Daikin RZAG100L7V1B Service Manual Download Page 84

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ESIE16-03B

Part 3. Repair

3.3. Unit specific repair procedures

Page 84

22/08/16

Version 1.1

SA R32 Sky-Air RZAG-L

3.3.2.11. Replacing solenoid valve

Removal

1. Switch off the Daikin unit via the user interface.

2. Switch off the Daikin unit with the field supplied circuit breaker.

3. Remove plate work when required (refer to

"Basic removal" on page 67

4. Recover the refrigerant (refer to

"Refrigerant repair procedures" on page 61

5. Connect a nitrogen hose to the outdoor suction service port.

6. Attach a hose with core-depressor to allow the release of the nitrogen.

7. Remove the solenoid valve coil (refer to

"Replacing solenoid valve coil" on page 85

8. Connect a nitrogen hose to the outdoor suction service port.

9. Attach a hose with core-depressor to allow the release of the nitrogen.

10. Cut the 2 solenoid valve pipes (1).

11. Remove the solenoid valve (2).

12. Supply nitrogen to the piping circuit.

13. Using an oxygen acetylene torch, heat the 2 solenoid valve pipes (1).

14. When the solder material is liquid, pull the 2 solenoid valve pipes (1).

15. Cut the nitrogen supply when the piping has cooled down.

Figure 3-20: Removing solenoid valve

Installation

1. Wrap a wet rag around the solenoid valve.

2. Proceed in reverse order.

AUTION

The maximum applied Nitrogen pressure must not exceed 0.02 MPa.

1. Solenoid valve pipe

2. Solenoid valve

ARNING

Overheating the solenoid valve will damage or destroy it.

Summary of Contents for RZAG100L7V1B

Page 1: ...Service Manual SA R32 Sky Air RZAG L ESIE16 03B Indoor unit Outdoor unit FCAHG71 100 125 140FVEB RZAG71 100 125 140L7V1B ...

Page 2: ...wledge No express or implied warranty is given for the completeness accuracy reliability or fitness for particular purpose of its content and the products and services presented therein Specifications are subject to change without prior notice Daikin Europe N V explicitly rejects any liability for any direct or indirect damage in the broadest sense arising from or related to the use and or interpr...

Page 3: ...ty 24 2 2 1 4 AJ 00 Capacity setting abnormality 25 2 2 1 5 C1 00 Transmission error indoor adapter PCB 25 2 2 1 6 C4 00 Heat exchanger thermistor abnormality 26 2 2 1 7 C5 00 Intermediate heat exchanger thermistor abnormality 26 2 2 1 8 C9 00 Suction air thermistor abnormality 27 2 2 1 9 CC 00 Humidity sensor system abnormality 27 2 2 1 10 CJ 00 Remote controller thermistor abnormality 27 2 2 2 O...

Page 4: ...4 2 Outdoor unit 47 2 4 2 1 4 way valve 47 2 4 2 2 Compressor 49 2 4 2 3 Electronic expansion valve 50 2 4 2 4 Fan motor 52 2 4 2 5 High pressure switch 53 2 4 2 6 Low pressure switch 54 2 4 2 7 Main PCB 55 2 4 2 8 Refrigerant thermistors 57 2 4 3 System 59 2 4 4 Others 59 2 5 Other capacity range 59 Part 3 Repair 61 3 1 Refrigerant repair procedures 61 3 1 1 Refrigerant piping handling 61 3 1 2 R...

Page 5: ...gh outdoor 105 5 1 3 Remote controller 106 5 2 Detailed information setting mode 107 5 2 1 Indoor unit 107 5 2 2 Outdoor unit 107 5 2 3 Remote controller 108 5 2 3 1 Quiet Low Noise Operation 108 5 2 3 2 I Demand Function 109 5 2 3 3 Setting for Low Humidity Application 109 5 2 3 4 Defrost Operation 112 5 3 Wiring diagram 114 5 3 1 Indoor unit 114 5 3 2 Outdoor unit 115 5 3 3 Field wiring 116 5 4 ...

Page 6: ...he electrical noise filter 80 Figure 3 17 Removing expansion valve 81 Figure 3 18 Removing expansion valve motor 82 Figure 3 19 Removing expansion valve motor 83 Figure 3 20 Removing solenoid valve 84 Figure 3 21 Removing solenoid valve coil 85 Figure 3 22 Removing high pressure switches 86 Figure 3 23 Removing low pressure switch 88 Figure 3 24 Removing the main PCB assembly 90 Figure 3 25 Stripp...

Page 7: ...sion log Version log 7 Safety precautions 8 General operation 11 How to use 12 Version code Description Date ESIE16 03A Document release 19 07 2016 ESIE16 03B Update chapter 2 1 2 correction of setting items in monitor mode for malfunction con tent of retry Update chapter 3 3 2 2 addition of 3D view of RZAG71 Update chapter 5 6 2 component checklist added 22 08 2016 ...

Page 8: ...telephone numbers for obtaining service In Europe EN378 provides the necessary guidance for this logbook 1 2 1 Meaning of symbols 1 2 2 Warnings WARNING Indicates a situation that could result in death or serious injury WARNING RISK OF ELECTROCUTION Indicates a situation that could result in electrocution WARNING RISK OF BURNING Indicates a situation that could result in burning because of extreme...

Page 9: ... PCB WARNING RISK OF BURNING Do NOT touch the refrigerant piping water piping or internal parts during and immediately after operation It could be too hot or too cold Give it time to return to normal temperature If you must touch it wear protective gloves Do NOT touch any accidental leaking refrigerant WARNING Always recover the refrigerants Do NOT release them directly into the environment Use a ...

Page 10: ...h wiring may cause electrical shock Make sure to use a dedicated power circuit NEVER use a power supply shared by another appliance Make sure to check the required fuses and or circuit breakers before starting works WARNING After finishing the electrical work confirm that each electrical component and terminal inside the electrical components box is connected securely Make sure all covers are clos...

Page 11: ...hence the temperature of the refrigerant is increased The hot refrigerant is blown into the room by a fan which blows over a heat exchanger Colder refrigerant flows back to the outdoor unit where temperature is further decreased by expansion through an expansion valve After the expansion valve the refrigerant is capable of taking up heat again This is enabled by a fan that sucks outdoor air over a...

Page 12: ... the Alt Back Arrow keys or the arrow in the top right hand corner of this page can be used to return to the previously viewed page NO YES NO YES N N N N N NO O O O O O Y Y Y Y Y YE E E E E ES S S S S S Is this your 1st encounter with this particular unit I I Is Is Is Is Is t t t t t th h h his with th What do you need to do W Wh Wh Wh Wh Wha at d Is an Error Code displayed I I Is Is Is Is Is a a ...

Page 13: ...pair The possible causes have been sorted to probability of occurrence and speed of execution 1 4 2 3 The repair chapter The chapter Repair on page 61 handles the removal and replacement of the major components in the product and discusses cleaning methods as well if applicable such as for filters Where applicable refrigerant handling precautions are mentioned for certain actions please consider t...

Page 14: ...ESIE16 03B Part 1 Introduction 1 4 How to use Page 14 22 08 16 Version 1 1 SA R32 Sky Air RZAG L ...

Page 15: ...layed on the user interface screen for more information about troubleshooting refer to Error based troubleshooting on page 23 Error codes check 15 Error based troubleshooting 23 Symptom based troubleshooting 44 Component checklist 45 Other capacity range 59 1 Screen 3 menu button 2 Operation lamp 4 cancel button Operation Status Display Abnormal shut down The system stops operating The operation l...

Page 16: ...u Enter button 8 3 Select RC Error History and press the Menu Enter button The error codes and unit No can be confirmed in the RC Error History screen 8 3 Press the Menu Enter button 8 4 In the RC Error History screen the last 10 items are displayed in order 8 4 1 Latest record 2 Unit no 8 5 Press the Cancel button in the RC Error History screen 3 times The Basic screen returns 8 5 INFORMATION The...

Page 17: ...uct all of the following operations 1 short beep Conduct steps 3 and 4 Continue the operation in step 4 until a buzzer remains ON The continuous buzzer indicates that the error code is confirmed Continuous beep No abnormality 3 Press the MODE selector button The left 0 upper digit indication of the error code flashes 4 Error code upper digit diagnosis Press the UP or DOWN button and change the err...

Page 18: ...n page 23 you find a description of how to reset the specific error or warning 1 Press INSPECTION TEST button Normal status Enters inspection mode from normal status when the INSPECTION TEST button is pressed When MODE selector button is pressed or no button is pressed for 1 minute equip ment returns to normal status 3 Press MODE selector button 5 Press MODE selector button ...

Page 19: ...ondition and diagnose the problem 2 Turn off the power switch After 5 seconds or more disconnect the connection wire 2 Then turn on the power switch If the HAP on the outdoor unit PCB flashes after about 10 seconds the PCB A1P is faulty 3 Also check for open phase INFORMATION The error detection monitor continues to indicate the previously generated error until the power switch is turned off Be su...

Page 20: ...H5P H6P H7P LED status w w w w w w w w Binary counting value 64 32 16 8 4 2 1 Setting item 14 latest error w x x w w w x 15 previous error w x x w w w w 16 2 before w x w x x x x MODE H1P On Off Blinking MODE H1P MODE H1P Setting mode 2 Setting mode 1 Monitor mode Push and hold the BS1 MODE button for 5 seconds Push the BS1 MODE button one time Push the BS1 MODE button one time Normal ...

Page 21: ...c c c c w w x x x x H9 Abnormal outdoor air thermistor c c w x c x x c c c w w x x x x J1 Abnormal pressure sensor c c x w x c c x c c w x x x x c c c w w x x x x J3 Abnormal discharge pipe thermistor c c w x x x c c c c w w x x x x J5 Abnormal suction pipe thermistor c c w x x c x c c c w w x x x x J6 Abnormal heat exchanger distributor pipe thermistor c c w x x c c x c c w w x x x x J7 Abnormal ...

Page 22: ... described in below procedure the content of retry can again be consulted in Monitor mode Setting item 2 latest retry Setting item 3 1 cycle before Setting item 4 2 cycles before To enter Monitor mode press the MODE BS1 button when in Setting mode 1 Selection of retry or error item Display of RETURN 1 When the RETURN BS3 button is pressed the LED display for RETURN 1 turns ON When SET BS2 button i...

Page 23: ... 31 F3 00 Discharge pipe temperature abnormality 31 H3 00 High pressure switch abnormality 32 H4 00 Low pressure switch abnormality 33 H9 00 Outdoor air temperature thermistor abnormality 33 J3 00 Discharge pipe thermistor abnormality 33 J5 00 Suction pipe thermistor abnormality 34 J6 00 Outdoor heat exchanger thermistor abnormality 34 J7 00 Intermediate heat exchanger thermistor abnormality 34 J8...

Page 24: ...ble cause Check Corrective action Defective drain pump Check drain pump Replace drain pump when required Improper drain piping work or clogging Check if drain piping is executed correctly Check if drain piping is clogged Correct or clean drain piping when required Defective flow switch Check flow switch Replace flow switch when required for optional drain pump kit Defective short circuit connector...

Page 25: ... capacity setting adaptor is not con nected or not recognised by the indoor PCB Unit will stop operating Power reset via outdoor unit Possible cause Check Corrective action Faulty indoor PCB Check if error still occurs after turning off power and turning it back on again Check if the indoor PCB receives power Check if the HAP LED is blinking in regu lar intervals Check if the correct spare part is...

Page 26: ...xchanger thermistor see Refrigerant thermistors on page 57 Replace heat exchanger thermistor when required Faulty indoor PCB Check if error still occurs after turning off power and turning it back on again Check if the indoor PCB receives power Check if the HAP LED is blinking in regu lar intervals Check if the correct spare part is installed Check the wiring to indoor PCB Adjust power to the indo...

Page 27: ...ct spare part or update indoor PCB Adjust wiring to indoor PCB when required Trigger Effect Reset The humidity sensor is disconnected or short circuit when the unit is running Unit will not stop operating Manual reset via user interface Possible cause Check Corrective action Faulty humidity sensor Check good connection to indoor PCB Replace the humidity sensor when required External factory e g el...

Page 28: ...hen required Faulty or disturbance of the power supply imbalance 10 Power drop Short cir cuit Check if the power supply is conform with regulations No fluctuations in frequency Adjust power supply when required Power reset via outdoor unit Trigger Effect Reset High pressure switch opens due to meas ure pressure 41 7 bar Unit will stop operating Manual reset via user interface High pressure control...

Page 29: ... through pressure sensor cable Check if pressure sensor connector is properly connected to the outdoor PCB board Connect or replace sensor cable when required Faulty capacity adapter on outdoor PCB Check if the correct adapter is installed Check if the correct spare part is installed Adjust capacity adapter when required Stop valve is closed Check if stop valve is open Open stop valve when require...

Page 30: ... nameplate for the correct charge Charge the correct refrigerant amount when required Humidity in refrigerant ice formation in expansion valve Check for humidity in the refrigerant In case of suspicion of humidity recover vacuum and recharge with virgin refriger ant Non condensables in refrigerant Check for non condensables in refriger ant In case of suspicion of non condensables recover vacuum an...

Page 31: ...k if the power supply is conform with regulations No fluctuations in frequency Adjust power supply when required Power reset via outdoor unit Faulty expansion valve Check the expansion valve see Elec tronic expansion valve on page 50 Replace the expansion valve body or motor see Replacing expansion valve body on page 81 when required Faulty capacity adapter on outdoor PCB Check if the correct adap...

Page 32: ...ace heat exchanger thermistor when required Faulty outdoor temperature thermistor Check outdoor temperature thermistor see Refrigerant thermistors on page 57 Replace outdoor temperature thermistor when required Trigger Effect Reset High pressure switch is activated when compressor is off Unit will stop operating Manual reset via user interface Possible cause Check Corrective action Stop valve is c...

Page 33: ...on valve body on page 81 or motor see Replacing expan sion valve motor on page 82 when required Faulty low pressure switch Check low pressure switch see Low pressure switch on page 54 Replace low pressure switch see Replacing low pressure switch on page 88 Trigger Effect Reset Thermistor input voltage is 4 96 V or 0 04 V when power is on Unit will stop operating Manual reset via user interface Pos...

Page 34: ...P LED is not blinking in regular intervals see Replacing main PCB on page 89 Faulty suction pipe thermistor R3T Check suction pipe thermistor R3T see Refrigerant thermistors on page 57 Replace suction pipe thermistor R3T when required Faulty capacity adapter on outdoor PCB Check if the correct adapter is installed Check if the correct spare part is installed Adjust capacity adapter when required T...

Page 35: ...eck if the correct spare part is installed Check if the outdoor main PCB receives power Adjust the power to the outdoor main PCB Replace outdoor main PCB when HAP LED is not blinking in regular intervals see Replacing main PCB on page 89 Faulty liquid pipe thermistor R6T Check liquid pipe thermistor R6T see Refrigerant thermistors on page 57 Replace liquid pipe thermistor R6T when required Faulty ...

Page 36: ... Avoid electrical interference Trigger Effect Reset Outdoor inverter PCB detects overcurrent to power transistor Unit will stop operating Manual reset via user interface Possible cause Check Corrective action Refrigerant circuit is clogged Check for possible blockage Replace blocked part when required Humidity in refrigerant ice formation in expansion valve Check for humidity in the refrigerant In...

Page 37: ...igerant charge Refer to the nameplate for correct charge Replace compressor when required see Replacing compressor on page 76 Investigate reason of breakdown Replace expansion valve when required see Replacing expansion valve body on page 81 Fix possible leak Trigger Effect Reset Outdoor inverter PCB detects compressor overload at start up Unit will stop operating Manual reset via user interface P...

Page 38: ...ry e g electrical noise cause when error is reset after power reset and error happens again after a while Check for source which could cause elec trical interference Avoid electrical interference Trigger Effect Reset Outdoor inverter PCB detects incorrect power supply Unit will stop operating Manual reset via user interface Automatic reset Possible cause Check Corrective action Faulty outdoor unit...

Page 39: ...when HAP LED is not blinking in regular intervals see Replacing main PCB on page 89 Trigger Effect Reset Outdoor main PCB detects a defective capacity in EEPROM Unit will stop operating Manual reset via user interface Power supply reset Possible cause Check Corrective action Position of PCB dip switches are not OK Check if dip switches are set to default OFF position Faulty outdoor unit main PCB C...

Page 40: ...th virgin refriger ant Non condensables in refrigerant Check for non condensables in refriger ant In case of suspicion of non condensables recover vacuum and recharge with virgin refrigerant Faulty compressor Check compressor see Compressor on page 49 Check connections and wiring of the com pressor Check expansion valve liquid back issue see Electronic expansion valve on page 50 Check the refriger...

Page 41: ...ith over voltage detection circuit Replace PCB when required Defective PAM control part Check PAM control part Replace PAM control part when required Faulty compressor Check compressor see Compressor on page 49 Check connections and wiring of the com pressor Check expansion valve liquid back issue see Electronic expansion valve on page 50 Check the refrigerant charge Refer to the nameplate for cor...

Page 42: ...acing DC fan motor assembly on page 79 Adjust wiring when required Faulty indoor unit main PCB Check if the HAP LED is blinking in regu lar intervals see Main PCB on page 55 Check if the correct spare part is installed Check if the indoor main PCB receives power Restore the power to the indoor main PCB Replace indoor main PCB when HAP LED is not blinking in regular intervals see Replacing main PCB...

Page 43: ... Corrective action Faulty wiring between indoor and outdoor unit Check wiring between indoor and outdoor unit see Wiring diagram on page 114 Correct wiring Refrigerant shortage incorrect charge leakage Check for refrigerant shortage Perform a leak test If required repair the leak and charge the correct amount of refrigerant Refrigerant circuit is clogged Check for possible blockage Blockages can b...

Page 44: ...om based troubleshooting Page 44 22 08 16 Version 1 1 SA R32 Sky Air RZAG L 2 3 Symptom based troubleshooting 2 3 1 Indoor unit Not available yet 2 3 2 Outdoor unit Not available yet 2 3 3 System Not available yet 2 3 4 Others Not available yet ...

Page 45: ... Sky Air RZAG L 2 4 Component checklist Overview of component checklists Indoor unit 46 Fan motor 46 Outdoor unit 47 4 way valve 47 Compressor 49 Electronic expansion valve 50 Fan motor 52 High pressure switch 53 Low pressure switch 54 Main PCB 55 Refrigerant thermistors 57 System 59 Others 59 ...

Page 46: ... circuit breaker 3 Remove casing when required 4 Check fuse on indoor PCB replace if blown 5 Check if fan motor connector is plugged into PCB 6 Power the Daikin unit 7 Check power supply the measured voltage must be 198 240 VAC if not replace indoor PCB Technical specification Description The motor has a single connector for DC power and the rotation counter feed back from the integrated pulse gen...

Page 47: ...tion of the 4 way valve as described below and replace the 4 way valve refer to Replacing 4 way valve body on page 73 7 While listening to the 4 way valve place a round permanent magnet on the core of the solenoid valve If you do not hear the 4 way valve switching it must be replaced refer to Replacing 4 way valve body on page 73 1 Switch off Daikin unit via the user interface 2 Switch off Daikin ...

Page 48: ...the 4 way valve coil refer to Replacing 4 way valve coil on page 75 7 Switch on the Daikin unit start cooling defrost operation If the temperature after the plate type heat exchanger rises the control of the 4 way valve is wrong Replace main PCB 1 Switch off Daikin unit via the user interface 2 Switch off Daikin unit with the field supplied circuit breaker 3 Slide a magnet over the front and the r...

Page 49: ...on connectors U V and W from the compressor take picture 9 Measure the compressor motor windings U V V W and U W refer to Product specific information on page 121 10 Megger the compressor using 500 or 1000 VDC the insulation must be higher than 3 MΩ 11 Replace the compressor if the windings and or insulation measurements fail refer to Replacing compressor on page 76 12 Run the compressor and measu...

Page 50: ... valve body on page 81 1 Switch off the Daikin unit via the user interface 2 Switch off the Daikin unit with the field supplied circuit breaker 3 Remove plate work when required refer to Basic removal on page 67 4 Check if the electrical connector of the expansion valve coil was correctly connected to the PCB if not connect the electrical connector 5 Disconnect the electrical connector of the expa...

Page 51: ...2 Troubleshooting 2 4 Component checklist 22 08 16 Version 1 1 Page 51 SA R32 Sky Air RZAG L 6 If one or more of the windings have no continuity replace the expansion valve coil Harness 5P 6P Connector Check 1 6 3 2 4 ...

Page 52: ...th the field supplied circuit breaker 3 Remove plate work when required refer to Basic removal on page 67 4 Check fuse on PCB replace if blown 5 Check if fan motor connector is plugged into PCB 6 Power the Daikin unit 7 Check power supply the measured voltage must be 198 240 VAC if not replace main PCB refer to Replacing main PCB on page 89 Technical specification Description The motor has a singl...

Page 53: ...igh pressure switches on page 86 9 Lower the refrigerant circuit pressure to 30 bar 10 Measure the switch contacts between high pressure switch connector pins 1 2 the switch must be closed 11 Replace the high pressure switch if the contact is not closed refer to Replacing high pressure switches on page 86 Technical specification Description The high pressure switch has a normally closed contact If...

Page 54: ...re switches on page 86 9 Increase the refrigerant circuit pressure to 1 bar 10 Measure the switch contacts between low pressure switch connector pins 1 2 the switch must be closed 11 Replace the low pressure switch if the contact is not closed refer to Replacing high pressure switches on page 86 Technical specification Description The low pressure switch has a normally closed contact If the pressu...

Page 55: ...lectrical noise filter on page 80 8 Switch off the Daikin unit via the user interface 9 Switch off the Daikin unit with the field supplied circuit breaker 10 Remove plate work when required 11 Open the compressor insulation 12 Remove the terminal cover of compressor wiring 13 Measure the voltage on S70 pin 7 4 and wait until it drops below 10 VDC 14 Disconnect the compressor wires and connect the ...

Page 56: ... not replace the inverter board refer to Replacing inverter PCB on page 87 18 Switch off the Daikin unit with the field supplied circuit breaker 19 Wait a few minutes and confirm that the LED s on the Inverter Analyzer are off 20 Disconnect the Inverter Analyzer from the U V W wiring 21 Reconnect the U V W leads to the compressor WARNING Electrical shock hazard Do not touch life wires CAUTION When...

Page 57: ... must be replaced E g R3T air thermistor main PCB connector S90 pin 1 2 type 1 Measured temperature with contact thermometer 23 1 C Unplug the sensor and measure the resistance between S90 1 2 21 86 kΩ The resistance values are defined by below table Thermistor resistance temperature characteristics type 1 Resistance at 23 C 21 85 kΩ Resistance at 24 C 20 90 kΩ Technical specification Description ...

Page 58: ...16 10 50 7 18 70 3 44 9 8 7 6 5 4 3 2 1 106 03 100 41 95 14 90 17 85 49 81 08 76 93 73 01 69 32 11 12 13 14 15 16 17 18 19 38 08 36 30 34 62 33 02 31 50 30 06 28 70 27 41 26 18 31 32 33 34 35 36 37 38 39 15 43 14 79 14 18 13 59 13 04 12 51 12 01 11 52 11 06 51 52 53 54 55 56 57 58 59 6 91 6 65 6 41 6 65 6 41 6 18 5 95 5 74 5 14 71 72 73 74 75 76 77 78 79 3 32 3 21 3 11 3 01 2 91 2 82 2 72 2 64 2 5...

Page 59: ...E16 03B Part 2 Troubleshooting 2 5 Other capacity range 22 08 16 Version 1 1 Page 59 SA R32 Sky Air RZAG L 2 4 3 System Not applicable 2 4 4 Others Not applicable 2 5 Other capacity range Not applicable 0 ...

Page 60: ...ESIE16 03B Part 2 Troubleshooting 2 5 Other capacity range Page 60 22 08 16 Version 1 1 SA R32 Sky Air RZAG L ...

Page 61: ...iquid state R32 can be charged in gas phase Make sure to use a digital scale no charging cylinder Execute correct vacuum drying procedure after repair work 0 1 MPa 760 mmHg 750 Torr 1 bar for at least 1 hour Connect the unit according the available service ports refer to Recovery procedure on page 61 Use related field setting where necessary to open expansion valve solenoid valve 3 1 2 Recovery pr...

Page 62: ...at the stop valves Connect both stop valve service ports to the manifold In case of 3 service ports at the stop valves Connect 1 hose to the suction stop valve service port and 1 hose to the service port between the expansion valve and outdoor H E 1 Vacuum pump 3 To recovery pump 2 Connect flexible hose to service port 3 stop valve INFORMATION See instruction of the recovery pump supplier how to r...

Page 63: ... liquid stop valve and gas stop valve 2 Carry out forced cooling operation 1 Vacuum pump 2 To recovery pump INFORMATION See instruction of the recovery pump supplier how to recover the refrigerant WARNING RISK OF EXPLOSION When the refrigeration circuit has a leak do not execute pump down with the compressor Use recovery system into separate cylinder Warning explosive hazard exists when executing ...

Page 64: ...g repair procedures Make sure to cover open pipe ends during repair work so no dust or moisture can enter Make sure to re apply insulation removed during repair Pipe expansion flare making Remove any burrs on the cut surface and use correct tool such as reamer or scraper note that excessive deburring can thin the pipe walls and cause cracking of the pipe Make sure the flare has the correct size us...

Page 65: ...s please check the Daikin Business Portal http www mydaikin eu Go to the tab After sales support on the left side and then select Technical support You will then find a button Service tools which gives you an overview on which service tool to use for which product Also additional information on the service tool instruction latest software can be found there ...

Page 66: ...ng 4 way valve body 73 Replacing 4 way valve coil 75 Replacing accumulator assembly 75 Replacing compressor 76 Replacing DC fan motor assembly 79 Replacing electrical noise filter 80 Replacing expansion valve body 81 Replacing expansion valve motor 82 Replacing solenoid valve 84 Replacing solenoid valve coil 85 Replacing high pressure switches 86 Replacing inverter PCB 87 Replacing low pressure sw...

Page 67: ...e 2 Switch off the Daikin unit with the field supplied circuit breaker 3 Loosen and remove the 9 screws 1 that fix the top plate assembly 2 4 Lift the top plate assembly 2 and remove it from the Daikin unit Figure 3 3 Removing the top plate assembly 5 Loosen and remove the screw 1 that fixes the front plate 2 6 Lift the front plate 2 and remove it from the unit 1 Screw 2 Top panel 1 2 1 2 1 1 1 1 ...

Page 68: ...and remove the 11 screws 1 that fix the front plate assembly 3 8 Loosen and remove the screw 2 that fixes the front plate assembly 3 9 Lift the front plate assembly 3 and remove it from the unit Figure 3 5 Removing the front plate assembly 1 Screw 2 Front plate CAUTION The screw 2 has a different length 1 Screw 3 Front plate assembly 2 Screw 2 1 1 1 3 1 2 1 ...

Page 69: ...15 Slightly twist the right side of the thermistor fixing plate 2 and gently pull the left side of the thermistor fixing plate 2 until it unlatches 16 Slide the thermistor fixing plate 2 until it detaches from the right side plate 4 17 Turn over the thermistor fixing plate 2 and unlatch the thermistor cover 18 Remove thermistor R1T 1 from the thermistor fixing plate 2 19 Remove the thermistor fixi...

Page 70: ...air 3 3 Unit specific repair procedures Page 70 22 08 16 Version 1 1 SA R32 Sky Air RZAG L Figure 3 8 Removing the right side plate 1 Thermistor R1T 3 Screw 2 Thermistor fixing plate 4 Right side plate 3 3 4 3 2 1 3 3 2 3 2 ...

Page 71: ...supplied circuit breaker 3 Remove plate work when required refer to Basic removal on page 67 Figure 3 9 Thermistor location Thermistor Processed on PCB Connector colour R1T air Main X11A R2T discharge Main X12A yellow R3T suction Main X12A green R4T heat exchanger Main X12A red R5T heat exchanger middle Main X12A white R6T liquid Main X13A blue R7T R8T Positive Temperature Coefficient 1 R1T 4 R4T ...

Page 72: ... insulation 3 and the thermistor wire 2 5 Cut the insulation 3 and remove it 6 Pull the clip 5 that fixes the thermistor 6 7 Remove the thermistor 6 from the thermistor holder 4 Figure 3 10 Replacing a thermistor Installation 1 Proceed in reverse order 1 Tie wrap 4 Thermistor holder 2 Thermistor wire 5 Clip 3 Insulation 6 Thermistor 2 3 4 1 1 5 6 ...

Page 73: ... hose with core depressor to allow the release of the nitrogen 8 Cut the 4 way valve pipes 1 9 Remove the 4 way valve 2 10 Supply nitrogen to the piping circuit 11 Using an oxygen acetylene torch heat a solder connection of the 4 way valve 2 12 When the solder material is liquid pull the 4 way valve pipe 1 13 Repeat steps 11 and 12 for the 3 remaining 4 way valve pipes 1 14 Cut the nitrogen supply...

Page 74: ...ESIE16 03B Part 3 Repair 3 3 Unit specific repair procedures Page 74 22 08 16 Version 1 1 SA R32 Sky Air RZAG L 1 Wrap a wet rag around the 4 way valve 2 2 Proceed in reverse order ...

Page 75: ...ix the 4 way valve coil wire 5 Unplug the 4 way valve connector from the main PCB 6 Loosen and remove the screw 1 that fixes the 4 way valve coil 2 7 Remove the 4 way valve coil 2 from the 4 way valve Figure 3 12 Removing 4 way valve body Installation 1 Proceed in reverse order 3 3 2 5 Replacing accumulator assembly Not applicable WARNING RISK OF FIRE When reconnecting a connector to the PCB do no...

Page 76: ...r to allow the release of the nitrogen 9 Cut the 2 tie wraps that fix the power and communication wires to the stop valve mounting plate 10 Loosen and remove the 4 screws 1 that fix the stop valves 11 Loosen and remove the 2 screws 2 that fix the stop valve mounting plate 3 12 Lift and remove the stop valve mounting plate 3 Figure 3 13 Removing stop valve mounting plate 13 Cut the tie wrap that fi...

Page 77: ...the dampers 4 from the compressor 7 21 Supply nitrogen to the piping circuit 22 Heat the 2 compressor pipes 1 using an oxygen acetylene torch 23 When the solder is liquid remove the 2 compressor pipes 1 24 Cut the nitrogen supply when the piping has cooled down Figure 3 14 Removing compressor 1 Compressor pipe 5 Bolt 2 R2T thermistor 6 Rubber grommet 3 Compressor wiring 7 Compressor 4 Dampers 2 1 ...

Page 78: ...e compressor pipes with a wet cloth to prevent overheating the compressor and the oil in the compression pipe 5 Proceed in reverse order CAUTION The oil in the compressor is hygroscopic Remove the caps from the compressor piping as late as possible INFORMATION Before installing a new compressor determine the cause of the compressor failure and take all required corrective actions INFORMATION If th...

Page 79: ...an motor cable 4 through the opening between the partition plate 6 and the stop valve mounting plate 7 8 Loosen and remove the 4 screws 9 that fix the fan motor 8 9 Remove the fan motor 8 from the unit Figure 3 15 Removing the DC fan motor assembly Installation 1 Proceed in reverse order 1 Upper fan motor connector 6 Partition plate 2 Lower fan motor connector 7 Stop valve mounting plate 3 Tie wra...

Page 80: ...als 1 3 6 Unplug the ground wires 6 7 Unlock the 9 standoffs 8 that fix the electrical noise filter PCB 8 Remove the electrical noise filter PCB 7 from the main PCB assembly Figure 3 16 Removing the electrical noise filter Installation 1 Proceed in reverse order WARNING RISK OF FIRE When reconnecting a connector to the PCB do not apply force as this may damage the connector or connector pins of th...

Page 81: ...ose to the outdoor suction service port 7 Attach a hose with core depressor to allow the release of the nitrogen 8 Cut the 2 expansion valve pipes 1 9 Remove the expansion valve 2 10 Supply nitrogen to the piping circuit 11 Using an oxygen acetylene torch heat the 2 expansion valve pipes 1 12 When the solder material is liquid pull the 2 expansion valve pipes 1 13 Cut the nitrogen supply when the ...

Page 82: ... unlock it 5 Remove the expansion valve Y1E motor 1 from the expansion valve Y1E 2 6 Cut all tie wraps that fix the expansion valve motor wiring 7 Unplug the expansion valve motor connector from the Main PCB Figure 3 18 Removing expansion valve motor Installation 1 Proceed in reverse order 2 When installing the expansion valve motor 1 lock it on the expansion valve 2 WARNING RISK OF FIRE When reco...

Page 83: ...ESIE16 03B Part 3 Repair 3 3 Unit specific repair procedures 22 08 16 Version 1 1 Page 83 SA R32 Sky Air RZAG L Figure 3 19 Removing expansion valve motor 1 Expansion valve motor 2 Expansion valve 1 2 ...

Page 84: ...efer to Replacing solenoid valve coil on page 85 8 Connect a nitrogen hose to the outdoor suction service port 9 Attach a hose with core depressor to allow the release of the nitrogen 10 Cut the 2 solenoid valve pipes 1 11 Remove the solenoid valve 2 12 Supply nitrogen to the piping circuit 13 Using an oxygen acetylene torch heat the 2 solenoid valve pipes 1 14 When the solder material is liquid p...

Page 85: ... 6 Attach a hose with core depressor to allow the release of the nitrogen 7 Loosen and remove the screw 1 that fixes the solenoid valve coil 2 to the solenoid valve 3 8 Remove the solenoid valve coil 2 from the solenoid valve 3 9 Cut tie wraps that fix the solenoid valve coil 2 wiring 10 Unplug the solenoid valve coil connector from the Main PCB Figure 3 21 Removing solenoid valve coil Installatio...

Page 86: ...release of the nitrogen 7 Unplug the high pressure switch connector 3 8 Cut the tie wrap 4 9 Cut the high pressure switch S1PH pipe 5 10 Remove the high pressure switch 1 or 2 11 Supply nitrogen to the piping circuit 12 Heat the pressure switch pipe 5 using an oxygen acetylene torch 13 When the solder is liquid pull the pressure sensor pipe 5 14 Cut the nitrogen supply when the piping has cooled d...

Page 87: ...pair procedures 22 08 16 Version 1 1 Page 87 SA R32 Sky Air RZAG L 1 Wrap a wet rag around the pressure sensor 2 Proceed in reverse order 3 3 2 14 Replacing inverter PCB The inverter is integrated in the main PCB see Replacing main PCB on page 89 ...

Page 88: ... low pressure switch connector on the main PCB 8 Cut the tie wrap that fixes the low pressure switch wiring 9 Cut the low pressure switch pipe 1 10 Remove the low pressure switch 2 11 Supply nitrogen to the piping circuit 12 Heat the low pressure switch pipe 1 using an oxygen acetylene torch 13 When the solder is liquid pull the low pressure switch pipe 1 14 Cut the nitrogen supply when the piping...

Page 89: ...ove the 3 screws 8 that fix the heat sink with a ring spanner or a wrench socket 11 Remove the 4 screws 7 that fix the main PCB support to the Daikin unit 12 Lift and turn the lid 10 to the left 13 Lift the main PCB 5 to release it from the unit 14 Slightly tilt max 15 the main PCB 5 and disconnect 2 connectors at the rear of the main PCB panel 15 Guide the wiring 11 through the slots WARNING RISK...

Page 90: ... Cut the tie wraps 1 that fix the protection sheet 2 remove the protection sheet 2 17 Cut the tie wrap 3 18 Loosen and remove the 2 screws 4 that fix the wiring 1 Protection sheet 7 Screw 2 Terminal block 8 Screw 3 Tie wrap 9 Cable clamp 4 Connectors 10 Compressor connector 5 Main PCB 11 Wiring 6 4 way valve coil 12 Lid 1 6 4 3 3 4 11 7 2 5 8 7 12 7 10 4 9 ...

Page 91: ...8 from the terminal block 23 Loosen and remove the 2 screws 9 that fix the terminal block Figure 3 25 Stripping the main PCB assembly front 24 Loosen and remove the 2 screws 1 that fix the wiring 25 Cut the 2 tie wraps 2 that fix the wiring 26 Unlock the 9 standoffs 3 that fix the electrical noise filter PCB 27 Remove the wiring from the cable clamp 4 28 Remove the electrical noise filter PCB 5 1 ...

Page 92: ...epair procedures Page 92 22 08 16 Version 1 1 SA R32 Sky Air RZAG L Figure 3 26 Stripping the main PCB assembly rear Installation 1 Proceed in reverse order 1 Screw 4 Cable clamp 2 Tie wrap 5 Electrical noise filter PCB 3 Standoff 1 2 3 5 3 2 4 3 ...

Page 93: ... circuit breaker 3 Loosen and remove the 4 nuts 1 that fix the air discharge grill 2 4 Press A the 2 latches to release the air discharge grill 2 5 Tilt B the air discharge grill 2 and remove it from the Daikin unit 6 Remove the nut 3 that fixes the propeller fan 4 7 Pull the propeller fan blade assembly 2 from the fan motor 5 Figure 3 27 Removing the propeller fan blade assembly 1 Nut 4 Propeller...

Page 94: ...ESIE16 03B Part 3 Repair 3 3 Unit specific repair procedures Page 94 22 08 16 Version 1 1 SA R32 Sky Air RZAG L ...

Page 95: ...erant clogs filters inside the piping and is basically the same phenomenon as pump down Pressure differential between high and low pressure becomes low Indoor unit 95 Outdoor unit 96 Cooling Heating Differential between suction temperature and discharge temperature 8 18 C 14 30 DB 27 C 20 C WB 19 C NA COOLING Low pressure High pressure Running current Dirty air filter Lower Lower Lower Short circu...

Page 96: ...rant freezes inside the electronic expansion valve and is basically the same phenomenon as pump down Dirt in the refrigerant clogs filters inside the piping and is basically the same phenomenon as pump down Pressure differential between high and low pressure becomes low CAUTION Make sure not to bend the hair fins COOLING Low pressure High pressure Running current Dirty air filter Higher Higher Hig...

Page 97: ...Air RZAG L Part 5 Appendix This part contains the following chapters Field setting 99 Detailed information setting mode 107 Wiring diagram 114 Piping diagram 117 Component overview of unit 118 Product specific information 121 Switch box 122 Field information report 122 ...

Page 98: ...ESIE16 03B Part 5 Appendix Page 98 22 08 16 Version 1 1 SA R32 Sky Air RZAG L ...

Page 99: ...n In the case of group total setting this operation is not needed In the case of individual setting per indoor unit current settings are displayed And Second Code No means no function 5 Highlight Second Code No of the First Code No to be changed and select desired Second Code No by using Up Down button Multiple identical mode number settings are available In the case of group total setting all of ...

Page 100: ...etting changes repeat 3 to 7 9 After all setting changes are completed press Cancel button twice 10 Backlight goes out and Connection under check Please wait for a moment is displayed for initialization After the initialization the basic screen returns CAUTION When an optional accessory is installed on the indoor unit settings of the indoor unit may be changed See the manual of the optional access...

Page 101: ...n for at least 4 s during normal mode to enter the Field setting mode 2 Press the MODE button to select the desired Mode No 3 Press the UP button to select the First code No 4 Press the DOWN button to select the Second code No 5 Press the RESERVE button to set the present settings 6 Press the INSPECTION TEST button to return to the Normal mode 1 Mode No 4 First code No 7 DOWN button 2 Field settin...

Page 102: ...lications Standard factory setting Slightly up Up 1 Selection of airflow direction 4 way flow factory setting 3 way flow 2 Flap moving in the swing mode All 4 flaps synchronized Two opposite flaps synchronized factory setting 4 Airflow range setting Upper Normal factory setting Lower 14 24 2 The largest time interval for Dust Collection Sign Display for self cleaning decoration panel About 1250 hr...

Page 103: ...ping down H5P H6P DEMAND During Setting mode 1 demand level is displayed H7P BS But ton BS1 MODE Used to change Setting mode BS2 SET Used to change Setting item and Setting condition BS3 RETURN Used to decide Setting item and Setting condition BS4 PUMP DOWN Used for pump down operation forced oil return operation and forced defrost operation Dip Switch DS1 1 ON EMERGENCY Switch from OFF to ON for ...

Page 104: ...ing mode 1 the lamp is always OFF Test operation display h In normal operation k In test operation l In line inspection operation Error display h Normal k Error Night time quiet operation display hh Normal operation hk Low noise level 1 kh Low noise level 2 kk Low noise level 3 Demand level display hh 30 Normal operation hk 40 Demand kh 50 Demand kk Demand h BLINK MODETEST DEMAND k ON l OFF Select...

Page 105: ... h h h k h h 43 C k h h h k h k Weather depending con trol in heating k h h h k k h 54 Weather depending control TeS Lower limit value A k k k h k k h 9 C factory set k h h h h h k 11 C k h h h h k h 13 C k h h h h k k 15 C k h h h k h h 57 Weather depending control TeS Lower limit value B k k k k h h k 2 C factory set k h h h h h k 4 C k h h h h k h 6 C k h h h h k k 8 C k h h h k h h 58 Weather ...

Page 106: ... capacity preceding Refer to Quiet Low Noise Oper ation on page 108 1 Automatic low noise start and stop time 22h00 06h00 22h00 08h00 Factory 20h00 08h00 Refer to Quiet Low Noise Oper ation on page 108 2 EDP room setting Disabled Factory setting EDP room setting EDP room setting no freeze up Refer to Setting for Low Humidity Application on page 109 3 Defrost starting setting Standard Factory setti...

Page 107: ... h h h l h h 40 of rated power consumption k h h h h l h 50 of rated power consumption k h h h h h l Push the RETURN BS3 button once to make a decision 30 of rated power consumption k h h h k h h 40 of rated power consumption k h h h h k h 50 of rated power consumption k h h h h h k Push the RETURN BS3 button once again for execution The LED display is in the initial status of Setting mode 2 k h h...

Page 108: ...peration can also be activated from the optional PCB Quiet low noise operation will start when the contact on LNOP COM is closed and will remain active as long as the contact is closed No field setting on the outdoor unit or by remote controller is required Quiet low noise operation will be ended when the contact is re opened Use of the KRP58M enables the use of an external time clock Same as with...

Page 109: ... Power consumption limitation set to 40 Demand 3 Forced thermostat OFF 5 2 3 3 Setting for Low Humidity Application Can be set when using the RZAG L units for year round cooling in low humidity applications such as computer rooms EDP rooms technical rooms etc to increase the capacity of the unit Model RZQG71 RZQG100 RZQG125 RZQG140 Sound reduction 6 dBA 5 dBA 6 dBA 7 dBA DS1 Setting Maximum Power ...

Page 110: ...or 20 minutes accumulated Change target Te 5 C Te 1 C for 30 minutes accumulated Change target Te 8 C See graph 1 See graph 2 See graph 3 Freeze protection function Start Te 1 C for 40 minutes accumulated OR Te A C for 1 minute continuous Indoor deci sion Te 1 C for 40 minutes accumulated OR Te 3 C for 1 minute continuous Outdoor decision Te 1 C for 40 minutes accumulated OR Te A C for 1 minute co...

Page 111: ...ow humidity application is selected Field setting 16 26 2 03 Outdoor Temp C DB Indoor Temp C WB 11 14 16 18 19 20 22 24 Capacity of standard point 15 0 62 0 76 0 86 0 95 1 00 1 02 1 07 1 11 10 0 62 0 76 0 86 0 95 1 00 1 02 1 07 1 11 5 0 62 0 81 0 91 1 01 1 06 1 16 1 21 1 26 0 0 62 0 81 0 91 1 01 1 06 1 16 1 21 1 26 C Te target acceptable area Te target Remote controller setting temp Te see note ta...

Page 112: ... 0 78 0 95 1 01 1 06 1 16 1 26 15 0 51 0 68 0 78 0 95 1 01 1 06 1 16 1 24 20 0 51 0 68 0 78 0 95 1 01 1 06 1 16 1 21 25 0 51 0 68 0 78 0 95 1 00 1 06 1 13 1 18 30 0 51 0 68 0 78 0 95 1 00 1 05 1 10 1 14 35 0 51 0 68 0 78 0 95 1 00 1 02 1 06 1 11 40 0 51 0 67 0 78 0 94 0 96 0 98 1 02 1 06 INFORMATION Operation range on indoor side expanded from minimum 12 CWB to 11 CWB when using LH setting Do not ...

Page 113: ...utes at longest Hp High pressure Tb Heat exchanger distributor pipe temperature Tm Intermediate heat exchanger temperature OFF A Hz ON ON OFF ON ON OFF ON ON 0 Hz 150 pls 480 pls 0 pls 5 60 sec 0 pls 5 sec Compressor Four way valve Electronic expansion valve Outdoor unit fan Indoor unit fan Previous control Defrosting start Defrosting complete wet protection control Defrost Time 10 sec Hp 2 45 MPa...

Page 114: ...al H3P A6P LED filtersign red Field supply H4P A6P LED defrost orange H5P A6P LED element cleaning red Symbols H6P A6P LED ventilation cleaning green X1M Main terminal KCR A7P Magnetic relay Earth wiring KFR A7P Magnetic relay Wire number 15 KHuR A7P Magnetic relay Hu Field wire K2R Magnetic relay Field cable M1F Fan motor indoor Connection continues on page 12 column 2 M1P Motor drain pump Severa...

Page 115: ... circuit breaker 30 mA Protective earth R2 R5 R6 Resistor Noiseless earth R1T Thermistor air Option R2T Thermistor discharge R3T Thermistor suction Colours R4T Thermistor heat exchanger inlet BLK Black R5T Thermistor heat exchanger middle BLU Blue R6T Thermistor liquid BRN Brown R7T R8T Thermistor Positive Temperature Coefficient GRN Green RC Signal receiver circuit PPL Purple S1PH A Automatic hig...

Page 116: ...n PS Switching power supply Protective earth 01DI Earth leakage circuit breaker 30 mA Noiseless earth R1 R5 Resistor Option R1T Thermistor air R2T Thermistor discharge Colours R3T Thermistor suction BLK Black R4T Thermistor heat exchanger inlet BLU Blue R5T Thermistor heat exchanger middle BRN Brown R6T Thermistor liquid GRN Green R7T Thermistor fin PPL Purple RC Signal receiver circuit RED Red S1...

Page 117: ...t 5 16 R2T Thermistor discharge d Filter 4x R3T Thermistor suction e Switch box cooling R4T Thermistor heat exchanger inlet f Pressure regulating valve R5T Thermistor heat exchanger middle g Heat exchanger R6T Thermistor liquid h Internal service port 5 16 S1PH A Automatic high pressure switch i Check valve S1PH M Manual high pressure switch j Compressor accumulator S1PL Low pressure switch k Liqu...

Page 118: ...2 08 16 Version 1 1 5 5 Component overview of unit 5 5 1 Indoor unit Figure 5 6 Components overview indoor unit a Switch box d Drain pipe connection VP25 g Fan motor b Gas pipe connection e Drain pump h Heat exchanger c Liquid pipe connection f Float switch i Hanger bracket f g h i c b a e d ...

Page 119: ...H A Automatic high pressure switch e Liquid receiver S1PH M Manual high pressure switch f Stop valve with service port liquid S1PL Low pressure switch g Stop valve with service port gas X1M Terminal communication and power supply h Cable tie mountings to fix the field wiring with cable ties to ensure stress relief Y1E Electronic expansion valve i Compressor accumulator Y3E Electronic expansion val...

Page 120: ...n e Liquid receiver S1PH A Automatic high pressure switch f Stop valve with service port liquid S1PH M Manual high pressure switch g Stop valve with service port gas S1PL Low pressure switch h Cable tie mountings to fix the field wiring with cable ties to ensure stress relief X1M Terminal communication and power supply i Compressor accumulator Y1E Electronic expansion valve Y3E Electronic expansio...

Page 121: ... class PCB Specific Outdoor unit M1C Motor compressor X502A X502A A1P M1F Motor upper fan X106A X106A A1P M2F Motor lower fan X107A A1P S1PH A Automatic high pressure switch X32A X32A A1P S1PH M Manual high pressure switch X32A X32A A1P S1PL Low pressure switch X31A X31A A1P Y1E Electronic expansion valve X21A X21A A1P Y3E Electronic expansion valve X22A X22A A1P Y1S Solenoid valve 4 way valve X25...

Page 122: ...3B Part 5 Appendix 5 7 Switch box SA R32 Sky Air RZAG L Page 122 22 08 16 Version 1 1 5 7 Switch box 5 7 1 Indoor unit Not applicable 5 7 2 Outdoor unit Not applicable 5 8 Field information report See next page ...

Page 123: ... information is required Please fill out the following form before contacting your distributor FIELD INFORMATION REPORT Key person info Name Company name Your contact details Phone number E mail address Site address Your reference Date of visit Claim info Title Problem description Error code Trouble date Problem frequency Investigation steps done Insert picture of the trouble Current situation sol...

Page 124: ...A1P Software version hydro PCB A5P Software version user interface Software version outdoor PCB Minimum water volume Maximum water volume Brine composition and mixture Brine freeze up temperature Space heating control leaving water temperature room thermostat ext room thermostat Space heating setpoint Domestic hot water control reheat only schedule only reheat schedule Domestic hot water setpoint ...

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Daikin RZAG100L7V1B, Service Manual

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