusively for R407C and never alternately with R22 10 4 For tubing installation procedures When the tubes are connected always apply HAB oil on the flare portions to improve the sealing of tubing The following is the HAB oil generally used Esso ZERICE S32 NOTE For details on tubing installation procedures refer to the installation manuals attached to
10. OFF oor Lise HI e ES SEN nous N Q too Unit B e t o E K gt V 001 Sg l oo le Terminal 5P Unit C1 SLE S Enn 2 ATK P3448G i e roo 3 To unit C1 r f OL Unit C Terminal 5 P Mio S 0107 01 o DIO on Oa d Gle 1 1 44Q i TTO 10 i Unit C2 Indoor unit B EEE Outd it To unit C2 Earth ground utaoor UNI 3 3 D 2 I NOTE Q uU Be Unit A B AWR609 V To out C Unit C AWR518 door unit Lina Q ro or i or S hovo Unit A B AWR609 Unit C1 C2 AWR609 7 FUNCTION Solenoid Valve Operation In the refrigeration circuit containing compressor 2 CM2 the operation of the two solenoid valves SVA and SVB are synchronized and controlled by the thermo ON signal of the indoor units Opening both of these solenoid valves SVA and SVB makes the two indoor units indoor unit A and B operate Opening just one solenoid valve makes only one indoor unit run either indoor unit A or B 3 minutes timer controlling the operation of compressor 2 CM2 starts counting as soon as the thermo ON signal is generated by indoor unit A or B Compressor 2 CM2 stops only under the condition when both indoor unit A and B have been stopped Once the compressor stops it will not start running again for at least 3 minutes even there has been an ON signal from one of the indoor units In order to save compressor power solenoid valv
11. and then gradually returns to its original position The range of deflection and deflection time differ according to the capacity of the capacitor 42 ciare Compressor motor capacitor Multimeter Fan motor capacitor Fig 12 5 argo cflimz s Via Varese 90 21013 Gallarate Va Italy Tel 39 0331 755111 Fax 39 0331 776240 www argoclima it Printed in italy
12. around the outdoor unit for free air da flow and servicing is given in Figs 6 5a and 6 5b The avoid the effects of humidity and ground moisture the unit should be placed on concrete blocks or slab at least 10 cm high above ground level Figs 6 6 The unit must be level and be anchored securely to its base with anchor bolts or the like An unsteady foundation will cause abnormal noise and vibration Required space around the unit AER534QC Obstacle above LLLLLLL LLLLLLL 7 F A Air intake Mintsem ave L KSC 2 side 2 Min 60 cm e 3 N Min 15 cm 50 cm N EN Air discharg Air discharge Min Obstacle 777777 7 7 7 rd Top view Ground Fig 6 5a Fig 6 5b Air intake Air intake Fig 6 6 6 3 Installation with Dual System Kit The Dual System Kit splits the refrigerant circuit into two circuits enabling two room air conditioning with a single outdoor unit When using the Dual System Kit two indoor units four units in total can be connected to a single outdoor unit Indoor Unit C1 Indoor Unit C2 Outdoor Unit Dual System Kit Fig 6 7 1 First remove the capi box to install the Dual System Kit 2 Connect the supplied connecting pipe to the Dual System Kit 3 Affix the Dual System Kit on the rear surface of the outdoor unit with the supplied tappi
13. correct 21 8 2 Air conditioner does not operate 8 2 1 Circuit breaker trips or fuse blows A When the circuit breaker is set to ON it is tripped soon Resetting is not possible There is a possibility of ground fault Check insulation resistance If resistance value is 1MQ or less insulation is defective NO Set circuit breaker to OFF D Remove both power supply wires and inter unit wires from terminal plate in outdoor unit Measure insulation resistance of outdoor unit Remove inter unit wires from terminal plate in indoor unit Measure insulation resistance of indoor unit Insulation of outdoor unit is defective e Measure insulation resistance of electrical parts in outdoor unit Insulation of indoor unit is defective e Measure insulation resistance of electrical parts in indoor unit B Circuit breaker trips in several minutes after turning the air conditioner on There is a possibility of short circuit Check capacity of circuit breaker Capacity of circuit breaker is suitable Measure resistance of outdoor fan motor winding FM Measure resistance of compressor motor winding CM1 CM2 Replace with suitable one larger capacity 22 8 2 2 Neither indoor nor outdoor unit runs Power is not supplied gt Check power supply Power is being supplied to the outdoor unit _
14. for only the outdoor unit Fig 9 5d NEE When opening or closing the service valve stem use the supplied accessory hex wrench Be sure to fully seat the wrench before turning the Open valve Close d Fig 9 5c Condition at Evacuation Condition at Charging in the Field c SSS D Vr Gaven Idd Va JL ws L Fig 9 5d Condition at Charging with Only Outdoor Unit d Zi 31 Va 10 REFRIGERANT R407C SPECIAL PRECAUTIONS WHEN SERVICING UNIT 10 1 Characteristics of new refrigerant R407C 10 1 1 What is new refrigerant R407C R407C is a new refrigerant that contains three types of non azeotropy type mixed refrigerant which does not adversely affect the Earth s ozone layer Its refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant R22 10 1 2 Components mixing proportions HFC32 23 HFC125 25 HFC 134a 52 10 1 3 Characteristics Less toxic more chemically stable refrigerant Composition of refrigerant R407C changes whether it is in gaseous phase or liquid phase Thus when there is a refrigerant leak the basic performance of the air conditioner may be degraded because of a change in composition of the remaining refrigerant Therefore do not add new refrigerant Instead recover the remaining refrigerant with the refrigerant recovery unit Then after evacuation totally recharge the specified amount of r
15. rate of 0 05Torr Standard time of evacuation Length of tubing Less than 10m More than 10m More than 10 min More than 15 min 34 5 Recharging Valve Be sure to charge the specified amount of refrigerant in liquid state using the service port of wide tube service valve The proper amount is listed on the unit s nameplate When the entire amount cannot be charged all at once charge gradually while operating the unit in Cooling Operation Never charge a large amount of liquid refrigerant at once to the unit This may cause A K damage to the compressor Single valve Charge the liquid refrigerant When charged with a refrigerant cylinder use the Wi he dene Fig 1 up side down position electronic scale for charging refrigerant In this case if the volume of refrigerant in the cylinder becomes less than 2096 of the fully charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the refrigerant cylinder is less than 20 Valve Also charge the minimum necessary amount to the cylinder before using it for charging the air conditioning unit Example In case of charging refrigerant to a unit requiring 0 76Kg using a capacity of 10Kg cylinder the minimum necessary amount for the cylinder is 0 76 10 x 0 20 2 76Kg me 7 Single valve with siphon tube For the remaining refrigerant refer to the Charge with
16. the other power wire Fig 12 1 12 1 2 Outdoor Unit Clamp a metallic part of the unit with the lead clip of the insulation resistance tester and measure the resistance by placing a probe on each terminal screw where power supply lines are connected on the terminal plate Fig 12 2 12 1 3 Measurement of Insulation Resistance for Electrical Parts Disconnect the lead wires of the desired electric part from terminal plate capacitor etc Similarly disconnect the connector Then measure the insulation resistance Figs 12 3 and 12 4 Niers Refer to Electric Wiring Diagram If the probe cannot enter the poles because the hole is too narrow then use a probe with a thinner pin 41 Ground wire Probe Insulation tester Fig 12 1 Terminal plate N b BE Clip Copper Insulation tube or O tester metallic part 2 Fig 12 2 N ae ip Copper tube or metallic part Insulation tester Fig 12 3 From fan motor compressor and other parts Metallic part Clip Insulation tester Fig 12 4 12 2 Checking Motor Capacitor Remove the lead wires from the capacitor terminals and then place a probe on the capacitor terminals as shown in Fig 12 5 Observe the deflection of the pointer setting the resistance measuring range of the multimeter to the maximum value The capacitor is good if the pointer bounces to a great extent
17. 609 ee L1 15 25 7 15 AER534QC B AWR609 C AWRB518 L2 7 5 20 7 25 If total tubing length becomes between Max allowable tubing length and Limit of tubing length charge additional refrigerant R407c No additional change of compressor oil is necessary Table 6 2 4 indoor unit s combination with dual system kit Combination Max allowable SA Limit of elevation Required amount of tubing length at ER ee 9 difference H additional Outdoor Unit Indoor Unit shipment m gm m refrigerant g m A AWR609 AWR5340C ERE L1 15 25 7 15 TE eese RE RER EN E EE C1 AWR609 DKR8585C V e L3 15 25 7 15 C2 AWR609 If total tubing length becomes between Max allowable tubing length and Limit of tubing length charge additional refrigerant R407c No additional change of compressor oil is necessary Li LaA LB L2 Lc Outdoor Unit Fig 6 2 Indoor Unit L1 LA LB L3 Lc1 Lc2 Outdoor Unit Dual System Kit Fig 6 3 Indoor Unit 6 2 Place and Space for Installation Choose a place as cool as possible The place should x a Exhaust e be well ventilated and the intake air should not be F RT z VJ H hotter than the outside temperature gj 1 3 Heat source max 45 C Outdoor unit Avoid the vicinity of heat sources exhaust fans etc Fig 6 4 Avoid direct sunlight provide awning if necessary Fig 6 4 Required space
18. Hz Operating time 3 minutes Solenoid Valve NEV MOAJ503B0 Coil NEV202DXF Valve AC 240V 50 60Hz 7 6W 45 35mA Coil resistance kQ at 20 C 1 15 70 Dual System Kit DKR8585C Relay R1 R2 Coil rating Coil resistance Contact rating Solenoid Valve SVC1 C2 Coil resistance kQ at 20 C Timer T Rating Operating time 650 15 AC 240V 4 4A NEV MOAJ503B0 Coil NEV202DXF Valve AC 240V 50 60Hz 7 6W 45 35mA 1 15 70 H3Y 2 0 AC 200 230V 50 60Hz 3 minutes MY2 02 US TS 3 DIMENSIONAL DATA Outdoor Unit AER534QC L 170 660 4110 1 30 Air intake LL rea sio D o e oo e eo S Air discharge 940 340 Wide tube service valve 912 7 1 2 145 Unit mm Dual System Kit DKR8585C 118 50 Narrow tube service valve Unit C1 6 35 1 4 Wide tube service valve HE Unit C1 29 52 3 8 Narrow tube service valve Unit C2 96 35 1 4 ESI Wide tube service valve AE Unit C2 29 52 3 8 Charge port 96 35 1 4 a Narrow tube service valve From Unit C 26 35 1 4 Wide tube service valve From Unit C 912 7 1 2
19. IGH or MEDIUM if performance of air conditioner is normal 25 Reduce cooling load or replace the air conditioner with larger capacity 8 4 3 Excessive cooling R NO Set temperature is suitable Remote control unit is placed where it can detect room temperature properly 26 Set temperature to higher value using temperature setting buttons of the remote control unit Change position of remote control unit 9 SPECIAL PRECAUTIONS WHEN SERVICING THE UNIT Model AER534QC IMPORTANT For your personal safety be sure to read and understand the following precautions before servicing Nm Injuries can occur from burns or inhalation of toxic gas if servicing is performed while refrigerant remains in the refrigeration circuit This servicing includes disassembling brazed tubing connections and removing any refrigeration parts or components To avoid risk of injury when servicing the outdoor unit for instance when replacing the compressor or repairing a refrigerant leak follow the procedure below for the refrigerant circuits of unit A and unit B Procedure 9 1 Blue green connector Before a u GRN attachment for servicing t Be 9 1 1 Confirm mains power is switched OFF then Condition for operation BLU 5 disconnect the connecto
20. TECHNICAL amp SERVICE MANUAL Zw AER534QC Dual System Kit DKR8585C Option MULTI SPLIT SYSTEM AIR CONDITIONER Model No Product Code No Model No Product Code No AER534QC 387007146 DKR8585C 387025905 Dual System Kit DKR8585C Option AER534QC 0 8180 234 0 03 2002 Important Please Read Before Starting This air conditioning system meets strict safety and operating standards As the installer or service person it is an important part of your job to install or service the system so it operates safely and efficiently For safe installation and trouble free operation you must Carefully read this instruction booklet before beginning e Follow each installation or repair step exactly as shown Observe all local state and national electrical codes Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard or Nmum unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or T unsafe practice which can result in personal injury or product or property damage If Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for a special problem contact our sales service outlet or your certified dealer for additional instructions In Case of Improper Installation
21. The manufacturer shall in no way be responsible for improper installation or maintenance service including failure to follow the instructions in this document Special Precautions When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate grounding can cause accidental injury or death Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause overheating at connection points and a possible fire hazard When Transporting Be careful when picking up and moving the indoor and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or metal frame to provide added support In a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors In Moist or Uneven L
22. d securely using flux and wax for R407C A S 3 Welding leaking points Prevent oxide film from forming inside the tubes utilizing substitution with nitrogen N2 in the OK refrigerant circuit of the unit Leave ends of tubes open during welding ee OK Use nitrogen gas for the pressurized gas and never use a refrigerant other than R407C Also do not use oxygen or any flammable gas 5b Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation OK of air due to a power interruption the valve will prevent the pump oil from flowing back The equipment may be damaged if moisture remains 6 Recharging in the tubing thus carry out the evacuation thoroughly When using a vacuum pump with exhaust air volume more than 25L min and ultimate vacuum pressure rate of 0 05Torr Standard time of evacuation Length of tubing Less than 10 m More than 10 m More than 10 min More than 15 min 36 6 Recharging Valve Be sure to charge the specified amount of refrigerant in liquid state using the service port of wide tube service valve The proper amount is listed on the unit s nameplate When the entire amount cannot be charged all at once charge gradually while operating the unit in Cooling Operation Never charge a large amount of liquid refrigerant at once to the unit This may cause U gt N damage to the compressor Sin
23. e C SVC which is used as a bypass valve opens only when either of indoor unit A or B is operating while it closes when both indoor unit A and B are operating Simultaneously Indoor Indoor Indoor Indoor Indoor Indoor Indoor Indoor unit A unit B unit A unit B unit A unit A unit B unit B ON ON OFF OFF ON OFF ON OFF Indoor unit A ON ON Solenoid valve A SVA OPEN OPEN L Indoor unit B i ON ON Solenoid valve B SVB OPEN OPEN Solenoid valve C SVC OPEN OPEN OPEN OPEN Compressor 2 CM2 i ON ON ON i 3 minutes XAER534QC 20 8 TROUBLESHOOTING 8 1 Check before and after troubleshooting K Hazardous voltage can cause ELECTRIC SHOCK or DEATH Disconnect power or turn off circuit breaker before you start checking or servicing 8 1 1 Check power supply wiring Check that power supply wires are correctly connected to terminals No 1 and No 2 on the 3P terminal plate in the outdoor unit 8 1 2 Check inter unit wiring Check that inter unit wiring is correctly connected to the indoor units from the outdoor unit 8 1 3 Check power supply Check that voltage is in specified range 10 of the rating Check that power is being supplied 8 1 4 Check lead wires and connectors Check that coating of lead wires is not damaged Check that lead wires and connectors are firmly connected Check that wiring is
24. efrigerant with the new refrigerant at its normal mixed composition state liquid phase When refrigerant R407C is used the composition will differ depending on whether it is in gaseous or liquid phase and the basic performance of the air conditioner will be degraded if it is charged while the refrigerant is in gaseous state Thus always charge the refrigerant while it is in the liquid phase Ether type oil is used for the compressor oil for R407C type units which is AN different from the mineral oil used for R22 Thus more attention to moisture prevention and faster replacement work compared with conventional models are required 10 2 Checklist before servicing Tubing precautions Refrigerant R407C is more easily affected by dust or moisture compared with R22 thus be sure to temporarily cover the ends of the tubing with caps or tape prior to installation No addition of compressor oil for R407C No additional charge of compressor oil is permitted No use of refrigerant other than R407C Never use a refrigerant other than R407C If refrigerant R407C is exposed to fire Through welding etc toxic gas may be released when R407C refrigerant is exposed to fire Therefore be sure to provide ample ventilation during installation work Caution in case of R407C leak Check for possible leak points with the special leak detector for R407C If a leak occurs inside the room immediately provide thorough ventilation 32 10
25. gerant recovery unit after completing the leak test 9 4 Evacuation using vacuum pump 9 4 1 Using a hex wrench set the valve stems of both the narrow and wide tube service valves as indicated in table below Service Valve Valve Position Narrow pe Unit A Wide Position c Narrow H Unit B Wide Position a Refer to M Service Valve Construction shown later 9 4 2 Connect the vacuum pump and a manifold valve as shown in either Fig 9 2 depending upon the model Confirm that all connections are correctly made In order to withstand negative suction pressure during evacuation the manifold valve should be equipped with a Hi Lo compound gauge with a minimum scale reading of 76cmHg 28 EI s Sek lo RA Disconnect switch Field supply pee Power gt gna br gt S het Supply 9 4 3 Install first by hand tightening then securely with a wrench flare nuts and bonnets at all service valves in the refrigeration circuit where evacuation will take place This process is highly important to completely evacuate the system Disconnect switch Field supply 9 4 4 Check that the blue green connector is properly attached Fig 9 2 gt Power 1 Supply 9 4 5 Turn the disconnect switch ON if it has been OFF to open the two solenoid valves SVA and SVB Fig 9 2
26. gle valve Charge the liquid refrigerant When charged with a refrigerant cylinder use the with the cylinder in the Fig 4 electronic scale for charging refrigerant In this case if DEES ER the volume of refrigerant in the cylinder becomes less than 20 of the fully charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the refrigerant R VARG cylinder is less than 20 Also charge the minimum necessary amount to the cylinder before using it for charging the air conditioning unit Example In case of charging refrigerant to a unit requiring 0 76Kg using a capacity of 10Kg cylinder the minimum necessary amount for the cylinder is 0 76 10 x 0 20 2 76Kg Single valve with siphon tube For the remaining refrigerant refer to the instructions Charge with the cylinder in the Fig 5 of the refrigerant manufacturer normal position Configurations and characteristics of cylinders If using a charging cylinder transfer the specified amount of liquid refrigerant from the refrigerant cylinder to the charging cylinder Prepare an evacuated charging cylinder beforehand f NO I To prevent the composition iara of R407C from changing Se never bleed the refrigerant gas into the atmosphere while transferring the refrigerant Fig 6 Do not use the refrigerant if the amount in the charging cylinder is less than 20 ging cy 3 Open Refrigerant
27. ng cylinder Junta Juni B Unit C Osen Fig 9 3 Before B GRN Condition at servicing BLU Procedure 9 2 9 5 H A AN After Condition at shipping Condition for operation BLU wa A E Terminal plate 1 CONNECTOR Fig 9 4 Terminal plate H Service Valve Construction Valve Position a The valve stems of both the wide and narrow tubes are turned all the way in The unit is shipped from the factory in this position Fig 9 5a Valve Position b The valve stems of both the wide and narrow tubes are turned all the way out BACK SEAT position This is the normal operating position Fig 9 5b Valve Position c With the narrow tube valve kept at BACK SEAT only the wide tube valve stem is turned to the halfway down position This position is used when refrigerant circuit evacuation is required from both narrow and wide tube valves at the same time This position is also used when additional refrigerant charging is required in the field with both the indoor and outdoor units installed Fig 9 5c Valve Position d Wide Tube Narrow Tube O ring Valve cap TEZZA 4 cd Fig 9 5a cia N IT Fig 9 5b With the valve stem of the wide tube turned all the way in only the narrow tube valve stem is turned to the halfway down position This position is used for refrigerant charging
28. ng screws 4 pcs and connect the Dual System Kit to the service valves of the outdoor unit as shown below Figs 6 8 The tubing work for Indoor Units A and B have to be carried out after completion of Dual System Kit installation air purging and a leak test AER534QC Capi box Connecting pipes Fig 6 8 Space for Dual System Kit AER534QC with DKR8585C NOTE LLLLLLLLLLLLL LL Min 25 cm When using the Dual System Kit be sure to keep a separation of 25 Air intake FA k L cm as minimum between the air Fe Sane intake of the outdoor unit rear T surface and wall or fence for 15cm Nr discharge Ee maintenance work Fig 6 9 TTTTTTTITI 7 7 7 Top view Fig 6 9 6 4 Wiring Instructions 6 4 1 General Precautions on Wiring Check the rated voltage on the unit s name plate before wiring according to the wiring diagram Provide a power outlet to be used exclusively for each unit with a power supply disconnect and a circuit breaker for overcurrent protection provided in the exclusive line To prevent possible hazards due to insulation failure the unit must be grounded Each wire must be connected firmly No wire should be allowed to touch refrigerant tubing the compressor or any moving parts of fan motors Regulations on wire diameters differ according to national and local requirements For field wiring regulations please refer to the LOCAL ELECTRICAL CODES befo
29. ocations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor unit This prevents water damage and abnormal vibration In an Area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame Provide a suitable air baffle In a Snowy Area for Heat Pump type Systems Install the outdoor unit on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing Use the flare method for connecting tubing Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them then tighten the nut with a torque wrench for a leak free connection Check carefully for leaks before starting the test run When Servicing Turn the power off at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site after you finish remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced Others AN Ventilate any enclosed areas when installing or testing the refrigeration system Escaped refrigerant gas on contact with fire or heat can produce dangerously toxic gas Confirm upon completing installation that no refrigerant gas is leaking If escaped gas comes in contact with a stove gas water heater electric room heater
30. or other heat source it can produce dangerously toxic gas Table of Contents Page UNIT COMBINATION OPERATING RANGE 1 SPECIFICATIONS 22 gor Component Speers CA Major Component Specifications Other Component Specifications DIMENSIONAL DATA REFRIGERANT FLOW DIAGRAM 9 ELECTRICAL DATA a Electrical Characteristic Electric Wiring Diagrams 6 INSTALLATION INSTRUCTION k Installation Site Selection Place and Space for Installation Installation with Dual System Kit Wiring Instruction FUNCTION 8 TROUBLESHOOTNG P 9 SPECIAL PRECAUTIONS WHEN SERVICINGTHEUNT 1 Service on outdoor unit 28 Evacuation using vacuum pump 28 4 Refrigerant charging 9 6 Reattaching green connectors for operation REFRIGERANT R407C SPECIAL PRECAUTION WHEN SERVICING THE UNIT Characteristics of new refrigerant R407c Checklist before servicing Tools specially for R407c 0 4 For tubing installation procedures In case of compressor malfunction In case refrigerant is leaking Charging additional refrigerant Retro fitting existing systems ARRANGEMENT OF ELECTRICAL COMPONENTS CHECKING ELECTRICAL COMPONENTS L HEIL Measurement of insulation resistance Checking motor capacitor B Unit Combination Combine indoor and outdoor units only as listed below Outdoor Unit AER534QC Outdoor Unit Fig 1 Dual System Kit Option Indoor Unit AWR609 AWR609 AWR518 Symbol of Indoo
31. perate either indoor unit A or B e Check to see if the lamp PW is on gt Replace the timer YES Check to see if the other lamp UP lights up as well YES UP min FW e min A e Confirm that the timer dial has been Nas set to 3 min as shown in figure right a 24 8 4 Air conditioner operates but abnormalities are observed 8 4 1 Indoor unit operates but there is no cooling Check solenoid valve in outdoor unit Measure coil resistance of solenoid valve SVA SVB 8 4 2 Poor cooling e Check position of remote control unit YES Cool air from air conditioner reaches position directly Wide and narrow tubes between indoor unit and outdoor unit are Change position of remote control unit Insulate both wide and narrow tubes insulated separately and then tape together YES Temperature difference e Measure temperature of suction is small Possibility of Charge gt refrigerant and discharge air of air conditioner gas shortage Temperature difference between suction and discharge air is large enough approx 10 deg or more gas R407c l Check for clogging of air filter Air filter is clogged Clean filter YES Fan speed is set to LOW Review cooling load estimate Set fan speed to either H
32. r Unit Refer to AWR609 AWR609 AWR609 DKR8585C AWR609 Indoor Unit Outdoor Unit Indoor Unit Dual System Kit Fig 2 1 OPERATING RANGE Temperature Indoor Air Intake Temp Outdoor Air Intake Temp Maximum 32 C D B 23 C W B 43 D B Cooling Minimum 19 C D B 14 C W B 19 C D B 2 SPECIFICATIONS 2 1 Unit Specifications Outdoor Unit AER534QC Symbol of indoor unit A B AWR609 C AWR518 Power Source 220 240 V 50 Hz Cooling 8 23 d Capacity KE e EE eer 98 ANN S m 29 d 28 Voltage rating ine Lal 990 P Available voltage ange EE 198 to 284 sss 8 Rumningamperes aa os neni ra en 2000 AL A A E a gop me a Compressor locked rotor amperes A 45 46 48 41 43 45 Fan speed n 2 El EE PME Rotary Hermetic Refrigerant Amount charged at shipment Bi et R407 A B 1 300 C 1200 GO Gapillary tub e Operation sound NE EE Refrigerant tubing connections ji flae ype n Max allowable tubing length at shipment mnl A B 15 C 75 5 Refrigerant tube Narrow tube mmumil A B 635 14 l Dual a MEANS i Wide tube MM in osse A B 9 52 8 8 C 127 M2 ss efigeranttubekt ses Optional maere ort ei ET EE Ee ET S ues m is gt Width mm 940 penp mal c 5 Package dimensions Height mm 1 343 5 Width mm 1 036 qm RE Depth mm i E ne T t ie S ai
33. re starting and carefully follow the regulations as you do the installation K Do not supply power to the system until all wiring and refrigerant tubing connections are completed and checked Wiring should only be done by an experienced qualified electrician This appliance must be grounded Table 6 3 and 6 4 lists recommended wire lengths and diameters for power supply systems Dual System Kit 6 4 2 Recommend Wire Length and Size Table 6 3 i Power Supply Line Inter Line Length Inter Kit Line Length Model AER534QC Length A B C D Fuse or Circuit Capacitor Cross Sectional Aria Mm 2 mm 2 mm Maximum Length m 14m 22m 20m NOTE Refer to the WIRING SYSTEM DIAGRAM for meaning of A B C and D in table 6 3 Wiring System Diagram Outdoor Unit AER534QC Outdoor Unit AER5340C Dual System Kit DKR8585C Power supply 220 240 V 50Hz Outdoor Unit P 220 240 V TM es Terminal 3P 50H switc E D Unit A Field supply He Disconnect 5 Terminal 3P T B di O it 5 1 Field supply E i SG 5 ei 8P NU 1 Unit A Ss e O Si i sr H Terminal 8P 9 GY tro o4 Unit B
34. rs GRN GRN to separate A and B Then connect A connector 16 Terminal plate GRN with connector C BLU Fig 9 1 EE CONNECTOR 9 1 2 Provide a disconnect switch to the 3p terminal After i late Figs 9 2 and 9 3 B7 CRN H Fig Condition at servicing Dela 9 1 3 Turn the disconnect switch ON to supply power KEE a single phase 220 240 V to the outdoor unit 6 Terminal plate This makes it possible to force open two solenoid valves SVA and SVB in the Fig 9 1 refrigeration circuit Figs 9 2 and 9 3 IMPORTANT The procedure given in 9 2 to 9 5 below must be carried out with the two solenoid valves SVA and SVB open 27 9 2 Refrigerant recovery 9 2 1 Open the service valve to recover refrigerant into refrigerant recovery unit Nen Refrigerant released into the air contributes to destruction of our planet s ozone layer You should always use the refrigerant recovery unit to help protect the environment 9 3 Service on outdoor unit 9 3 1 After making sure that the refrigerant in the circuit has been completely discharged perform the required servicing such as replacing the compressor or repairing refrigerant leaks 9 3 2 Before going on to the next step leak test all joints where welding has been done Nitrogen gas is best when pressurizing the system for a leak test However if it is necessary to instead test with refrigerant gas be sure to recover all gas into the refri
35. tdoor air temperature 35 C D B 24 C W B 2 2 Major Component Specifications Outdoor Unit AER534QC Symbol of indoor uni A B AWR609 C AWR518 or C1 C2 AWR609 Type EE SA een ene ete Model name Q ty Compressor Per terre v Ca Code No DAR EVER TA Nominal output _ ono nel W Compressoroil ss ce G Coil resistance Ambient temp 25 C Q 5 SE EE eh E AV o Overload relay Qty Safety i eroi et Art I AAA devices Operating temp Run capacitor Qty PRESTI EN PEER H E VAC PE eee leche NN Q ty Dia mm 8 Nominal output tn W i 2 Coil resistance Ambient temp 20 Q WHT BRN 127 3 WHT Violet 56 73 s cL TH Violet YEL 15 04 YEL PNK 723 v L 3 Safety EEN KR devices Operating temp Run capacitor Coll Ti EE Rows 1 M NT PACA ah uL elle MIN EE ito Face area m 0 456 x 2 External Finish Acrylic baked on enamel finish DATA SUBJECT TO CHANGE WITHOUT NOTICE 2 3 Other Component Specifications Outdoor Unit AER534QC Relay MCS24A2F1 Coil rating AC 240V Coil resistance kQ at 20 C 15 5 15 Contact rating AC 250V 5A Power Relay PR1 PR2 G7L 2A TUB Pd num Nd a aka dd OSR TV Sege Soe Coil resistance Q at 23 C 21 15 Contact rating AC 220V 25A Thermostat Fan Speed Control YTB 4U201F Switching temp high gt LOW 24 C 13 low HIGH 26 1 5 Timer T H3Y 2 Rating AC 220V 50 60
36. the cylinder in the instructions of the refrigerant manufacturer normal position Configurations and characteristics of cylinders Fig 2 If using a charging cylinder transfer the specified amount of liquid refrigerant from the refrigerant cylinder to the charging cylinder Prepare an evacuated charging cylinder beforehand To prevent the composition Mv of R407C from changing Charging P never bleed the refrigerant cylinder gas into the atmosphere while transferring the ED refrigerant Fig 3 Do not use the refrigerant if the amount in the charging cylinder is less than 20 amp ER Refrigerant cylinder Fig 3 35 10 6 In case refrigerant is leaking Never attempt to charge additional refrigerant when refrigerant has been leaking from the unit Follow the procedure described below to locate points of leaks and carry out repairs then recharge the refrigerant 1 Detecting Leaks Use the detector for R407C to locate refrigerant leak points 2 Recovering refrigerant 1 Detecting leaks e Never release the gas to the atmosphere recover residual refrigerant using the refrigerant recovery unit for R407C instead 1 composition will have been altered 2 Recovering refrigerant 3 Welding leaking points OK Do not reuse the recovered refrigerant because its Y OK Confirm again that no residual refrigerant exists in the unit before starting welding Y Wel
37. the indoor unit and outdoor unit 33 10 5 In case of compressor malfunction Should the compressor malfunction be sure to replace compressor as quickly as possible Use only the tools indicated exclusively for R407C gt See 10 3 Tools specifically for R407C 10 5 1 Procedure for replacing compressor 1 Recovering refrigerant Any remaining refrigerant inside the unit should not be released to the atmosphere but recovered using the refrigerant recovery unit for R407C OK 1 Recovering refrigerant Do not reuse the recovered refrigerant since will contain impurities 2 Replacing compressor 2 Replacing compressor Soon after removing pinched pipes of both discharge and suction tubes of the new compressor replace it quickly OK 3 Checking for sealing 3 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R407C Also do not use OK oxygen or any flammable gas 4 Evacuation Y Use a solenoid valve installed vacuum pump so 4 Evacuation that even if power is cut off in the middle of evacuation OK of air due to a power interruption the valve will prevent the pump oil from flowing back The equipment may be damaged if moisture remains in the tubing thus carry out the evacuation thoroughly 5 Recharging When using a vacuum pump with exhaust air volume more than 25L min and ultimate vacuum pressure
38. ts then retighten the connection 29 9 5 4 With a hex wrench open the service valve little by little to let liquid refrigerant enter the circuit Fig 9 3 Write down the gradation levels on the charging cylinder before and after the charging This allows you to calculate the charging volume Gradation level after charging Gradation Charging volume level before charging 9 5 5 If it is not possible to completely charge the unit with the proper amount of refrigerant you can do a additional charging after installing the units At that time refrigerant should be recharged in the liquid state a little at a time using the wide tube service port and the air conditioner should be operating in COOLING mode during the entire charging process Charging the unit with a large amount of refrigerant at once may damage the compressor Always charge the unit at a constant charging rate of about 100 g 9 6 Reattaching green connectors for operation 9 6 1 Turn off the power source 9 6 2 Connect the two green connectors to each other as in the original state Fig 9 4 Remember to reattach the green connectors in the original position Otherwise the system will not operate correctly and damage may occur 30 Disconnect switch Field supply een Power ER Supply P N lt E e EN ee O O O Hex wrench Chargi
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