Airwell BS 12 DCI Service Manual Download Page 1

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BS DCI Series

Indoor Units

Outdoor Units

BS 12 DCI

GC 12 DCI

OCTOBER – 2008

REFRIGERANT

R410A

HEAT PUMP

SM BS DCI 1-A.1 GB

CONTENTS

Summary of Contents for BS 12 DCI

Page 1: ...BS DCI Series Indoor Units Outdoor Units BS 12 DCI GC 12 DCI OCTOBER 2008 REFRIGERANT R410A HEAT PUMP SM BS DCI 1 A 1 GB CONTENTS ...

Page 2: ...r original and changed pages are Original 0 May 2005 Total number of pages in this publication is 68 consisting of the following Page No Revision No Page No Revision No Page No Revision No Title 1 A 1 i 1 1 1 1 3 1 2 1 1 3 1 1 4 1 1 5 1 5 5 1 6 1 6 2 1 7 1 1 8 1 1 9 1 1 10 1 1 11 1 11 16 1 12 1 12 6 1 13 1 13 5 1 Appendix A 1 Zero in this column indicates an original page Due to constant improveme...

Page 3: ... CONDITIONS 3 1 4 OUTLINE DIMENSIONS 4 1 5 PERFORMANCE DATA PRESSURE CURVES 5 1 6 AIRFLOW CURVES 6 1 7 ELECTRICAL DATA 7 1 8 WIRING DIAGRAMS 8 1 9 REFRIGERATION DIAGRAMS 9 1 10 TUBING CONNECTIONS 10 1 11 CONTROL SYSTEM 11 1 12 TROUBLESHOOTING 12 1 13 EXPLODED VIEWS AND SPARE PARTS LISTS 13 1 14 APPENDIX A 14 1 ...

Page 4: ...door temperature down to 15ºC Advanced test and diagnostics mode M2L diagnostics softwear cable port for PC Network connectivity The Indoor unit can be easily modiﬁed to a vertical or horizontal installation up to 4 different air inlet and discharge applications Base heater connection Easy installation and service 1 3 Indoor Unit The indoor unit is a Low Silhouette ducted unit and can be easily ﬁt...

Page 5: ...re charged For further information please refer to the Product Data Sheet Chapter 2 It includes Single DC inverter Rotary Compressor mounted in a soundproofed compartment DC Inverter Outdoor Fan Motor Advanced controller Axial fan Outdoor coil with hydrophilic louver ﬁns Outlet air fan grill Outdoor Unit Features Feature GC 12 DCI Diagnostics Display 3 LED s Base Heater Optional Outdoor Fan Variab...

Page 6: ...XD35 BS 12 DCI GC 9 DCI R410A GC 12 DCI R410A The above table lists outdoor units and BS DCI indoor unit which can be matched together In addition the listed outdoor units can be matched with other types of indoor units such as cassettes and wall mounted For further information please refer to the relevant Service Manual CONTENTS ...

Page 7: ... External static pressure Min Max Pa 25 Sound power level 3 H M L dB A 59 55 52 Sound pressure level 4 H M L dB A 42 38 35 Moisture removal l hr 1 3 Condensate drain tube I D mm 16 Dimensions WxHxD mm 860x245x680 Weight kg 30 Package dimensions WxHxD mm 1055x305x728 Packaged weight kg 33 5 Units per pallet units 6 units per pallet Stacking height units 6 leveBS OUTDOOR Refrigerant control EEV Comp...

Page 8: ...ling Indoor 27o C DB 19o C WB Outdoor 35 o C DB Heating Indoor 20o C DB Outdoor 7o C DB 6o C WB 3 1 Operating Limits 3 1 1 R410A Indoor Outdoor Cooling Upper limit 32o C DB 23o C WB 46o C DB Lower limit 21o C DB 15o C WB 10o C DB Heating Upper limit 27o C DB 24o C DB 18o C WB Lower limit 10o C DB 15o C DB 16o C WB Voltage 198 264 V CONTENTS ...

Page 9: ...4 1 OUTLINE DIMENSIONS SM BS DCI 1 A 1 GB 4 OUTLINE DIMENSIONS 4 1 Indoor Unit BS 12 DCI 4 2 Outdoor Unit GC 12 DCI CONTENTS ...

Page 10: ... 3 66 3 88 4 11 SC 2 58 2 63 2 69 2 74 2 79 PI 0 84 0 86 0 87 0 89 0 90 35 TC 3 06 3 28 3 50 3 72 3 94 SC 2 51 2 57 2 62 2 67 2 73 PI 0 93 0 95 0 96 0 97 0 99 40 TC 2 89 3 12 3 34 3 56 3 78 SC 2 45 2 50 2 55 2 61 2 66 PI 1 02 1 03 1 05 1 06 1 08 46 TC 2 70 2 92 3 14 3 36 3 58 SC 2 37 2 42 2 47 2 53 2 58 PI 1 13 1 14 1 15 1 17 1 18 LEGEND TC Total Cooling Capacity kW SC Sensible Capacity kW PI Powe...

Page 11: ... 3 01 PI 1 16 1 24 1 32 2 1 TC 3 47 3 28 3 09 PI 1 20 1 28 1 36 7 6 TC 4 49 4 30 4 11 PI 1 26 1 34 1 42 10 9 TC 4 74 4 55 4 36 PI 1 33 1 42 1 50 15 12 TC 4 99 4 80 4 60 PI 1 41 1 49 1 57 15 24 TC 85 105 of nominal Protection Range PI 80 120 of nominal LEGEND TH Total Heating Capacity kW PI Power Input kW WB Wet Bulb Temp o C DB Dry Bulb Temp o C ID Indoor OD Outdoor 5 1 4 Capacity Correction Facto...

Page 12: ...ubing Length BS 12 DCI Cooling 5 1 6 Heating 0 91 0 92 0 93 0 94 0 95 0 96 0 97 0 98 0 99 1 00 1 01 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Tubing Length m Capacity Ratio 0 90 0 92 0 94 0 96 0 98 1 00 1 02 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Tubing Length m Capacity Ratio CONTENTS ...

Page 13: ...900 1000 1100 1200 1300 1400 10 15 20 25 30 35 40 45 Outdoor DB Temperature ºC Suction Pressure kPa 22 15 24 17 27 19 29 21 32 23 Indoor DB WB Discharge Pressure Vs Outdoor Temp 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 10 15 20 25 30 35 40 45 Outdoor DB Temperature ºC Discharge Pressure kPa 22 15 24 17 27 19 29 21 32 23 Indoor DB WB CONTENTS ...

Page 14: ...400 500 600 700 800 900 1000 1100 1200 1300 15 10 5 0 5 10 15 Outdoor WB Temperature ºC Suction Pressure kPa 15 20 25 indoor DB Discharge Pressure Vs Outdoor Temp 1000 1250 1500 1750 2000 2250 2500 2750 3000 3250 3500 3750 4000 15 10 5 0 5 10 15 Outdoor WB Temperature ºC Discharge Pressure kPa 15 20 25 Indoor DB CONTENTS ...

Page 15: ... TC 1 07 1 05 1 03 1 02 1 00 LEGEND TC Total Capacity SC Sensible Capacity PI Power Input Airflow Vs External Static Pressure S DCI 0 10 20 30 40 50 60 300 400 500 600 700 800 900 1000 1100 1200 Air Flow Rate m 3 hr External Static Pressure Pa Super High High Medium Low Nominal System Resistance Max System Resistance Curve s colors according to fan motor wires colors The System characteristics def...

Page 16: ...5 Circuit Breaker A 16 Power Supply Wiring No X Cross Section mm2 3x1 5 mm2 Interconnecting Cable No X Cross Section mm2 4x1 5 mm2 a Inrush current is the current when power is up charging the DC capacitors at outdoor unit controller b Starting current is the current at compressor start up NOTE Power wiring cord should comply with local lows and electrical regulations requirements CONTENTS ...

Page 17: ...5 Blue Brown EEV Y G P21 OFAN Yellow V sp Outdoor unit controller PCB Orange Black Red P14 P12 EARTH L P10 N COM N COM P3 P13 P9 P11 U V W JP9 4 2 1 3 5 6 P1 P4 1 1 2 P17 P16 P18 2 Choke coil Red Blue White Brown Black COMP V cc V dc EARTH 1 2 3 4 Base heater valve Reverse Blue P7 6 5 4 3 2 1 megatool 2 1 P6 3 4 P19 P2 P22 2 1 2 1 P8 P20 2 1 2 1 FG 5 6 OCT OAT SUCT CTT OUTDOOR UNIT CIRCUIT DIAGRAM...

Page 18: ...9 1 REFRIGERATION DIAGRAMS SM BS DCI 1 A 1 GB 9 REFRIGERATION DIAGRAMS 9 1 Heat Pump Models 9 1 1 BS 12 DCI EEV EEV CONTENTS ...

Page 19: ... Valve Protection Cap end 2 Refrigerant Valve Port use Allen wrench to open close 3 Valve Protection Cap 4 Refrigerant Valve 5 Service Port Cap 6 Flare Nut 7 Unit Back Side 8 Copper Tube When the outdoor unit is installed above the indoor unit an oil trap is required every 5m along the suction line at the lowest point of the riser Incase the indoor unit is installed above the outdoor no trap is re...

Page 20: ...voiding it f supplying the requested capacity The capacity request is transferred via indoor to outdoor communication an represented by a parameter called NLOAD NLOAD is an integer number w values between 0 and 127 and it represents the heat or cool load felt by indoor unit 11 3 Compressor Frequency Control 11 3 1 NLOAD setting The NLOAD setting is done by the indoor unit controller based on a PI ...

Page 21: ...between minimum and maximum frequency 10 Minimum frequency 0 Compressor is stopped Target frequency limits as a function of outdoor air temperature OAT OAT Range Cool mode limits Heat mode limits OAT 6 No limit 6 OAT 15 MaxFreqAsOAT1H 15 OAT 24 MaxFreqAsOATC 24 OAT No limit MaxFreqAsOAT2H 11 3 3 Frequency Changes Control Frequency change rate is 1 Hz sec 11 3 4 Compressor Starting Control Frequenc...

Page 22: ...om temperature 22 for cooling or 25 for heating 11 5 Heating Element Control Heating element can be started if LOAD 0 8 MaximumNLOAD AND Indoor Coil temperature 45 The heating element will be stopped when LOAD 0 5 MaximumNLOAD OR if Indoor Coil temperature 50 11 6 Outdoor Fan Control 7 outdoor fan speeds are determined for each model 3 speeds for cool and dry modes and 3 speeds for heat mode and a...

Page 23: ...s 11 7 EEV electronic Expansion valve Control EEV opening is defined as EEV EEVOL EEVCV x EEVOL is the initial EEV opening as a function of the compressor frequency operation mode unit model and capacity x EEVCV is a correction value for the EEV opening that is based on the comp temperature x During the first 10 minutes of compressor operation EEVCV 0 x Once the first 10 minutes are over the corre...

Page 24: ... between actual room temperature and user set point temperature by PI control In high medium low indoor fan user setting unit will operate fan in selected speed In Auto Fan user setting fan speed will be adjusted automatically according to the calculated NLOAD 11 14 Heat Mode NLOAD is calculated according to the difference between actual room temperature and user set point temperature by PI contro...

Page 25: ...o heat when compressor is off for 3 minutes and T 3 Unit will switch from heat to cool when compressor is off for 5 minutes and T 3 11 18 Dry Mode As long as room temperature is higher then the set point indoor fan will work in low speed and compressor will work between 0 and MaxNLOADIF1C Hz When the room temperature is lower than the set point compressor will be switched OFF and indoor fan will c...

Page 26: ...9 2 Indoor Coil over Heating Protection ICT Trend ICT Fast Decreasing Decreasing No Change Increasing Fast Increasing ICT 55 SC SC SC SC SC 53 ICT 55 D1 D1 D2 D2 D2 49 ICT 53 SR SR D1 D2 D2 47 ICT 49 SR SR SR D1 D2 45 ICT 47 Norm Norm SR SR D1 43 ICT 45 Norm Norm Norm SR SR ICT 43 Normal 11 19 3 Compressor over Heating Protection Compressor temperature can be in one of 5 control zones 4 in protect...

Page 27: ...9 4 Compressor over Current Protection Normal Stop Rise HzDown1 HzDown2 Stop Compresor CCROC1 CCROC2 CCROC3 CCROC4 CCR 11 19 5 Heat Sink over Heating Protection NA for DCI 25 and 35 HST Trend HST Decreasing No Change Increasing HST 90 SC SC SC 85 HST 90 D1 D2 D2 82 HST 85 SR D1 D2 80 HST 82 SR SR D1 78 HST 80 Norm Norm SR HST 78 Normal CONTENTS ...

Page 28: ...ng DI Deicing Interval Time Interval between Two Deicing Deicing interval time when compressor is first started in heat mode is 10 minutes if OCT 2 and is 40 minutes in other cases Deicing interval time is changed increased decreased in 10 minutes steps as a function of deicing time If deicing time is shorter then former deicing time the deicing interval time will be increased If deicing time is l...

Page 29: ...ch of the pins P1 P2 P3 can have two options 1 When it is shorted with P4 0 When it is not shorted to P4 11 20 1 3 Levels Logic used in floor ceiling models P2 P3 Level 0 0 L0 1 0 L1 1 1 L2 3 0 1 L4 Water Level ANY 0 BLINK NLOAD OPER LED LEVEL1 LEVEL2 3 LEVEL4 NORMAL ON Pump OFF CONTENTS ...

Page 30: ...F 8 min 11 21 Indoor Unit Dry Contact Indoor unit Dry contact has two alternative functions that are selected by J8 Function Contact Open Contact Short J8 Open Presence Detector Connection No Limit Forced to STBY J8 Short Power Shedding Function No Limit Limit NLOAD 11 22 Operating the Unit from the Mode Button Forced operation allows starting stopping and operating in Cooling or Heating in pre se...

Page 31: ...ITCH COOL HEAT OFF Every short pressing the next operation mode is selected in this order SB Cool Mode Heat Mode SB In long pressing system enters diagnostic mode RESET FILTER SWITCH For short pressing When Filter LED is on turn off the FILTER INDICATOR after a clean filter has been reinstalled When Filter LED is off enable disable the buzzer announcer if selected 11 24 Outdoor Unit Controller Ind...

Page 32: ...N 9 ODU3 PIN 7 ODU2 PIN 5 ODU1 PIN 3 ODU0 PIN 1 GND PIN 10 GND PIN 8 GND PIN 6 GND PIN 4 GND PIN 2 11 25 3 ODU MODEL SELECTION ODU3 ODU2 ODU1 ODU0 ODU Model OFF OFF OFF OFF Reserved OFF OFF OFF ON PIN1 PIN2 A DCI 25 OFF OFF ON PIN3 PIN4 OFF B DCI 35 OFF OFF ON PIN3 PIN4 ON PIN1 PIN2 C DCI 50 OFF ON PIN5 PIN6 OFF OFF D OFF ON PIN5 PIN6 OFF ON PIN1 PIN2 E Duo OFF ON PIN5 PIN6 ON PIN3 PIN4 OFF F OFF ...

Page 33: ...the unit will operate in ﬁxed settings according to the indoor fan speed setting Indoor Fan Speed Setting Unit Setting Low Minimum Capacity Setting High Nominal Capacity Setting Auto Maximum Capacity Setting During test mode protections are disabled except for stop compressor status 11 28 SW Parametera 11 28 1 Indoor Unite SW Parameters General Parameters for All Models Parameters deﬁning the indo...

Page 34: ... 950 1050 1100 IFHIGHC 1050 1100 1200 1250 IFTURBOC 1150 1200 1250 1300 IFVLOWH 700 700 700 800 IFLOWH 800 850 900 950 IFMEDH 950 1000 1100 1150 IFHIGHH 1100 1150 1200 1250 IFTURBOH 1200 1250 1300 1300 Nominal Compressor Frequency NomLoadC 40 62 62 85 NomLoadH 55 67 74 80 Parameter Name Floor mounted Ducted 9 12 BS 12 18 NLOAD limits as a function of selected indoor fan speed MaxNLOADIF1C 40 40 40...

Page 35: ...OAT2H 60 60 60 60 60 Compressor Over Heating Protection CTTOH1 94 94 94 90 94 CTTOH2 98 98 98 95 98 CTTOH3 102 102 102 102 102 CTTOH4 105 105 105 105 105 Compressor Over Current Protection A CCR01 7 1 7 1 10 10 11 4 CCR02 7 5 7 5 10 5 10 5 11 8 CCR03 7 9 7 9 10 8 10 8 12 2 CCR04 8 3 8 3 11 2 11 2 12 6 Outdoor Fan Speed RPM VL 200 200 200 200 200 OFLOWC 550 550 600 600 550 OFMEDC 700 700 760 830 70...

Page 36: ...trol message but Operate indicator Green LED does not light up Problem with display PCB Replace display PCB If still not OK replace controller Unit in heat mode and coil is still not warm Change to cool mode and check 4 Indoor fan does not start louvers are opened and Green LED does light up Problem with PCB or capacitor Change to high speed and Check power supply to motor is higher than 130VAC fo...

Page 37: ... generating noise and no suction occurs Phase order to compressor is wrong Check compressor phase order 14 Water leakage from indoor unit Indoor unit drainage tube is blocked Check and open drainage tube 15 Freezing of outdoor unit in heat mode and outdoor unit base is blocked with ice Connect base heater 16 Unit operates with wrong fan speeds or wrong frequency Wrong jumper settings Perform diagn...

Page 38: ...The last fault code will be displayed even if the system has recovered from that fault The last fault will be deleted from the EEPROM after the system has exit diagnostics mode In diagnostics mode system fault status will be indicated by blinking of Filter Timer LEDs The coding method will be as follows Filter LED will blink 5 times in 5 seconds and then will be shut off for the next 5 seconds Tim...

Page 39: ... unit operation 8 Bad Communication Communication quality is low reliabilityCheck Indoor to Outdoor wiring and grounding 9 Using EEPROM data No problem System is using EEPRRRROM parameters 12 3 3 Outdoor Unit Diagnostics No Problem 5 4 3 2 1 1 OCT is disconnected 0 0 0 0 1 2 OCT is shorted 0 0 0 1 0 3 CTT is disconnected 0 0 0 1 1 4 CTT is shorted 0 0 1 0 0 5 HST is disconnected when enabled 0 0 1...

Page 40: ...r Lock Switch unit to STBY and restart 9 Bad Communication Communication quality is low reliability Check Indoor to Outdoor wiring and grounding 12 4 Judgment by MegaTool MegaTool is a special tool to monitor the system states Using MegaTool requires x A computer with RS232C port x A connection wire for MegaTool x A special MegaTool software Use MegaTool according to following procedure x Setup Me...

Page 41: ...0VAC 12 5 6 Checking the electrical expansion valve EEV The EEV has two parts drive part and valve The drive part is a step motor it is ringed on the valve Check the drive voltage 12VDC When Outdoor unit is power on EEV shall run and have click and vibration 12 6 Precaution Advise and Notice Items 12 6 1 High voltage in Outdoor unit controller Whole controller including the wires that are connecte...

Page 42: ...13 1 EXPLODED VIEWS AND SPARE PARTS LISTS SM BS DCI 1 A 1 GB 13 EXPLODED VIEWS AND SPARE PARTS LISTS 13 1 Indoor Unit BS 12 DCI CONTENTS ...

Page 43: ...13 2 EXPLODED VIEWS AND SPARE PARTS LISTS SM BS DCI 1 A 1 GB 13 2 Indoor Unit BS 12 DCI CONTENTS ...

Page 44: ...REMOTE CONTROL RC RC3 1 7 403879 AIR INLET FRAME ASSY BS 035 040 055 1 8 403546 AIR FILTER 830 216 GTW 11 15 18 1 9 403794 MOTOR 73W 5S GTW 11 1 10 403438 RT FAN ASSY EBS 50 60 GTW11 18 1 11 442256 CAPACITOR 400V 4mF 1 12 433605 STORM2 CONTROL 1 13 402730 CABLE 8 WIRES 7M WTH CONNECTORS 1 14 402713 WIRE DISPLAY BOX EMD ELD 1 15 403877 AIR OUTLET FRAME ASSY BS 035 040 055 1 16 489117 RELAY AC SPST ...

Page 45: ...13 4 EXPLODED VIEWS AND SPARE PARTS LISTS SM BS DCI 1 A 1 GB 13 4 Outdoor Unit GC 12 DCI CONTENTS ...

Page 46: ... 19 4526219 Fuse 65TS 15A 230 150 031 00 1 20 204107 Cable clip nylon 1 21 4519188 4 poles terminal block 1 22 433229 Value cover 1 23 4522509 4 Way valve coil 1 24 4526367 4 way valve welding Assy DCI25 1 4526393 4 way valve welding Assy DCI35 1 25 4518952 4 way valve DCI25 1 4518951 4 way valve DCI35 1 26 4526221 Compressor wire 1 27 4526204 DC Inverter compressor Assy 5RS102XAB 1 28 4526775 Com...

Page 47: ...14 1 APPENDIX A SM BS DCI 1 A 1 GB APPENDIX A INSTALLATION AND OPERATION MANUAL OPERATING MANUAL BS 12 DCI INSTALLATION MANUAL BS 12 DCI CONTENTS ...

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