DURASTAR DRA4U36M1B Installation Manual

Multi-zone outdoor unit

Hide thumbs Also See for DRA4U36M1B:

Installation manual (96 pages)

Installation manual (38 pages)

Installation manual (7 pages)

page of 68

/ 68
Bookmarks

Quick Links

Download this manual

INSTALLATION MANUAL

MULTI-ZONE OUTDOOR UNIT

SPLIT-STYLE AIR CONDITIONER

DRA2U18M1B, DRA3U28M1B, DRA4U36M1B,

Model Number:

Serial Number:

Purchase Date:

Installing Contractor Company Name:

TIP

Capture relevant information about your Durastar mini-split equipment before it is

installed and write it above for future reference.

DRA5U48M1B, DRA5U55M1B

DURASTAR.COM

Need help?

Do you have a question about the DRA4U36M1B and is the answer not in the manual?

Questions and answers

Summary of Contents for DURASTAR DRA4U36M1B

Page 1 MULTI-ZONE OUTDOOR UNIT SPLIT-STYLE AIR CONDITIONER DRA2U18M1B, DRA3U28M1B, DRA4U36M1B, DRA5U48M1B, DRA5U55M1B Model Number: Serial Number: Purchase Date: Installing Contractor Company Name: Capture relevant information about your Durastar mini-split equipment before it is installed and write it above for future reference. DURASTAR.COM...
Page 2 STEP 2: REMOVE BURRS ..................... 17 STEP 3: FLARE PIPE ENDS ..................18 STEP 4: CONNECT PIPES ..................... 19 SYSTEM EVACUATION ....................20 FINAL CHECKS ........................22 TEST RUN ..........................23 TROUBLESHOOTING .....................24 WIRING DIAGRAMS ......................28 ERROR AND OPERATING CODES ................32 JOB SITE INFORMATION SHEET ................33 DURASTAR.COM...
Page 3 • Read the troubleshooting section of this manual as it will help you diagnose and solve common issues. • Visit us on the web at WWW.DURASTAR.COM to download product guides and up-to-date information. • If you need warranty service, our friendly customer service representatives are available via email at QUESTIONS@DURASTAR.COM or by telephone at 1-888-320-0706.
Page 4 Do not wash the air conditioner with water as this could cause an electric shock. • Disconnect the power supply by turning it off at the circuit breaker when cleaning the air conditioner. Otherwise, you could risk electric shock. DURASTAR.COM...
Page 5 • The air conditioner’s circuit board (PCB) is designed with a fuse to provide over-current protection. The specifications of the fuse are printed on the circuit board. DURASTAR.COM...
Page 6 Do not climb onto or place objects on top of the outdoor unit. • Do not allow the air conditioner to operate for long periods of time with doors or windows open, or if the humidity is very high. DURASTAR.COM...
Page 7 Regularly inspect and clean air filters. NOTE Your Durastar air conditioner's outdoor unit is equipped with a base pan heater, allowing it to continue to operate at freezing temperatures as low as -13°F (-25°C). When outdoor air temperatures are at or below 32°F (0°C), we strongly recommend keeping the unit plugged in at all times to ensure smooth ongoing performance.
Page 8 • Wire strippers • HVAC manifold gauge set • Wire crimper • Micron Gauge • Multimeter • Refrigerant leak detector • Electroprobe • Copper pipe cutter • Level • Flaring tool • Burr reamer • Crescent or spanner wrench DURASTAR.COM...
Page 9 PARTS IDENTIFICATION WARNING When installing a Multi-zone outdoor unit, a minimum of 2 associated indoor units must be installed and operational for the system to operate properly. DRA5U55M1B DRA5U48M1B DRA4U36M1B DRA3U28M1B DRA2U18M1B Signal Cable, Refrigerant Pipes, and Drain Pipe Air Inlets...
Page 10 Near animals or plants that will be harmed by hot air discharge. • Near any source of combustible gas. • In a location that is exposed to large amounts of dust. • In a location exposed to an excessive amount of salty air. DURASTAR.COM...
Page 11 (M10). Mount the unit on a cement slab, condenser mounting pad, or other level surface able to support the unit's weight. Do not place the unit directly on the ground. If using a wall- mounting bracket, make sure the attached structure can support at least four times the unit's weight. DURASTAR.COM...
Page 12 DRA3U28M1B - 37 1/4 ” x 31 7/8” x 16 1/8” (946 x 810 x 410) 26-1/2” (673) 15-7/8” (403) DRA4U36M1B - 37 1/4” x 31 7/8” x 16 1/8” (946 x 810 x 410) 15-15/16” (404) DRA5U48M1B - 37 1/2” x 52 1/2” x 16 5/16” (952 x 1333 x 415) 24-15/16”...
Page 13 When installing multiple indoor units with a single outdoor unit, ensure that the length of the refrigerant pipe and the drop height between the outdoor and indoor units, and between indoor units, meets the requirements below. DRA2U18M1B DRA3U28M1B DRA4U36M1B DRA5U48M1B DRA5H55M1B Max. length for all rooms 131' (40m) 197' (60m)
Page 14 8. Replace the wire cover on the side of the unit, and screw it in place. Terminal block Connecting cable Power supply cord Conduit panel Wire Cover Select the appropriate holes to feed the wires through according to their diameter. DURASTAR.COM...
Page 15 5/8” “A” and “B” valve ports. Note on master valves For DRA3U28M1B, DRA4U36M1B, DRA5U48M1B, and DRA5U55M1B Initial startup Once installation is complete, open all zone valves connected to an indoor unit. Connect the high side hose of the manifold gauge to the gas side master valve to gain access to all connected zones.
Page 16 Indoor Unit 19’ 9” (6m) 32’ 10” (10m) Required distance between oil traps when Required distance between oil traps when the indoor unit is installed higher than the the outdoor unit is installed higher than the outdoor unit. indoor unit. DURASTAR.COM...
Page 17 Burrs can affect the airtight seal of the refrigerant piping connection and must be completely removed. 1. Hold the pipe at a downward angle to prevent burrs from falling into the pipe. 2. Using a reamer or deburring tool, remove all burrs from the cut section of the pipe. Pipe Reamer Point downward DURASTAR.COM...
Page 18 0.04" (1.0mm) 0.07" (1.8mm) Ø 5/8" (15.9mm) 0.078" (2.0mm) 0.086" (2.2mm) Ø 3/4" (19.1mm) 0.078" (2.0mm) 0.094" (2.4mm) Flare form TIP: THICKNESS COMPARISON • 0.0275" = A Thumbnail • 0.04" = A Dime • 0.078" = A Nickle Pipe DURASTAR.COM...
Page 19 4. While firmly gripping the nut on the unit tubing, use a torque wrench to tighten the flare nut according to the torque values in the table on the next page. Loosen the flaring nut slightly, then tighten again. DURASTAR.COM...
Page 20 Use a vacuum pump and manifold gauge to evacuate the refrigerant system, removing any non-condensible gas and moisture from the system. Evacuation should be performed upon initial installation and if unit is relocated. DURASTAR.COM...
Page 21 Do not try to force the valves to open further. Manifold Gauge Low pressure Flare nut gauge Low pressure High pressure valve valve Low pressure hose Auxiliary hose Vacuum pump Valve body Valve stem Low pressure valve DURASTAR.COM...
Page 22 The refrigerant should be charged from the service port on the outdoor unit's low pressure valve. Additional refrigerant information can be found in the SUBMITTALS DOCUMENTS at WWW.SERVICE.DURASTAR.COM. Additional refrigerant can be calculated using the following formula: Liquid Side Ø 1/4" (6.35mm) Liquid Side Ø...
Page 23 A: Low pressure stop valve B: High pressure stop valve C & D: Indoor unit ﬂare nuts Use the Durastar Job Site Information Sheet at the end of this manual as a commissioning report to record your start up readings. TEST RUN TEST RUN INSTRUCTIONS You should perform the test run for at least 30 minutes.
Page 24 The indoor unit makes A rushing air sound may occur when the louver resets its position. noises A squeaking sound may occur after running the unit in HEAT mode due to expansion and contraction of the unit’s plastic parts. DURASTAR.COM...
Page 25 • Press ON/OFF button on remote control to restart operation. NOTE If problem persists, contact a local dealer or your nearest customer service center. Provide them with a detailed description of the unit malfunction as well as your model number. DURASTAR.COM...
Page 26 Incompressible gas or moisture has Evacuate and recharge the system with quently entered the system refrigerant The compressor is broken Replace the compressor The voltage is too high or too low Install a manostat to regulate the voltage DURASTAR.COM...
Page 27 If not, disconnect the power, then connect it again. Turn the unit on. appears If the problem persists, disconnect the power and contact your nearest customer service center. NOTE If your problem persists after performing the checks and diagnostics above, turn off your unit immediately and contact an authorized service center. DURASTAR.COM...
Page 28 WIRING DIAGRAMS DRA2U18M1B COMP TOP 5(8) Dotted line indicates this component is optional. Your conﬁguration many vary. 16022000035644 DURASTAR.COM...
Page 29 DRA3U28M1B Dotted line indicates this component is optional. Your conﬁguration many vary. 16022300002514 DURASTAR.COM...
Page 30 DRA4U36M1B Dotted line indicates this component is optional. Your conﬁguration many vary. 16022300002633 DURASTAR.COM...
Page 31 DRA5U48M1B and DRA5U55M1B IPM&PFC BOARD MAIN CONTROL BOARD INDOOR COIL OUTLET TEMP.SENSOR Dotted line indicates this component is optional. Your conﬁguration many vary. 16022000036851 DURASTAR.COM...
Page 32 High temperature protection of Evaporator PH91 Low temperature protection of Evaporator LC06 High temperature protection of Inverter module (IPM) Note: DF (defrost) and FC (forced cooling) are normal operating codes, not malfunctions. [ ] Applicable to some units only. DURASTAR.COM...
Page 33 Line Voltage (Power Off): L1 to L2 _____________ L1 to G _____________ L2 to G ________________ Line Voltage (Power On): L1 to L2 _____________ L1 to G _____________ L2 to G ________________ Outdoor Thermal Readings Discharge: _________°F Ambient: _________°F DURASTAR.COM...
Page 34 (Circle Liquid and Gas Line): Electrical Readings Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________ Voltage Readings: 1-2 ___________ AC 2-3 ___________DC Thermal Readings Return Air: _________°F Supply Air: _________°F Room Air: _________°F Gas Line Saturation: _________°F Liquid Line Saturation: _________°F DURASTAR.COM...
Page 35 (Circle Liquid and Gas Line): Electrical Readings Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________ Voltage Readings: 1-2 ___________ AC 2-3 ___________DC Thermal Readings Return Air: _________°F Supply Air: _________°F Room Air: _________°F Gas Line Saturation: _________°F Liquid Line Saturation: _________°F DURASTAR.COM...
Page 36 (Circle Liquid and Gas Line): Electrical Readings Power/Control Wire Color: 1 _______________ 2 _______________ 3 ________________ Voltage Readings: 1-2 ___________ AC 2-3 ___________DC Thermal Readings Return Air: _________°F Supply Air: _________°F Room Air: _________°F Gas Line Saturation: _________°F Liquid Line Saturation: _________°F DURASTAR.COM...
Page 37 NOTES: DURASTAR.COM...
Page 38 THIS PAGE INTENTIONALLY LEFT BLANK. DURASTAR.COM...
Page 39 THIS PAGE INTENTIONALLY LEFT BLANK. DURASTAR.COM...
Page 41 CEILING CASSETTE INDOOR UNIT SPLIT-STYLE AIR CONDITIONER DRAC09F1A, DRAC12F1A, DRAC18F1A, DRAC24F1A Model Number: Serial Number: Purchase Date: Installing Contractor Company Name: Capture relevant information about your Durastar mini-split equipment before it is installed and write it above for future reference. DURASTAR.COM...
Page 42 STEP 3: DRILL WALL HOLE FOR CONNECTIVE PIPING ............. 15 STEP 4: CONNECT DRAIN PIPE ......................16 STEP 5: CONNECT SIGNAL CABLE ....................17 STEP 6: PREPARE REFRIGERANT PIPING .................. 19 STEP 7: WRAP PIPES AND CABLE ....................19 STEP 8: INSTALL PANEL ........................20 TROUBLESHOOTING ..........................24 DURASTAR.COM...
Page 43 • Read the troubleshooting section of this manual as it will help you diagnose and solve common issues. • Visit us on the web at www.durastar.com to download product guides and up-to-date information. • If you need warranty service, our friendly customer service representatives are available via email at questions@durastar.com or by telephone at 1-888-320-0706.
Page 44 Do not wash the air conditioner with water as this could cause an electric shock. • Disconnect the power supply by turning it off at the circuit breaker when cleaning the air conditioner. Otherwise, you could risk electric shock. DURASTAR.COM...
Page 45 • The air conditioner’s circuit board (PCB) is designed with a fuse to provide overcurrent protection. The specifications of the fuse are printed on the circuit board. DURASTAR.COM...
Page 46 Do not climb onto or place objects on top of the outdoor unit. • Do not allow the air conditioner to operate for long periods of time with doors or windows open, or if the humidity is very high. DURASTAR.COM...
Page 47 Regularly inspect and clean air filters. NOTE Your Durastar air conditioner's outdoor unit is equipped with a base pan heater, allowing it to continue to operate at freezing temperatures as low as -13°F (-25°C). When outdoor air temperatures are at or below 32°F (0°C), we strongly recommend keeping the unit plugged in at all times to ensure smooth ongoing performance.
Page 48 Indoor and outdoor connection wire • Outdoor power supply cord • Drain pipe • Pipe and cable wrapping tape • Wall hole sleeve and cover • Putty • Suspension bolts and necessary hardware to hang indoor unit • Wiring u-lugs DURASTAR.COM...
Page 49 Refrigerant leak detector • Copper pipe cutter • Flaring tool • Burr reamer • Crescent or spanner wrench • Hexagonal wrench set • Torque wrench • Multimeter • Electroprobe • Level • Hammer • Wire strippers • Wire crimper DURASTAR.COM...
Page 50 Wiring Terminal Air Outlet Panel Refrigerant Pipes Valve Cover Air Inlet Remote Control Air Inlet Control Panel Drain Pipe Air Outlet NOTE Illustrations in this manual are for explanatory purposes. The actual shape of your mini-split equipment may vary slightly. DURASTAR.COM...
Page 51 INSTALLATION OVERVIEW - INDOOR UNIT Install the indoor unit Install the drain pipe Install the outdoor unit Connect the wires Evacuate and charge the Connect the refrigerant refrigeration system pipes Install the panel Perform a test run DURASTAR.COM...
Page 52 Near any source of heat, steam, or combustible gas • Near flammable items such as curtains or clothing • Near any obstacle that might block air circulation • Near a doorway • In a location subject to direct sunlight DURASTAR.COM...
Page 53 If there is no pre-existing refrigerant piping, when choosing a location, leave ample room for a wall hole (see Step 3: Drill Wall Hole for Connective Piping) for the signal cable and refrigerant piping that connect the indoor and outdoor units. DURASTAR.COM...
Page 54 2. Drill four holes 2" deep in the internal ceiling for each of the required suspension bolt anchors (field supplied). Make sure to hold the drill at a 90o angle to the ceiling. 3. Using a hammer, insert the suspension bolt anchors into the pre-drilled holes. 4. Install the four suspension bolts. DURASTAR.COM...
Page 55 After the sleeve is inserted through the wall, connect the wall hole sleeve cover to the wall sleeve on the outside end. Make sure the cover is flush with the outside wall. DURASTAR.COM...
Page 56 Incorrect installation can cause water to flow back into the unit and leaks. Ceiling 39-59” ≤11 3/4” (300mm) (1-1.5m) ≤20 7/8” (530mm) ≤29 1/2” (750mm) 8 5/8” (220mm) 0-3” (0-75mm) DURASTAR.COM...
Page 57 12. To avoid getting an electric shock, never touch the electrical components soon after the power supply has been turned off. After turning off the power, always wait 10 minutes or more before you touch the electrical components. WARNING Before performing any electrical or wiring work, turn off the main power to the system. DURASTAR.COM...
Page 58 6. After checking to make sure every connection is secure, use the cable clamp to fasten the signal cable to the unit. Screw the cable clamp down tightly. 7. Replace the control box lid. WARNING All wiring must be performed strictly in accordance with the wiring diagram located on the inside of the control box lid. DURASTAR.COM...
Page 59 Drain pipe NOTE The drain pipe MUST be at the bottom of the bundle. Putting the drain pipe at the top of the bundle can cause the drain pan to overflow, which can lead to fire or water damage. DURASTAR.COM...
Page 60 2. Install the main panel body by aligning the arrow on the panel to the arrow on the unit. Attach the panel body to the unit with the supplied screws as shown below. Main panel body Screws (M5 - supplied with the panel) DURASTAR.COM...
Page 61 5. Remove the control box lid and connect the two cables from the main panel body to the main board on the unit. 5-core wire 10-core wire 6. Replace the control box lid with its screws and close the inner panel making sure it latches securely in place. DURASTAR.COM...
Page 62 3/16 - 1/4". The edge of the panel should be in contact with the ceiling board. Adjust the panel so that the ceiling opening is completely covered. Latch Piping side Drain side Screwdriver DURASTAR.COM...
Page 63 If necessary, the height can be adjusted by loosening the upper nut, and adjusting the lower nut at each of the corners. Make sure the internal wiring and drain pipe are not affected by this adjustment. 1-Loosen upper nut Gap not allowed 2-Adjust lower nut DURASTAR.COM...
Page 64 The indoor unit makes A rushing air sound may occur when the louver resets its position. noises A squeaking sound may occur after running the unit in HEAT mode due to expansion and contraction of the unit’s plastic parts. DURASTAR.COM...
Page 65 • Press ON/OFF button on remote control to restart operation. NOTE If problem persists, contact a local dealer or your nearest customer service center. Provide them with a detailed description of the unit malfunction as well as your model number. DURASTAR.COM...
Page 66 Incompressible gas or moisture has Evacuate and recharge the system with entered the system refrigerant The compressor is broken Replace the compressor The voltage is too high or too low Install a manostat to regulate the voltage DURASTAR.COM...
Page 67 If the problem persists, disconnect the power and contact your nearest customer appears service center. NOTE If your problem persists after performing the checks and diagnostics above, turn off your unit immediately and contact an authorized service center. DURASTAR.COM...

This manual is also suitable for:

Dra3u28m1b Dra2u18m1b Dra5u48m1b Dra5u55m1b Dra5h55c181818 Dr4h48c12121212 ... Show all