Carrier 42NQV050M, 42NQV060M, 42NQV050M-N, 42NQV060M-N, 42NQV050M-A Service Manual

FILE NO. SVM-10052-3

SERVICE MANUAL

SPLIT TYPE

Indoor Unit

<High Wall, Heat Pump Type>

42NQV050M

42NQV060M 42NQV050M-N 42NQV060M-N 42NQV050M-A 42NQV060M-A

Outdoor Unit

<Heat Pump Type>

38NYV050M2

38NYV060M2 38NYV050M-A 38NYV060M-A

R410A

Revised May, 2011

CONTENTS

FILE NO. SVM-10052

1.	SAFETY PRECAUTIONS ..........................................................................	2
2.	SPECIFICATIONS .....................................................................................	4
3.	REFRIGERANT R410A .............................................................................	8
4.	CONSTRUCTION VIEWS ........................................................................	16
5.	WIRING DIAGRAM ..................................................................................	18
6.	SPECIFICATIONS OF ELECTRICAL PARTS .........................................	19
7.	REFRIGERANT CYCLE DIAGRAM ........................................................	20
8.	CONTROL BLOCK DIAGRAM ................................................................	22
9.	OPERATION DESCRIPTION ...................................................................	24
10.	INSTALLATION PROCEDURE ................................................................	45
11.	HOW TO DIAGNOSE THE TROUBLE ......................................................	58
12.	HOW TO REPLACE THE MAIN PARTS ...................................................	80
13.	EXPLODED VIEWS AND PARTS LIST ...................................................	95

– 1 –

1. SAFETY PRECAUTIONS

FILE NO. SVM-10052

For general public use

Power supply cord of outdoor unit shall be more than 1.5 mm2 (H07RN-F or 60245IEC66) polychloroprene sheathed flexible cord.

•Read this “SAFETY PRECAUTIONS” carefully before servicing.

•The precautions described below include the important items regarding safety. Observe them without fail.

•After the servicing work, perform a trial operation to check for any problem.

•Turn off the main power supply switch (or breaker) before the unit maintenance.

CAUTION

New Refrigerant Air Conditioner Installation

•THIS AIR CONDITIONER ADOPTS THE NEW HFC REFRIGERANT (R410A) WHICH DOES NOT DESTROY OZONE LAYER.

R410A refrigerant is apt to be affected by impurities such as water, oxidizing membrane, and oils because the working pressure of R410A refrigerant is approx. 1.6 times of refrigerant R22. Accompanied with the adoption of the new refrigerant, the refrigeration machine oil has also been changed. Therefore, during installation work, be sure that water, dust, former refrigerant, or refrigeration machine oil does not enter into the new type refrigerant R410A air conditioner circuit.

To prevent mixing of refrigerant or refrigerating machine oil, the sizes of connecting sections of charging port on main unit and installation tools are different from those used for the conventional refrigerant units.

Accordingly, special tools are required for the new refrigerant (R410A) units. For connecting pipes, use new and clean piping materials with high pressure fittings made for R410A only, so that water and/or dust does not enter. Moreover, do not use the existing piping because there are some problems with pressure fittings and possible impurities in existing piping.

CAUTION

TO DISCONNECT THE APPLIANCE FROM THE MAIN POWER SUPPLY

This appliance must be connected to the main power supply by a circuit breaker or a switch with a contact separation of at least 3 mm.

DANGER

•ASK AN AUTHORIZED DEALER OR QUALIFIED INSTALLATION PROFESSIONAL TO INSTALL/MAINTAIN THE AIR CONDITIONER.

INAPPROPRIATE SERVICING MAY RESULT IN WATER LEAKAGE, ELECTRIC SHOCK OR FIRE.

•TURN OFF MAIN POWER SUPPLY BEFORE ATTEMPTING ANY ELECTRICAL WORK. MAKE SURE ALL POWER SWITCHES ARE OFF. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

DANGER: HIGH VOLTAGE

The high voltage circuit is incorporated.

Be careful to do the check service, as the electric shock may be caused in case of touching parts on the P.C. board by hand.

•CORRECTLY CONNECT THE CONNECTING CABLE. IF THE CONNECTING CABLE IS INCORRECTLY CONNECTED, ELECTRIC PARTS MAY BE DAMAGED.

•CHECK THAT THE EARTH WIRE IS NOT BROKEN OR DISCONNECTED BEFORE SERVICE AND INSTALLATION. FAILURE TO DO SO MAY CAUSE ELECTRIC SHOCK.

–2 –

FILE NO. SVM-10052

•DO NOT INSTALL NEAR CONCENTRATIONS OF COMBUSTIBLE GAS OR GAS VAPORS. FAILURE TO FOLLOW THIS INSTRUCTION CAN RESULT IN FIRE OR EXPLOSION.

•TO PREVENT THE INDOOR UNIT FROM OVERHEATING AND CAUSING A FIRE HAZARD, PLACE THE UNIT WELL AWAY (MORE THAN 2 M) FROM HEAT SOURCES SUCH AS RADIATORS, HEAT REGISTORS, FURNACE, STOVES, ETC.

•WHEN MOVING THE AIR-CONDITIONER FOR INSTALLATION IN ANOTHER PLACE, BE VERY CAREFUL NOT TO ALLOW THE SPECIFIED REFRIGERANT (R410A) TO BECOME MIXED WITH ANY OTHER GASEOUS BODY INTO THE REFRIGERATION CIRCUIT. IF AIR OR ANY OTHER GAS IS MIXED IN THE REFRIGERANT, THE GAS PRESSURE IN THE REFRIGERATION CIRCUIT WILL BECOME ABNORMALLY HIGH AND IT MAY RESULT IN THE PIPE BURSTING AND POSSIBLE PERSONNEL INJURIES.

•IN THE EVENT THAT THE REFRIGERANT GAS LEAKS OUT OF THE PIPE DURING THE SERVICE WORK AND THE INSTALLATION WORK, IMMEDIATELY LET FRESH AIR INTO THE ROOM. IF THE REFRIGERANT GAS IS HEATED, SUCH AS BY FIRE, GENERATION OF POISONOUS GAS MAY RESULT.

WARNING

•Never modify this unit by removing any of the safety guards or bypass any of the safety interlock switches.

•Do not install in a place which cannot bear the weight of the unit. Personal injury and property damage can result if the unit falls.

•After the installation work, confirm that refrigerant gas does not leak.

If refrigerant gas leaks into the room and flows near a fire source, such as a cooking range, noxious gas may generate.

•The electrical work must be performed by a qualified electrician in accordance with the Installation Manual. Make sure the air conditioner uses an exclusive circuit.

An insufficient circuit capacity or inappropriate installation may cause fire.

•When wiring, use the specified cables and connect the terminals securely to prevent external forces applied to the cable from affecting the terminals.

•Be sure to provide grounding.

Do not connect ground wires to gas pipes, water pipes, lightning rods or ground wires for telephone cables.

•Conform to the regulations of the local electric company when wiring the power supply.

Inappropriate grounding may cause electric shock.

CAUTION

•Exposure of unit to water or other moisture before installation may result in an electrical short. Do not store in a wet basement or expose to rain or water.

•Do not install in a place that can increase the vibration of the unit. Do not install in a place that can amplify the noise level of the unit or where noise or discharged air might disturb neighbors.

•To avoid personal injury, be careful when handling parts with sharp edges.

•Perform the specified installation work to guard against an earthquake.

If the air conditioner is not installed appropriately, accidents may occur due to the falling unit.

For Reference:

If a heating operation would be continuously performed for a long time under the condition that the outdoor temperature is 0°C or lower, drainage of defrosted water may be difficult due to freezing of the bottom plate, resulting in a trouble of the cabinet or fan.

It is recommended to procure an antifreeze heater locally for a safe installation of the air conditioner. For details, contact the dealer.

– 3 –

2-1. Specifications

42NQV050M / 38NYV050M2 42NQV060M / 38NYV060M2

FILE NO. SVM-10052

2. SPECIFICATIONS

Unit model		Indoor				42NQV050M			42NQV060M
		Outdoor				38NYV050M2			38NYV060M2
Cooling capacity					(kW)	5.0			6.0
Cooling capacity range					(kW)	1.1-6.0			1.2-6.7
Heating capacity					(kW)	5.8			7.0
Heating capacity range					(kW)	0.8-6.3			1.0-7.5
Power supply						1Ph/50Hz/220-240V,			1Ph/60Hz/220-230V
Electric		Indoor	Operation mode			Cooling		Heating	Cooling		Heating
characteristic			Running current		(A)	0.30-0.28		0.30-0.28	0.38-0.35		0.38-0.35
			Power consumption		(W)	40		40	50		50
			Power factor		(%)	60		60	60		60
		Outdoor	Operation mode			Cooling		Heating	Cooling		Heating
			Running current		(A)	6.82-6.25		7.19-6.59	8.93-8.19		9.78-8.96
			Power consumption		(W)	1470		1565	1945		2130
			Power factor		(%)	98		99	99		99
			Starting current		(A)	7.49-6.87			10.16-9.31
COP						3.31		3.61	3.01		3.21
Sound Pressure	Indoor		H/M+/M/L+/L		(dB-A)	44/41/38/35/32		44/41/39/35/32	47/44/41/38/35		47/44/42/38/35
level		Outdoor	H		(dB-A)	49		50	52		51
Sound power		Indoor	H/M+/M/L+/L		(dB-A)	59/56/53/50/47		59/56/54/50/47	62/59/56/53/50		62/59/57/53/50
level		Outdoor	H		(dB-A)	64		65	67		66
Indoor unit		Unit model				42NQV050M			42NQV060M
		Dimension	Height		(mm)	320			320
			Width		(mm)	1050			1050
			Depth		(mm)	228			228
		Net weight			(kg)	13			13
		Fan motor output			(W)	30			30
		Air flow rate		(Cooling/Heating)	(m3/min)	15.9/16.5			18.0/18.3
Outdoor unit		Unit model				38NYV050M2			38NYV060M2
		Dimension	Height		(mm)	550			550
			Width		(mm)	780			780
			Depth		(mm)	290			290
		Net weight			(kg)	41			41
		Compressor	Motor output		(W)	1100			1100
			Type			Twin rotary type with DC-inverter variable speed control
			Model			DA130A1F-27F			DA150A1F-20F
		Fan motor out	put		(W)	43			43
		Air flow rate		(Cooling/Heating)	(m3/min)	36.3/31.9			38.6/37.2
Piping		Type				Flare connection			Flare connection
connection		Indoor unit	Liquid side		(mm)	6.35			6.35
			Gas side		(mm)	12.70			12.70
		Outdoor unit	Liquid side		(mm)	6.35			6.35
			Gas side		(mm)	12.70			12.70
		Maximum leng	th		(m)	20			20
		Maximum chargeless length			(m)	15			15
		Maximum height difference			(m)	10			10
Refrigerant		Name of refrigerant				R410A			R410A
		Weight			(kg)	1.40			1.40
Wiring		Power supply						3Wires:includes	earth(Outdoor)
connection		Interconnection						4Wires:includes earth
Usable temperature range			Indoor	(Cooling/Heating)	(°C)	21~32/ ~28			21~32/ ~28
			Outdoor (Cooling/Heating)		(°C)	-10~46/-15~24			-10~46/-15~24
Accessory		Indoor unit	Installation plate				1			1
			Wireless remote controller				1			1
			Batteries				2			2
			Remote controller holder				1			1
			Nano Photo Copper Zine filter				2			2
			Nano Silver Ginseng filter				2			2
			Mounting screw			6( 4x25L)			6( 4x25L)
			Remote controller holder			2( 3.1Lx16L)			2( 3.1Lx16L)
			Pan head wood screw
			Plasma air purifier				-			-
			Installation manual				1			1
			Owner's manual				1			1
		Outdoor unit	Drain nipple				1			1
			Water-proof rubber cap				2			2

* The specifications may be subject to change without notice for purpose of improvement.

– 4 –

FILE NO. SVM-10052

42NQV050M-N / 38NYV050M2

42NQV060M-N / 38NYV060M2

Unit model

Indoor

42NQV050M-N

42NQV060M-N

Outdoor

38NYV050M2

38NYV060M2

Cooling capacity

(kW)

5.0

6.0

Cooling capacity range

(kW)

1.1-6.0

1.2-6.7

Heating capacity

(kW)

5.8

7.0

Heating capacity range

(kW)

0.8-6.3

1.0-7.5

Power supply

1Ph/50Hz/220-240V,

1Ph/60Hz/220-230V

Electric

Indoor

Operation mode

Cooling

Heating

Cooling

Heating

characteristic

Running current

(A)

0.30-0.28

0.30-0.28

0.38-0.35

0.38-0.35

Power consumption

(W)

40

40

50

50

Power factor

(%)

60

60

60

60

Outdoor

Operation mode

Cooling

Heating

Cooling

Heating

Running current

(A)

6.82-6.25

7.19-6.59

8.93-8.19

9.78-8.96

Power consumption

(W)

1470

1565

1945

2130

Power factor

(%)

98

99

99

99

Starting current

(A)

7.49-6.87

10.16-9.31

COP

3.31

3.61

3.01

3.21

Sound Pressure

Indoor

H/M/L

(dB-A)

44/41/38/35/32

44/41/39/35/32

47/44/41/38/35

47/44/42/38/35

level

Outdoor

H

(dB-A)

49

50

53

52

Sound power

Indoor

H/M/L

(dB-A)

59/56/53/50/47

59/56/54/50/47

62/59/56/53/50

62/59/57/53/50

level

Outdoor

H

(dB-A)

64

65

68

67

Indoor unit

Unit model

42NQV050M-N

42NQV060M-N

Dimension

Height

(mm)

320

320

Width

(mm)

1050

1050

Depth

(mm)

228

228

Net weight

(kg)

13

13

Fan motor output

(W)

30

30

Air flow rate

(Cooling/Heating)

(m3/min)

15.9/16.5

18.0/18.3

Outdoor unit

Unit model

38NYV050M2

38NYV060M2

Dimension

Height

(mm)

550

550

Width

(mm)

780

780

Depth

(mm)

290

290

Net weight

(kg)

41

41

Compressor

Motor output

(W)

1100

1100

Type

Twin rotary type with DC-inverter variable speed control

Model

DA130A1F-27F

DA150A1F-20F

Fan motor out

put

(W)

43

43

Air flow rate

(Cooling/Heating)

(m3/min)

36.3/31.9

38.6/37.2

Piping

Type

Flare connection

Flare connection

connection

Indoor unit

Liquid side

(mm)

6.35

6.35

Gas side

(mm)

12.70

12.70

Outdoor unit

Liquid side

(mm)

6.35

6.35

Gas side

(mm)

12.70

12.70

Maximum leng

th

(m)

20

20

Maximum chargeless length

(m)

15

15

Maximum height difference

(m)

10

10

Refrigerant

Name of refrigerant

R410A

R410A

Weight

(kg)

1.40

1.40

Wiring

Power supply

3Wires:includes

earth(Outdoor)

connection

Interconnection

4Wires:includes earth

Usable temperature range

Indoor

(Cooling/Heating)

(°C)

21~32/ ~28

21~32/ ~28

Outdoor (Cooling/Heating)

(°C)

-10~46/-15~24

-10~46/-15~24

Accessory

Indoor unit

Installation plate

1

1

Wireless remote controller

1

1

Batteries

2

2

Remote controller holder

1

1

Nano Photo Copper Zine filter

2

2

Nano Silver Ginseng filter

2

2

Mounting screw

6( 4x25L)

6( 4x25L)

Remote controller holder

2( 3.1Lx16L)

2( 3.1Lx16L)

Pan head wood screw

Plasma air purifier

-

-

Installation manual

1

1

Owner's manual

1

1

Outdoor unit

Drain nipple

1

1

Water-proof rubber cap

2

2

* The specifications may be subject to change without notice for purpose of improvement.

– 5 –

								FILE NO. SVM-10052-1
42NQV050M-A / 38NYV050M-A
42NQV060M-A / 38NYV060M-A
	Unit model	Indoor				42NQV050M-A			42NQV060M-A
		Outdoor				38NYV050M-A			38NYV060M-A
	Cooling capacity				(kW)	5.0			6.0
	Cooling capacity range				(kW)	1.1-6.0			1.2-6.7
	Heating capacity				(kW)	5.8			7.0
	Heating capacity range				(kW)	0.8-6.3			1.0-7.5
	Power supply							1Ph/50Hz/220	-240V
	Electric	Indoor	Operation mode			Cooling		Heating	Cooling		Heating
	characteristic		Running current		(A)	0.30-0.28		0.30-0.28	0.38-0.35		0.38-0.35
			Power consumption		(W)	40		40	50		50
			Power factor		(%)	60		60	60		60
		Outdoor	Operation mode			Cooling		Heating	Cooling		Heating
			Running current		(A)	6.82-6.25		7.19-6.59	8.93-8.19		9.78-8.96
			Power consumption		(W)	1470		1565	1945		2130
			Power factor		(%)	98		99	99		99
			Starting current		(A)	7.49-6.87			10.16-9.31
	COP					3.31		3.61	3.01		3.21
	Sound Pressure	Indoor	H/M+/M/L+/L		(dB-A)	44/41/38/35/32		44/41/39/35/32	47/44/41/38/35		47/44/42/38/35
	level	Outdoor	H		(dB-A)	49		50	53		52
	Sound power	Indoor	H/M+/M/L+/L		(dB-A)	59/56/53/50/47		59/56/54/50/47	62/59/56/53/50		62/59/57/53/50
	level	Outdoor	H		(dB-A)	64		65	68		67
	Indoor unit	Unit model				42NQV050M-A			42NQV060M-A
		Dimension	Height		(mm)	320			320
			Width		(mm)	1050			1050
			Depth		(mm)	228			228
		Net weight			(kg)	13			13
		Fan motor output			(W)	30			30
		Air flow rate		(Cooling/Heating)	(m3/min)	15.9/16.5			18.0/18.3
	Outdoor unit	Unit model				38NYV050M-A			38NYV060M-A
		Dimension	Height		(mm)	550			550
			Width		(mm)	780			780
			Depth		(mm)	290			290
		Net weight			(kg)	41			41
		Compressor	Motor output		(W)	1100			1100
			Type			Twin rotary type with DC-inverter variable speed control
			Model			DA130A1F-27F			DA150A1F-20F
		Fan motor out	put		(W)	43			43
		Air flow rate		(Cooling/Heating)	(m3/min)	36.3/31.9			38.6/37.2
	Piping	Type				Flare connection			Flare connection
	connection	Indoor unit	Liquid side		(mm)	6.35			6.35
			Gas side		(mm)	12.70			12.70
		Outdoor unit	Liquid side		(mm)	6.35			6.35
			Gas side		(mm)	12.70			12.70
		Maximum leng	th		(m)	20			20
		Maximum chargeless length			(m)	15			15
		Maximum height difference			(m)	10			10
	Refrigerant	Name of refrigerant				R410A			R410A
		Weight			(kg)	1.40			1.40
	Wiring	Power supply						3Wires:includes	earth(Outdoor)
	connection	Interconnection						4Wires:includes earth
	Usable temperature range		Indoor	(Cooling/Heating)	(°C)	21~32/ ~28			21~32/ ~28
			Outdoor (Cooling/Heating)		(°C)	-10~46/-15~24			-10~46/-15~24
	Accessory	Indoor unit	Installation plate				1			1
			Wireless remote controller				1			1
			Batteries				2			2
			Remote controller holder				1			1
			Nano Photo Copper Zine filter				2			2
			Nano Silver Ginseng filter				2			2
			Mounting screw			6( 4x25L)			6( 4x25L)
			Remote controller holder			2( 3.1Lx16L)			2( 3.1Lx16L)
			Pan head wood screw
			Plasma air purifier				-			-
			Installation manual				1			1
			Owner's manual				1			1
		Outdoor unit	Drain nipple				1			1
			Water-proof rubber cap				2			2

* The specifications may be subject to change without notice for purpose of improvement.

– 6 –

2-2. Operation Characteristic Curve

<Cooling>

		10.00
		9.00
		8.00	42NQV060M
			42NQV060M-N
		7.00	42NQV060M-A
	<![if ! IE]> <![endif]>(A)	6.00	42NQV050M
			42NQV050M-N
	<![if ! IE]> <![endif]>Current	5.00	42NQV050M-A
		4.00

3.00

2.00

1.00

0.00 0 10 20 30 40 50 60 70 80 90 100 110 120

Compressor Speed (RPS)

FILE NO. SVM-10052

<Heating>

	10.00
	9.00
	8.00	42NQV060M
		42NQV060M-N
	7.00	42NQV060M-A
<![if ! IE]> <![endif]>(A)	6.00
		42NQV050M
<![if ! IE]> <![endif]>Current
	5.00	42NQV050M-N
		42NQV050M-A
	4.00

3.00

2.00

1.00

0.00

0

10

20

30

40

50

60

70

80

90

100

110

120

Compressor Speed (RPS)

2-3. Capacity Variation Ratio According to Temperature

<Cooling>
	105
	100
	95
	90					42NQV050M
						42NQV050M-N
<![if ! IE]> <![endif]>(%)	85					42NQV050M-A
						42NQV060M
<![if ! IE]> <![endif]>Ratio	80					42NQV060M-N
						42NQV060M-A
<![if ! IE]> <![endif]>Capacity	75
	70				Condition
	65				Indoor: DB27oC / WB19oC
					Indoor Air-Flow Volume:
	60				Pipe Length: 7.5m
	55				Capacity Ratio: 100%=
					5.0kW (42NQV050M,42NQV050M-N,42NQV050M-A)
	50				6.0kW (42NQV060M,42NQV060M-N,42NQV060M-A)
	32	33	34	35	36	37	38	39	40	41	42	43	44	45	46

Outdoor Temperature (oC)

	<Heating>
	120
	100		42NQV050M
			42NQV050M-N
			42NQV050M-A
			42NQV060M
<![if ! IE]> <![endif]>(%)	80		42NQV060M-N
			42NQV060M-A
<![if ! IE]> <![endif]>Ratio	60
<![if ! IE]> <![endif]>Capacity
	40	Condition
		Indoor: DB20oC
		Indoor Air-Flow Volume: High
	20	Pipe Length: 7.5m
		Capacity Ratio: 100%=
		5.8kW (42NQV050M,42NQV050M-N,42NQV050M-A)
	0	7.0kW (42NQV060M,42NQV060M-N,42NQV060M-A)
	-15	-10	-5	0	5	10

Outdoor Temperature (oC)

– 7 –

FILE NO. SVM-10052

3. REFRIGERANT R410A

This air conditioner adopts the new refrigerant HFC (R410A) which does not damage the ozone layer.

The working pressure of the new refrigerant R410A is 1.6 times higher than conventional refrigerant (R22). The refrigerating oil is also changed in accordance with change of refrigerant, so be careful that water, dust, and existing refrigerant or refrigerating oil are not entered in the refrigerant cycle of the air conditioner using the new refrigerant during installation work or servicing time.

The next section describes the precautions for air conditioner using the new refrigerant. Conforming to contents of the next section together with the general cautions included in this manual, perform the correct and safe work.

3-1. Safety During Installation/Servicing

As R410A’s pressure is about 1.6 times higher than that of R22, improper installation/servicing may cause a serious trouble. By using tools and materials exclusive for R410A, it is necessary to carry out installation/servicing safely while taking the following precautions into consideration.

1.Never use refrigerant other than R410A in an air conditioner which is designed to operate with R410A.

If other refrigerant than R410A is mixed, pressure in the refrigeration cycle becomes abnormally high, and it may cause personal injury, etc. by a rupture.

2.Confirm the used refrigerant name, and use tools and materials exclusive for the refrigerant R410A.

The refrigerant name R410A is indicated on the visible place of the outdoor unit of the air conditioner using R410A as refrigerant. To prevent mischarging, the diameter of the service port differs from that of R22.

3.If a refrigeration gas leakage occurs during installation/servicing, be sure to ventilate fully.

If the refrigerant gas comes into contact with fire, a poisonous gas may occur.

4.When installing or removing an air conditioner, do not allow air or moisture to remain in the refrigeration cycle. Otherwise, pressure in the refrigeration cycle may become abnormally high so that a rupture or personal injury may be caused.

5.After completion of installation work, check to make sure that there is no refrigeration gas leakage.

If the refrigerant gas leaks into the room, coming into contact with fire in the fan-driven heater, space heater, etc., a poisonous gas may occur.

6.When an air conditioning system charged with a large volume of refrigerant is installed in a small room, it is necessary to exercise care so that, even when refrigerant leaks, its concentration does not exceed the marginal level.

If the refrigerant gas leakage occurs and its concentration exceeds the marginal level, an oxygen starvation accident may result.

7.Be sure to carry out installation or removal according to the installation manual.

Improper installation may cause refrigeration trouble, water leakage, electric shock, fire, etc.

8.Unauthorized modifications to the air conditioner may be dangerous. If a breakdown occurs please call a qualified air conditioner technician or electrician.

Improper repair’s may result in water leakage, electric shock and fire, etc.

3-2. Refrigerant Piping Installation

3-2-1. Piping Materials and Joints Used

For the refrigerant piping installation, copper pipes and joints are mainly used. Copper pipes and joints suitable for the refrigerant must be chosen and installed. Furthermore, it is necessary to use clean copper pipes and joints whose interior surfaces are less affected by contaminants.

1.Copper Pipes

It is necessary to use seamless copper pipes which are made of either copper or copper alloy and it is desirable that the amount of residual oil is less than 40 mg/10 m. Do not use copper pipes having a collapsed, deformed or discolored portion (especially on the interior surface).

Otherwise, the expansion valve or capillary tube may become blocked with contaminants.

As an air conditioner using R410A incurs pressure higher than when using R22, it is necessary to choose adequate materials.

Thicknesses of copper pipes used with R410A are as shown in Table 3-2-1. Never use copper pipes thinner than 0.8 mm even when it is available on the market.

– 8 –

			FILE NO. SVM-10052
	Table 3-2-1 Thicknesses of annealed copper pipes
			Thickness (mm)
Nominal diameter	Outer diameter (mm)	R410A	R22
1/4	6.35	0.80	0.80
3/8	9.52	0.80	0.80
1/2	12.70	0.80	0.80
5/8	15.88	1.00	1.00

2.Joints

For copper pipes, flare joints or socket joints are used. Prior to use, be sure to remove all contaminants.

a)Flare Joints

Flare joints used to connect the copper pipes cannot be used for pipings whose outer diameter exceeds 20 mm. In such a case, socket joints can be used.

Sizes of flare pipe ends, flare joint ends and flare nuts are as shown in Tables 3-2-3 to 3-2-6 below.

b)Socket Joints

Socket joints are such that they are brazed for connections, and used mainly for thick pipings whose diameter is larger than 20 mm.

Thicknesses of socket joints are as shown in Table 3-2-2.

Table 3-2-2 Minimum thicknesses of socket joints

	Nominal diameter	Reference outer diameter of	Minimum joint thickness
		copper pipe jointed (mm)	(mm)
	1/4	6.35	0.50
	3/8	9.52	0.60
	1/2	12.70	0.70
	5/8	15.88	0.80

3-2-2. Processing of Piping Materials

When performing the refrigerant piping installation, care should be taken to ensure that water or dust does not enter the pipe interior, that no other oil than lubricating oils used in the installed air-water heat pump is used, and that refrigerant does not leak. When using lubricating oils in the piping processing, use such lubricating oils whose water content has been removed. When stored, be sure to seal the container with an airtight cap or any other cover.

1.Flare processing procedures and precautions

a)Cutting the Pipe

By means of a pipe cutter, slowly cut the pipe so that it is not deformed.

b)Removing Burrs and Chips

If the flared section has chips or burrs, refrigerant leakage may occur. Carefully remove all burrs and clean the cut surface before installation.

c)Insertion of Flare Nut

– 9 –

FILE NO. SVM-10052

d) Flare Processing

Make certain that a clamp bar and copper pipe have been cleaned.

By means of the clamp bar, perform the flare processing correctly.

Use either a flare tool for R410A or conventional flare tool.

Flare processing dimensions differ according to the type of flare tool. When using a conventional flare tool, be sure to secure “dimension A” by using a gauge for size adjustment.

ØD

A

Fig. 3-2-1 Flare processing dimensions

Table 3-2-3 Dimensions related to flare processing for R410A

		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R410A	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	Clutch type	Wing nut type
	1/4	6.35	0.8		0 to 0.5	1.0 to 1.5	1.5 to 2.0
	3/8	9.52	0.8		0 to 0.5	1.0 to 1.5	1.5 to 2.0
	1/2	12.70	0.8		0 to 0.5	1.0 to 1.5	2.0 to 2.5
	5/8	15.88	1.0		0 to 0.5	1.0 to 1.5	2.0 to 2.5
		Table 3-2-4 Dimensions related to flare processing for R22
		Outer				A (mm)
	Nominal		Thickness
		diameter			Flare tool for R22	Conventional flare tool
	diameter		(mm)
		(mm)
					clutch type	Clutch type	Wing nut type
	1/4	6.35	0.8		0 to 0.5	0.5 to 1.0	1.0 to 1.5
	3/8	9.52	0.8		0 to 0.5	0.5 to 1.0	1.0 to 1.5
	1/2	12.70	0.8		0 to 0.5	0.5 to 1.0	1.5 to 2.0
	5/8	15.88	1.0		0 to 0.5	0.5 to 1.0	1.5 to 2.0

Table 3-2-5 Flare and flare nut dimensions for R410A

Nominal	Outer diameter	Thickness		Dimension (mm)					Flare nut width
diameter	(mm)	(mm)	A		B	C		D	(mm)
1/4	6.35	0.8	9.1		9.2	6.5		13	17
3/8	9.52	0.8	13.2		13.5	9.7		20	22
1/2	12.70	0.8	16.0		16.6	12.9		23	26
5/8	15.88	1.0	19.0		19.7	16.0		25	29

– 10 –

																										FILE NO. SVM-10052
		Table 3-2-6 Flare and flare nut dimensions for R22
Nominal	Outer diameter									Thickness									Dimension (mm)												Flare nut width
diameter		(mm)										(mm)						A		B		C				D					(mm)
1/4	6.35									0.8							9.0			9.2	6.5					13					17
3/8	9.52									0.8							13.0			13.5	9.7					20					22
1/2	12.70									0.8							16.0			16.2	12.9					20					24
5/8	15.88									1.0							19.0			19.7	16.0					23					27
3/4	19.05									1.0							23.3			24.0	19.2					34					36
			46
	45		to
								B			A													C			D

				43	to
					45

Fig. 3-2-2 Relations between flare nut and flare seal surface

2.Flare Connecting Procedures and Precautions

a)Make sure that the flare and union portions do not have any scar or dust, etc.

b)Correctly align the processed flare surface with the union axis.

c)Tighten the flare with designated torque by means of a torque wrench. The tightening torque for R410A is the same as that for conventional R22. Incidentally, when the torque is weak, the gas leakage may occur.

When it is strong, the flare nut may crack and may be made non-removable. When choosing the tightening torque, comply with values designated by manufacturers. Table 3-2-7 shows reference values.

NOTE :

When applying oil to the flare surface, be sure to use oil designated by the manufacturer.

If any other oil is used, the lubricating oils may deteriorate and cause the compressor to burn out.

Table 3-2-7 Tightening torque of flare for R410A [Reference values]

	Nominal	Outer diameter	Tightening torque	Tightening torque of torque
				wrenches available on the market
	diameter	(mm)	N•m (kgf•cm)
				N•m (kgf•cm)
	1/4	6.35	14 to 18 (140 to 180)	16 (160), 18 (180)
	3/8	9.52	33 to 42 (330 to 420)	42 (420)
	1/2	12.70	50 to 62 (500 to 620)	55 (550)
	5/8	15.88	63 to 77 (630 to 770)	65 (650)

– 11 –

FILE NO. SVM-10052

3-3. Tools

3-3-1. Required Tools

The service port diameter of packed valve of the outdoor unit in the air-water heat pump using R410A is changed to prevent mixing of other refrigerant. To reinforce the pressure-resisting strength, flare processing dimensions and opposite side dimension of flare nut (For Ø12.7 copper pipe) of the refrigerant piping are lengthened.

The used refrigerating oil is changed, and mixing of oil may cause a trouble such as generation of sludge, clogging of capillary, etc. Accordingly, the tools to be used are classified into the following three types.

1.Tools exclusive for R410A (Those which cannot be used for conventional refrigerant (R22))

2.Tools exclusive for R410A, but can be also used for conventional refrigerant (R22)

3.Tools commonly used for R410A and for conventional refrigerant (R22)

The table below shows the tools exclusive for R410A and their interchangeability.

Tools exclusive for R410A (The following tools for R410A are required.)

Tools whose specifications are changed for R410A and their interchangeability

				R410A		Conventional air-water
				air-water heat pump installation		heat pump installation
	No.	Used tool	Usage
				Existence of	Whether conven-	Whether new equipment
				new equipment	tional equipment	can be used with
				for R410A	can be used	conventional refrigerant
	1	Flare tool	Pipe flaring	Yes	*(Note 1)	Yes
		Copper pipe gauge for	Flaring by
	2	adjusting projection		Yes	*(Note 1)	*(Note 1)
			conventional flare tool
		margin
	3	Torque wrench	Connection of flare nut	Yes	No	No
		(For Ø12.7)
	4	Gauge manifold	Evacuating, refrigerant	Yes	No	No
	5	Charge hose	charge, run check, etc.
	6	Vacuum pump adapter	Vacuum evacuating	Yes	No	Yes
	7	Electronic balance for	Refrigerant charge	Yes	No	Yes
		refrigerant charging
	8	Refrigerant cylinder	Refrigerant charge	Yes	No	No
	9	Leakage detector	Gas leakage check	Yes	No	Yes
	10	Charging cylinder	Refrigerant charge	*(Note 2)	No	No

(Note 1) When flaring is carried out for R410A using the conventional flare tools, adjustment of projection margin is necessary. For this adjustment, a copper pipe gauge, etc. are necessary.

(Note 2) Charging cylinder for R410A is being currently developed.

General tools (Conventional tools can be used.)

In addition to the above exclusive tools, the following equipments which serve also for R22 are necessary as the general tools.

1.Vacuum pump

Use vacuum pump by attaching vacuum pump adapter.

2.Torque wrench (For Ø6.35, Ø9.52)

3.Pipe cutter

4.	Reamer	9.	Hole core drill (Ø65)
5.	Pipe bender	10.	Hexagon wrench
6.	Level vial		(Opposite side 4mm)
7.	Screwdriver (+, –)	11.	Tape measure
8.	Spanner or Monkey wrench	12.	Metal saw

Also prepare the following equipments for other installation method and run check.

1.	Clamp meter	3.	Insulation resistance tester
2.	Thermometer	4.	Electroscope

– 12 –

FILE NO. SVM-10052

3-4. Recharging of Refrigerant

When it is necessary to recharge refrigerant, charge the specified amount of new refrigerant according to the following steps.

Recover the refrigerant, and check no refrigerant remains in the equipment.

Connect the charge hose to packed valve service port at the outdoor unit’s gas side.

Connect the charge hose to the vacuum pump adapter.

Open fully both packed valves at liquid and gas sides.

Place the handle of the gauge manifold Low in the fully opened position, and turn on the vacuum pump’s power switch. Then, evacuating the refrigerant in the cycle.

When the compound gauge’s pointer has indicated –0.1 MPa (–76 cmHg), place the handle Low in the fully closed position, and turn off the vacuum pump’s power switch.

Keep the status as it is for 1 to 2 minutes, and ensure that the compound gauge’s pointer does not return.

Set the refrigerant cylinder to the electronic balance, connect the connecting hose to the cylinder and the connecting port of the electronic balance, and charge

liquid refrigerant.

(For refrigerant charging, see the figure below.)

1.Never charge refrigerant exceeding the specified amount.

2.If the specified amount of refrigerant cannot be charged, charge refrigerant bit by bit in COOL mode.

3.Do not carry out additional charging.

When additional charging is carried out if refrigerant leaks, the refrigerant composition changes in the refrigeration cycle, that is characteristics of the air conditioner changes, refrigerant exceeding the specified amount is charged, and working pressure in the refrigeration cycle becomes abnormally high pressure, and may cause a rupture or personal injury.

(Indoor unit)	(Outdoor unit)

Opened

	Refrigerant cylinder
	(with siphon)
	Check valve	Opened
	Opened
	Open/close	Closed
	valve for charging
		Service port
	Electronic balance for refrigerant charging

Fig. 3-4-1 Configuration of refrigerant charging

– 13 –

FILE NO. SVM-10052

1.Be sure to make setting so that liquid can be charged.

2.When using a cylinder equipped with a siphon, liquid can be charged without turning it upside down.

It is necessary for charging refrigerant under condition of liquid because R410A is mixed type of refrigerant. Accordingly, when charging refrigerant from the refrigerant cylinder to the equipment, charge it turning the cylinder upside down if cylinder is not equipped with siphon.

[ Cylinder with siphon ]	[ Cylinder without siphon ]
Gauge manifold	Gauge manifold
OUTDOOR unit	OUTDOOR unit

Refrigerant

cylinder

Electronic

balance

cylinder Refrigerant

Electronic

balance

Siphon

R410A refrigerant is HFC mixed refrigerant. Therefore, if it is charged with gas, the composition of the charged refrigerant changes and the characteristics of the equipment varies.

Fig. 3-4-2

3-5. Brazing of Pipes

3-5-1. Materials for Brazing

1.Silver brazing filler

Silver brazing filler is an alloy mainly composed of silver and copper. It is used to join iron, copper or copper alloy, and is relatively expensive though it excels in solderability.

2.Phosphor bronze brazing filler

Phosphor bronze brazing filler is generally used to join copper or copper alloy.

3.Low temperature brazing filler

1.Phosphor bronze brazing filler tends to react with sulfur and produce a fragile compound water solution, which may cause a gas leakage. Therefore, use any other type of brazing filler at a hot spring resort, etc., and coat the surface with a paint.

2.When performing brazing again at time of servicing, use the same type of brazing filler.

3-5-2. Flux

1. Reason why flux is necessary

Low temperature brazing filler is generally called solder, and is an alloy of tin and lead. Since it is weak in adhesive strength, do not use it for refrigerant pipes.

•By removing the oxide film and any foreign matter on the metal surface, it assists the flow of brazing filler.

•In the brazing process, it prevents the metal surface from being oxidized.

•By reducing the brazing filler’s surface tension, the brazing filler adheres better to the treated metal.

– 14 –

2.Characteristics required for flux

•Activated temperature of flux coincides with the brazing temperature.

•Due to a wide effective temperature range, flux is hard to carbonize.

•It is easy to remove slag after brazing.

•The corrosive action to the treated metal and brazing filler is minimum.

•It excels in coating performance and is harmless to the human body.

As the flux works in a complicated manner as described above, it is necessary to select an adequate type of flux according to the type and shape of treated metal, type of brazing filler and brazing method, etc.

3.Types of flux

•Noncorrosive flux

Generally, it is a compound of borax and boric acid.

It is effective in case where the brazing temperature is higher than 800°C.

•Activated flux

Most of fluxes generally used for silver brazing are this type.

It features an increased oxide film removing capability due to the addition of compounds such as potassium fluoride, potassium chloride and sodium fluoride to the borax-boric acid compound.

4.Piping materials for brazing and used brazing filler/flux

Piping material	Used brazing filler	Used flux
Copper - Copper	Phosphor copper	Do not use
Copper - Iron	Silver	Paste flux
Iron - Iron	Silver	Vapor flux

1.Do not enter flux into the refrigeration cycle.

2.When chlorine contained in the flux remains within the pipe, the lubricating oil deteriorates. Therefore, use a flux which does not contain chlorine.

3.When adding water to the flux, use water which does not contain chlorine (e.g. distilled water or ion-exchange water).

4.Remove the flux after brazing.

FILE NO. SVM-10052

3-5-3. Brazing

As brazing work requires sophisticated techniques, experiences based upon a theoretical knowledge, it must be performed by a person qualified.

In order to prevent the oxide film from occurring in the pipe interior during brazing, it is effective to proceed with brazing while letting dry Nitrogen gas (N2) flow.

Never use gas other than Nitrogen gas.

1.Brazing method to prevent oxidation

1)Attach a reducing valve and a flow-meter to the Nitrogen gas cylinder.

2)Use a copper pipe to direct the piping material, and attach a flow-meter to the cylinder.

3)Apply a seal onto the clearance between the piping material and inserted copper pipe for Nitrogen in order to prevent backflow of the Nitrogen gas.

4)When the Nitrogen gas is flowing, be sure to keep the piping end open.

5)Adjust the flow rate of Nitrogen gas so that it is lower than 0.05 m3/Hr or 0.02 MPa (0.2kgf/cm2) by means of the reducing valve.

6)After performing the steps above, keep the Nitrogen gas flowing until the pipe cools down to a certain extent (temperature at which pipes are touchable with hands).

7)Remove the flux completely after brazing.

M Flow meter

Stop valve

Nitrogen gas cylinder

From Nitrogen cylinder

Pipe

Nitrogen gas

Rubber plug

Fig. 3-5-1 Prevention of oxidation during brazing

– 15 –

4.CONSTRUCTION VIEWS	FILE NO. SVM-10052

4-1. Indoor Unit

42NQV050M,42NQV060M 42NQV050M-N,42NQV060M-N 42NQV050M-A,42NQV060M-A

<![if ! IE]>

<![endif]>157

56 19

Wireless remote controller

<![if ! IE]>

<![endif]>125

63

26

Remote controller holder

−16 −

FILE NO. SVM-10052

4.2 Outdoor Unit

				A
				28	108	125
			600				<![if ! IE]> <![endif]>30
		50	R15
		36
			<![if ! IE]> <![endif]>320	<![if ! IE]> <![endif]>86
<![if ! IE]> <![endif]>320	<![if ! IE]> <![endif]>306		Ø6 hole
			R5.5
A detail Drawing (Back leg)				Ø25 Drain outlet	2- Ø11 x 14		Hole
					(For Ø8 -Ø10 anchor bolt)

	<![if ! IE]> <![endif]>320	<![if ! IE]> <![endif]>306
	Ø6 hole		36	R15
	Ø11x14 hole
			50

B Detail Drawing (Front leg)

		FAN-GUARD
		Ø 436
		<![if ! IE]> <![endif]>550
		<![if ! IE]> <![endif]>275
	290	90	600	90	69	320
						342

COVER-PV

Z

		Electrical part cover
		Liquid side
		(Flare Ø6.35)
		Gas side
		(Flare 12.7)
<![if ! IE]> <![endif]>129	<![if ! IE]> <![endif]>84	5
		4

	Z View		Service port
			2-R5-5 x 17L Ushope
	600		(For 8- 10 anchor bolt)
100 or more		Air intlel
			600 or more
<![if ! IE]> <![endif]>320
100 or more	Air outlel	600 or more
			2- 11x14 Long holes
	Installation dimension		(For 8 - 10 anchor bolt)

− 17−

FILE NO. SVM-10052-1

5. WIRING DIAGRAM

COMPRESSOR
CM	1 1	RED P04
	2 2	WHI	P05
		BLK	P06	Q200	205
	3 3			IGBT
		P25			R221			6 6
	YEL		P24
					R220			5 5	PMV
		P23						4 4
	YEL		P22					3 3
		P21			R219			2 2
	BRW		P20					1 1
		P35			L03	C13		3 3
	YEL	P34						2
								1 1
									TS
							AC250V		(SUCTION PIPE
								2 2	TEMP. SENSOR)
				POWER			CN602
								1 1
				RELAY					TO
									(OUTDOOR
					CT			3 3	TEMP. SENSOR)
							CN601 2
								1 1
	1 1								TD
	2 2				RELAY				(DISCHARGE PIPE
									TEMP. SENSOR)
								2 2
							CN600
								1 1	TE
						1	3
									(CONDENSER PIPE
			PUR		1 2	1	3		TEMP. SENSOR)
					1 2
							COIL
							FOR
							4WAY
							VALVE
							220-240V~,50Hz / 220-230V~,60Hz
							: (42NQV050M,42NQV060M,42NQV050M-N,42NQV060M-N)
							220-240V~,50Hz : 42NQV050M-A,42NQV060M-A

Heat

Exchanger

GRN&YEL

– 18 –

FILE NO. SVM-10052

6. SPECIFICATIONS OF ELECTRICAL PARTS

6-1. Indoor Unit

No.	Parts name

Fan motor

1(for indoor)

2Room temp. sensor (TA-sensor)

3Heat exchanger temp. sensor (TC-sensor)

4Louver motor

Type	Specifications
ICF-340-30-2B	DC-340V, 30W
( − )	10kΩ at 25°C
( − )	10kΩ at 25°C
MP24Z3T	Output (Rated) 1W, 16 poles, DC12V

6-2. Outdoor Unit

	No.		Parts name	Model name			Rating
	1	Reactor			CH-57		L = 10mH, 16A
	2	Outdoor fan motor		ICF-140-43-4R			DC140V, 43W
	3	Suction temp. sensor (TS sensor)		(Inverter attached)			10kΩ (25°C)
	4	Discharge temp. sensor (TD sensor)		(Inverter attached)			62kΩ (20°C)
	5	Outside air temp. sensor (TO sensor)		(Inverter attached)			10kΩ (25°C)
	6	Heat exchanger temp. sensor (TE sensor)		(Inverter attached)			10kΩ (25°C)
	7	Terminal block (6P)					20A, AC250V
	8	Compressor	38NYV050M2,38NYV050M-A	DA130A1F-27F			3-phases 4-poles 1100W
			38NYV060M2,38NYV060M-A	DA150A1F-20F
	9	COIL FOR P.M.V.		CAM-MD12TF-10			DC12V
	10	Coil for 4-way valve			STF		AC220-240V

– 19 –

FILE NO. SVM-10052

7. REFRIGERANT CYCLE DIAGRAM

7-1. Refrigerant Cycle Diagram

42NQV050M / 38NYV050M2 42NQV050M-N / 38NYV050M2 42NQV050M-A / 38NYV050M-A

P Pressure measurement

Gauge attaching port

Vacuum pump connecting port

Deoxidized copper pipe

Outer dia. : 12.7mm

Thickness : 0.8mm

INDOOR UNIT	T1	Temp. measurement
Indoor heat
exchanger
	TC	<![if ! IE]> <![endif]>height	<![if ! IE]> <![endif]>length
Cross flow fan				Min.	: 2m
	TA	<![if ! IE]> <![endif]>10m		Max.	: 20m
			<![if ! IE]> <![endif]>Allowablepipe
		<![if ! IE]> <![endif]>:
Deoxidized copper pipe		<![if ! IE]> <![endif]>Allowable difference		Chargeless : 15m
Outer dia. : 6.35mm				Charge : 20g/m
Thickness : 0.8mm				(16 to 20m)
Sectional shape
of heat insulator

4-way valve
(STF-0108Z)	Muffler
	Muffler
Accumulater	TD
tank

Compressor

DA130A1F-27F

TS
	TO
Outdoor heat	Split capillary
exchanger	2 - Dia 1.2 x 80

Strainer

Pulse Modulating valve at liquid side (CAM-B22YGTF-3)

		TE	DISTRIBUTOR
	Propeller fan		Refrigerant amount : 1.40kg

OUTDOOR UNIT	NOTE :		Gas leak check position
			Refrigerant flow (Cooling)
			Refrigerant flow (Heating)

NOTE :

•The maximum pipe length of this air conditioner is 20 m. When the pipe length exceeds 15m, the additional charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 100g)

–20 –

42NQV060M / 38NYV060M2 42NQV060M-N / 38NYV060M2 42NQV060M-A / 38NYV060M-A

FILE NO. SVM-10052

P Pressure measurement

Gauge attaching port Vacuum pump connecting port

Deoxidized copper pipe Outer dia. : 12.7mm Thickness : 0.8mm

INDOOR UNIT	T1	Temp. measurement
Indoor heat
exchanger
	TC	<![if ! IE]> <![endif]>height	<![if ! IE]> <![endif]>length
Cross flow fan				Min.	: 2m
	TA	<![if ! IE]> <![endif]>10m		Max.	: 20m
			<![if ! IE]> <![endif]>Allowablepipe
		<![if ! IE]> <![endif]>:
Deoxidized copper pipe		<![if ! IE]> <![endif]>Allowable difference		Chargeless : 15m
Outer dia. : 6.35mm				Charge : 20g/m
Thickness : 0.8mm				(16 to 20m)
Sectional shape
of heat insulator

4-way valve (STF-0213Z)

Accumulater tank

NOTE :

Strainer

Muffler

Muffler		Pulse Modulating
		valve at liquid side
TD		(CAM-B22YGTF-3)
Compressor
DA150A1F-20F
TS
TO	Split capillary
Outdoor heat
	1 -Dia 2.0 x 100
exchanger
	2 - 4 Dia 2.0 x 66
	1
	2
	3
	4
	DISTRIBUTOR
Propeller fan	TE		Refrigerant amount : 1.40kg
OUTDOOR UNIT		NOTE :	Gas leak check position

Refrigerant flow (Cooling)

Refrigerant flow (Heating)

•The maximum pipe length of this air conditioner is 15 m. When the pipe length exceeds 15m, the additional charging of refrigerant, 20g per 1m for the part of pipe exceeded 15m is required. (Max. 100g)

–21 –

FILE NO. SVM-10052-1

8. CONTROL BLOCK DIAGRAM

8-1. Indoor Unit

M.C.U.	Indoor Unit Control Unit

Heat Exchanger Sensor (TC)

Room Temperature Sensor (TA)

Infrared Rays Signal Receiver

and Indication

Initializing Circuit

Clock Frequency

Oscillator Circuit

Functions

•Cold draft preventing Function

•3-minute Delay at Restart for Compressor

• Fan Motor Starting Control

•Processing

(Temperature Processing)

•Timer

•Serial Signal Communication

Louver

Motor

Louver Motor

Drive Control

Indoor Fan

Motor Control

Indoor

Fan Motor

Power Supply

Circuit

Converter (D.C circuit)

	Noise Filter		Serial Signal Transmitter/Receiver
From Outdoor Unit
			Serial Signal Communication
220-240V~, 50Hz / 220-230V~, 60Hz : 42NQV050M,42NQV060M,
	42NQV050M-N,42NQV060M-N		(Operation Command and Information)
220-240V~, 50Hz : 42NQV050M-A,42NQV060M-A
			Remote Controller	Infrared Rays, 36.7kHz

REMOTE CONTROLLER

Operation ()

Operation Mode Selection

AUTO, COOL, DRY, HEAT, FAN ONLY

Thermo. Setting

Fan Speed Selection

ON TIMER Setting

OFF TIMER Setting

Louver AUTO Swing

Louver Direction Setting

ECO

Hi-POWER

SLEEP (1,3,5,9 OFF TIMER)

QUIET

– 22 –

For INDOOR UNIT	MICRO-COMPUTER BLOCK DIAGRAM

	220-240V~, 50Hz / 220-230V~, 60Hz : (38NYV050M2,38NYV060M2,
	220-240V~, 50Hz : (38NYV050M-A,38NYV060M-A)
			MCC5009 (P.C.B)				OUTDOOR UNIT
	Indoor unit		M.C.U			Current
	send/receive
	circuit					detect
		•	PWM synthesis function
		•	Input current release control			Gate drive
	Discharge	•	IGBT over-current detect control
		•	Outdoor fan control			circuit
	temp. sensor
		•	High power factor correction control
	Outdoor air	•	Inverter output frequency control
	temp. sensor	•	A/D converter function			Current
		•	P.M.V. control			detect
<![if ! IE]> <![endif]>–	Suction temp.
		•	Discharge temp. control
<![if ! IE]> <![endif]>23
	sensor
		•	4-way valve control
<![if ! IE]> <![endif]>–						Gate drive
	Heat exchanger	•	Signal communication to indoor unit
	temp.sensor					circuit
		High Power		Clock
		factor Correction		frequency
			circuit	4MHz
	Noise	Input current		Converter		Inverter	Outdoor
	Filter		sensor	(AC → DC)		(DC → AC)	Fan motor
			Driver circuit		Relay	Inverter	Compressor
			of P.M.V.		circuit	(DC → AC)

P.M.V. : Pulse Motor Valve

4-way M.C.U. : Micro Control Unit P.M.V. valve

<![if ! IE]>

<![endif]>Assembly) (Inverter Unit Outdoor .2-8

<![if ! IE]>

<![endif]>1-10052-SVM .NO FILE

FILE NO. SVM-10052

9. OPERATION DESCRIPTION

9-1. Outline of Air Conditioner Control

This air conditioner is a capacity-variable type air conditioner, which uses DC motor for the indoor

for motor and the outdoor fan motor. And the capacityproportional control compressor which can change the motor speed in the range from 11 to 120 rps is mounted. The DC motor drive circuit is mounted to the indoor unit. The compressor and the inverter to control fan motor are mounted to the outdoor unit.

The entire air conditioner is mainly controlled by the indoor unit controller.

The indoor unit controller drives the indoor fan motor based upon command sent from the remote controller, and transfers the operation command to the outdoor unit controller.

The outdoor unit controller receives operation command from the indoor unit side, and controls the outdoor fan and the pulse Modulating valve. (P.M.V) Besides, detecting revolution position of the compressor motor, the outdoor unit controller controls speed of the compressor motor by controlling output voltage of the inverter and switching timing of the supply power (current transfer timing) so that motors drive according to the operation command.

And then, the outdoor unit controller transfers reversely the operating status information of the outdoor unit to control the indoor unit controller.

As the compressor adopts four-pole brushless DC motor, the frequency of the supply power from inverter to compressor is two-times cycles of the actual number of revolution.

1.Role of indoor unit controller

The indoor unit controller judges the operation commands from the remote controller and assumes the following functions.

•Judgment of suction air temperature of the indoor heat exchanger by using the indoor temp. sensor. (TA sensor)

•Judgment of the indoor heat exchanger temperature by using heat exchanger sensor (TC sensor) (Prevent-freezing control, etc.)

•Louver motor control

•Indoor fan motor operation control

•LED (Light Emitting Diode) display control

•Transferring of operation command signal (Serial signal) to the outdoor unit

•Reception of information of operation status (Serial signal including outside temp. data) to the outdoor unit and judgment/display of error

•Air purifier operation control

2.Role of outdoor unit controller

Receiving the operation command signal (Serial signal) from the indoor unit controller, the outdoor unit performs its role.

•Detection of inverter input current and current release operation

•Over-current detection and prevention operation to IGBT module (Compressor stop function)

•Compressor and outdoor fan stop function when serial signal is off (when the serial signal does not reach the board assembly of outdoor control by trouble of the signal system)

•Transferring of operation information (Serial signal) from outdoor unit controller to indoor unit controller

•Detection of outdoor temperature and operation revolution control

•Defrost control in heating operation (Temp. measurement by outdoor heat exchanger and control for 4-way valve and outdoor fan)

3.Contents of operation command signal (Serial signal) from indoor unit controller to outdoor unit controller

The following three types of signals are sent from the indoor unit controller.

•Operation mode set on the remote controller

•Compressor revolution command signal defined by indoor temperature and set temperature (Correction along with variation of room temperature and correction of indoor heat exchanger temperature are added.)

•Temperature of indoor heat exchanger

•For these signals ([Operation mode] and [Compressor revolution] indoor heat exchanger temperature), the outdoor unit controller monitors the input current to the inverter, and performs the followed operation within the range that current does not exceed the allowable value.

4.Contents of operation command signal (Serial signal) from outdoor unit controller to indoor unit controller

The following signals are sent from the outdoor unit controller.

•The current operation mode

•The current compressor revolution

•Outdoor temperature

•Existence of protective circuit operation

For transferring of these signals, the indoor unit controller monitors the contents of signals, and judges existence of trouble occurrence.

Contents of judgment are described below.

•Whether distinction of the current operation status meets to the operation command signal

•Whether protective circuit operates

When no signal is received from the outdoor unit controller, it is assumed as a trouble.

•Compressor operation control

•Operation control of outdoor fan motor

•P.M.V. control

•4-way valve control

	Operations followed to judgment
	of serial signal from indoor side.

– 24 –

		FILE NO. SVM-10052
9-2.	Operation Description
	1.	Basic operation ...........................................................................................................	26
		1. Operation control ...................................................................................................	26
		2. Cooling/Heating operation .....................................................................................	27
		3. AUTO operation .....................................................................................................	27
		4. DRY operation ........................................................................................................	27
	2.	Indoor fan motor control .............................................................................................	28
	3.	Outdoor fan motor control...........................................................................................	30
	4.	Capacity control ..........................................................................................................	31
	5.	Current release control ...............................................................................................	31
	6.	Release protective control by temperature of indoor heat exchanger ........................	32
	7.	Defrost control (Only in heating operation) ................................................................	33
	8.	Louver control .............................................................................................................	34
		1) Louver position .......................................................................................................	34
		2) Air direction adjustment .........................................................................................	34
		3) Swing .....................................................................................................................	34
	9.	ECO operation ............................................................................................................	35
	10.	Temporary operation ...................................................................................................	36
	11.	Pulse Modulating valve (P.M.V.) control ......................................................................	36
	12.	Remote-A or B selection ............................................................................................	37
	13.	Short Timer ................................................................................................................	37
	14.	Hi-POWER Mode ......................................................................................................	38
9-3.	Auto Restart Function................................................................................................		39
	9-3-1. How to Set the Auto Restart Function .............................. ........................................		39
	9-3-2. How to Cancel the Auto Restart Function ................................................................ .		40
	9-3-3. Power Failure During Timer Operation ................................................................... .		40
9-4. Remote Controller and Its Fuctions ......................................................................			41
	9-4-1. Parts Name of Remote Controller ...............................................................................		41
	9-4-2. Operation of remote control .......................................................................................		41
	9-4-3. Name and Functions of Indications on Remote Controller .........................................		44

25 −

–

FILE NO. SVM-10052

Item

Operation flow and applicable data, etc.

Description

1. Basic 1. Operation control

operation Receiving the user’s operation condition setup, the operation statuses of indoor/outdoor units are controlled.

1)The operation conditions are selected by the remote controller as shown in the below.

2)A signal is sent by ON button of the remote controller.

3)The signal is received by a sensor of the indoor unit and processed by the indoor controllers as shown in the below.

4)The indoor controller controls the indoor fan motor and louver motor.

5)The indoor controller sends the operation command to the outdoor controller, and sends/receives the control status with a serial signal.

6)The outdoor controller controls the operation as shown in the left, and also controls the compressor, outdoor fan motor, 4-way valve and pulse Modulating valve.

Remote controller

Selection of operation conditions

ON/OFF

Control contents of remote controller

•ON/OFF (Air conditioner/Air purifier)

•Operation select (COOL/HEAT/AUTO/DRY)

•Temperature setup

•Air direction

•Swing

•Air volume select (AUTO/LOW/LOW+/MED/MED+/HIGH)

•ECO

•ON timer setup

•OFF timer setup

•Hi-POWER

				Indoor unit
	Signal receiving			Indoor unit control
				• Command signal generating function of
	Indoor unit control			indoor unit operation		• Indoor fan motor
				• Calculation function (temperature calculation)
				• Activation compensation function of indoor fan		• Louver motor
	Operation command
				• Cold draft preventive function
				• Timer function
	Serial signal send/receive			• Indoor heat exchanger release control

Outdoor unit

~

Serial signal send/receive

Outdoor unit control

Inverter

• Frequency control of inverter output

Outdoor unit control

• Waveform composite function

• Calculation function

• Compressor

(Temperature calculation)

• Outdoor fan motor

• AD conversion function

• 4-way valve

• Quick heating function

• Pulse Modulating valve

• Delay function of compressor reactivation

(P.M.V.)

• Current release function

• GTr over-current preventive function

• Defrost operation function

– 26 –

		FILE NO. SVM-10052
Item	Operation flow and applicable data, etc.	Description
1. Basic	2. Cooling/Heating operation
operation	The operations are performed in the following parts by controls according to cooling/heating conditions.

1)Receiving the operation ON signal of the remote controller, the cooling or heating operation signal starts being transferred form the indoor controller to the outdoor unit.

2)At the indoor unit side, the indoor fan is operated according to the contents of “2. Indoor fan motor control” and the louver according to the contents of “9. Louver control”, respectively.

3)The outdoor unit controls the outdoor fan motor, compressor, pulse Modulating valve and 4-way valve according to the operation signal sent from the indoor unit.

Operation ON

Setup of remote controller

Indoor fan motor control / Louver control / Operation Hz

Indoor unit control

Control (Requierment)

Sending of operation command signal

Compressor revolution control / Outdoor fan motor control /

Operation Hz control (Include limit control)

Outdoor unit control

4-way valve control

In cooling operation: ON

[

In heating operation: OFF ]

Pulse Modulating valve control

3. AUTO operation

1) Detects the room temperature (Ta) when

Selection of operation mode

the operation started.

As shown in the following figure, the operation starts by

2) Selects an operation mode from Ta in

selecting automatically the status of room temperature

the left figure.

(Ta) when starting AUTO operation.

3) Fan operation continues until an

*1. When reselecting the operation mode, the fan

operation mode is selected.

speed is controlled by the previous operation mode.

4) When AUTO operation has started

within 2 hours after heating operation

Ta

stopped and if the room temperature is

Cooling operation

20°C or more, the fan operation is

performed with ”Super Ultra LOW” mode

Ts + 1

for 3 minutes.

Monitoring (Fan)

Then, select an operation mode.

5) If the status of compressor-OFF

Ts – 1

continues for 15 minutes the room

Heating operation

temperature after selecting an operation

mode (COOL/HEAT), reselect an

operation mode.

4. DRY operation

1) Detects the room temperature (Ta) when

DRY operation is performed according to the difference

the DRY operation started.

between room temperature and the setup temperature as

2) Starts operation under conditions in the

shown below.

left figure according to the temperature

In DRY operation, fan speed is controlled in order to

difference between the room tempera-

prevent lowering of the room temperature and to avoid air

ture and the setup temperature (Tsc).

flow from blowing directly to persons.

Setup temperature (Tsc)

= Set temperature on remote controller

[ C]

(Ts) + (0.0 to 1.0)

3) When the room temperature is lower

Ta

L– (W5)

1°C or less than the setup temperature,

turn off the compressor.

+1.0

(W5+W3) / 2

+0.5

SUL (W3)

Tsc

Fan speed

–− 27 −

FILE NO. SVM-10052

Item

Operation flow and applicable data, etc.

Description

2. Indoor fan

<In cooling operation>

motor control

(This operation controls the fan speed at indoor unit side.)

* Symbols

The indoor fan (cross flow fan) is operated by the phase-

UH

: Ultra High

control induction motor. The fan rotates in 5 stages in

H

: High

MANUAL mode, and in 5 stages in AUTO mode, respec-

M+

: Medium+

tively. (Table 1)

M

: Medium

L+

: Low+

L

: Low

COOL ON

L-

: Low–

UL

: Ultra Low

SUL

: Super Ultra Low

Fan speed setup

MANUAL

* The fan speed broadly varies due

(Fig. 1)

to position of the louver, etc.

The described value indicates one

AUTO

Indication

Fan speed

under condition of inclining

L

W6

downward blowing.

1) When setting the fan speed to L,

L+

(L + M) / 2

L+, M, M+ or H on the remote

M

W9

controller, the operation is

performed with the constant

M+

(M + H) / 2

speed shown in Fig. 1.

H

WC

2) When setting the fan speed to

AUTO on the remote controller,

(Fig. 2)

revolution of the fan motor is

controlled to the fan speed level

shown in Fig. 2 and Table 1

Ta

Air volume AUTO

according to the setup tempera-

ture, room temperature, and heat

[ C]

M+(WB)

exchanger temperature.

+2.5

+2.0

a

*3

*3 : Fan speed = [(M+)–L] x 3/4 + L

+1.5

b

*4

*4 : Fan speed = [(M+)–L] x 2/4 + L

+1.0

c

*5

*5 : Fan speed = [(M+)–L] x 1/4 + L

+0.5

d

L(W6)

(Linear approximation

Tsc

e

from M+ and L)

(Table 1)

Indoor fan air flow rate

42NQV050M,42NQV050M-N 42NQV060M,42NQV060M-N

Fan speed COOL

HEAT

DRY

42NQV050M-A

42NQV060M-A

Fan speed

Air flow r ate

Fan speed

Air flow rate

level

(rpm)

(m3/h)

(rpm)

(m3/h)

WF

UH

1100

991

1200

1101

WE

H

1100

991

1200

1101

WD

M+

1090

980

1200

1101

WC

H

1070

957

1180

1079

WB

M+

M

980

858

1080

968

WA

940

813

1020

902

W9

M

L+

890

758

980

858

W8

L

780

636

850

713

W7

L+

L-

L+

750

603

810

669

W6

L

L

740

591

800

658

W5

L-

UL

L-

700

547

760

614

W4

UL

UL

700

547

700

547

W3

SUL

SUL

650

492

650

492

W2

SUL

500

325

500

325

W1

500

325

500

325

– 28 –

FILE NO. SVM-10052

Item

Operation flow and applicable data, etc.

Description

2. Indoor fan

<In heating operation>

1) When setting the fan speed to L,

motor control

L+, M, M+ or H on the remote

controller, the operation is per-

formed with the constant speed

HEAT ON

shown in Fig. 3 and Table 1.

2) When setting the fan speed to

AUTO on the remote controller,

MANUAL

revolution of the fan motor is

Fan speed setup

(Fig. 3)

controlled to the fan speed level

shown in Fig. 5 according to the set

Indication

Fan speed

temperature and room temperature.

3) Min air flow rate is controlled by

L

W8

temperature of the indoor heat

L+

(L + M) / 2

AUTO

exchanger (Tc) as shown in Fig. 4.

M

WA

4) Cold draft prevention, the fan

M+

(M + H) / 2

speed is controlled by temperature

of the indoor heat exchanger (Tc)

H

WE

as shown in Fig. 6.

YES

5) In order to prevent Cold draft when

TC ≥ 42 C

compressor step during heating

Min air flow rate control

operation. Then louver will move to

NO

upper position and fan speed will

Tc

Limited to Min WD tap

reduce or off.

52

51

*

41

42

No limit

* Fan speed =

– W8) + W8

(Fig. 4)

(TC –

Cold draft preventive control

Basic fan control

Fan speed

Tc

TA [ C]

b

AUTO

46

46

34

H (WE)

TSC

L+ (W9)

45

45

33

–0.5

c

Line-approximate

d

*1

33

33

21

H and SUL with Tc.

–1.0

32

32

20

e

*2

–1.5

*A+4

*A+4

*A+4

f

SUL (W2)

–2.0

*3

*A-4

*A-4

*A-4

g

Stop

–2.5

–5.0

M+ (WD)

Fan speed MANUAL in starting

Fan speed AUTO in stability

–5.5

H (WE)

Fan speed AUTO in starting

*1: Fan speed = [(M+)-(L+)] x 14 + L+ *2: Fan speed = [(M+)-(L+)] x 24 + L+ *3: Fan speed = [(M+)-(L+)] x 34 + L+

(Calculated with linear approximation from M+ and L+)

(Fig. 5)

*No limitation while fan speed MANUAL mode is in stability.

*A: When Tsc ≥ 24, A is 24, and when Tsc < 24, A is Tsc Tsc: Set value

(Fig. 6)

[In starting and in stability]

			In starting			In stability
		• Until 12 minutes passed after operation start		• When 12 to 25 minutes passed after operation start
	FAN AUTO	• When 12 to 25 minutes passed after operation			and room temp. is higher than (set temp. –3°C)
		start and room temp. is 3°C or lower than set temp.		•	When 25 minutes or more passed after operation start
	FAN Manual	• Room temp. < Set temp. –4°C		•	Room temp. ≥ Set temp. –3.5°C

– 29 –