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2

SERVICING

33

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WARNING: TURN OFF all power source switches

5. Detach the hook holding the left side of the heat exchanger

and remove one (1) screw fixing the heat exchanger.

6. Remove one (1) screw fixing the heat exchanger and

detach the hook holding the right side of the heat
exchanger.

7. Lift up the heat exchanger, Draw out the rear piping of the

heat exchanger from the square hole by pulling the upper
part of the heat exchanger forward and remove the heat
exchanger.

8. For attaching the heat exchanger, perform the reverse

procedures for removing.

NOTE:

After attaching the heat exchanger, check to ensure that
the hooks and the screws at the right and the left sides of
the heat exchanger are correctly attached.

2.5.9

REMOVING FAN AND FAN MOTOR

1. Remove the heat exchanger according to the item 2.5.8,

”Removing Heat Exchanger”.

2. Remove the supporting plate for the bearing by pushing the

knobs at both sides of the supporting plate toward the
inside and detaching the hooks.

3. Remove the motor holders 1 and 2 fixing the fan motor.

For removing the motor holder, insert the screwdriver at the
hook part and screw it.

4. After removing the motor holder 1, loosen one screw (1)

fixing the motor shaft and the fan.

Detach Hook

Screw

Detach
Hook

Screw

Unit Body

Square Hole

Pull the upper part of the heat
exchanger forward

Heat Exchanger

Supporting Plate

Push Knobs at both
sides and detach Hooks

Knob

Hook

Hook

Bearings (inside)

Motor Holder 1

Motor Holder 1,2

Fan Motor

Motor Holder 2

Screwdriver

Hook

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Summary of Contents for FS3 Series

Page 1: ...Service Manual SET FREE FSG FS3 Outdoor Units 5 20 HP Indoor Units Type In the Ceiling 4 Way Cassette 2 Way Cassette Wall Floor Floor Concealed Ceiling Total Heat Exchangers ...

Page 2: ......

Page 3: ...in order that HITACHI may bring the latest innovations to their customers Whilst every effort is made to ensure that all dimensions and specifications are correct any printers errors not rectified are outside the control of HITACHI who cannot be held responsible for same ...

Page 4: ......

Page 5: ...F CENTRAL STATION PSC 3S1 1 89 1 3 6 PROCEDURE OF CHECHING OTHER MAIN PARTS 1 90 1 4 TEST RUN 1 101 1 4 1 TEST RUN MODE REMOTE CONTROL SWITCH 1 101 1 4 2 TEST RUN FROM OUTDOOR UNIT SIDE 1 102 1 4 3 CHECKING LIST FSG AND FS3 SERIES 1 103 2 SERVICING 2 1 OUTDOOR UNIT 2 1 2 1 1 REMOVING AIR INTAKE GRILLE 2 1 2 1 2 REMOVING FRONT SERVICE PANEL 2 1 2 1 3 REMOVING FAN GUARD NETS 2 1 2 1 4 REMOVING OUTDO...

Page 6: ...TYPE 2 28 2 5 1 REMOVING AIR FILTER 2 28 2 5 2 REMOVING FRONT PANEL 2 29 2 5 3 REMOVING MOTOR FOR AUTOMATIC LOUVER 2 30 2 5 4 REMOVING THERMISTORS FOR LIQUID PIPE GAS PIPE DISCHARGE AIR AND SUCTION AIR 2 30 2 5 5 REMOVING ELECTRICAL BOX COVER 2 31 2 5 6 REMOVING INDOOR PCB 2 32 2 5 7 REMOVING DRAIN PAN 2 32 2 5 8 REMOVING HEAT EXCHANGER 2 32 2 5 9 REMOVING FAN AND FAN MOTOR 2 33 2 5 10 REMOVING EL...

Page 7: ...PROTECTIVE FUNCTION 3 7 3 2 THERMISTOR 3 8 3 2 1 RESISTANCE VALUE OF THERMISTOR 3 9 3 3 ELECTRONIC EXPANSION VALVE 3 11 3 3 1 ELECTRONIC EXPANSION VALVE FOR OUTDOOR UNITS 3 11 3 3 2 ELECTRONIC EXPANSION VALVE FOR INDOOR UNITS 3 12 3 4 PRESSURE SENSOR 3 13 3 5 NOISE FILTER 3 14 3 6 CAPACITOR 3 16 3 7 REACTOR DCL 3 16 3 8 CIRCUIT DIAGRAM FOR PRINTED CIRCUIT BOARD OF OUTDOOR UNIT 3 19 3 9 CIRCUIT DIA...

Page 8: ...IDE 4 20 4 4 3 SIMULTANEOUS OPERATION 4 20 4 4 4 EMERGENCY OPERATION 4 22 4 4 5 OPTIONAL FUNCTION SETTING 4 22 4 4 6 OPTIONAL FUNCTIONS OF WIRELESS REMOTE CONTROL SWITCH 4 23 4 5 7 DAY TIMER PSC 3T 4 24 4 5 1 NAME OF PARTS 4 24 4 5 2 OPERATION PROCEDURE FOR RUNNING PATTERN 4 25 4 5 3 OPERATION PROCEDURE FOR OPERATION PATTERN 4 25 4 6 OPTIONAL CENTRAL STATION PSC 3S1 4 26 4 6 1 NAME OF PARTS 4 26 4...

Page 9: ...t 7 Unit 8 Unit 9 Unit 10 Unit 11 Unit 12 Unit 13 Unit 14 Unit 15 b Optional Function Setting DSW2 Note The n mark indicates position of dip switches Figures show the setting before shipment No setting is required Setting position before shipment is all OFF 21 2 c Capacity Code Setting DSW3 No setting is required due to setting before shipment This switch is used for setting the capacity code whic...

Page 10: ...he switches do not work and the contents of the setting are invalid Mark of n indicates the position of dip switches Set the dip switches according to the next information Quantity and Position of Dip Switches The PCB in the outdoor unit is operated with 10 types of dip switches and 3 types of push switch Dips switches position is the following 6 6 6 6 6 6 6 6 6 6 36 36 36 6 8 8 8 8 6 Note The mar...

Page 11: ...ired Setting Before shipment The Outdoor Unit is located higher than Indoor Unit 0 50m The Outdoor Unit is located lower than Indoor Unit 0 20m 21 2 The Outdoor Unit is located lower than Indoor Unit 20 40m 21 2 n DSW4 Test Operation Service Settings Setting is required This dip switch is utilized for test operation or when servicing operation is performed Setting before shipment 21 2 Test Cooling...

Page 12: ...s Setting II No setting is required Before shipment 21 2 n DSW10 Transmitting Setting Setting is required for cancellation of end resistance and when fuse is melted Before shipment No 1 pin of DSW10 is set at ON side 21 2 In case that Outdoor Unit quantity in the same H Link is 2 or more set No 1 pin of DSW10 at the OFF side from 2nd Unit If only one Outdoor Unit is used no setting is required 21 ...

Page 13: ...or Unit 0RGHO 3RZHU 6XSSO 0D 5XQQLQJ XUUHQW 3RZHU 6XSSO LQH PP 1RPLQDO FXUUHQW 1RPLQDO 6HQVLWLYH XUUHQW P XVH 5 6 6 5 6 6 0 64 5 6 6 5 6 6 0 64 5 6 6 5 6 6 0 64 5 6 6 5 6 6 0 64 5 6 6 5 6 6 9 0 64 ELB Earth leakage Breaker Apply low sensibility type MLFC Flame Retardant Polyflex Wire Note Regarding the wiring or breakers follow to the local code Example for Electrical Wiring Connection of FSG and ...

Page 14: ...r supply to the Indor Unit 2 Duplication of Indoor Unit number Normal Case The outdoor unit s on board 7 segment LED display is not indicated The outdoor unit s on board 7 segment LED display indicates as follows if there is something wrong a The indoor units are not supplied with power 0 3 continues to flash after 30 seconds b Disconnection of the operating line between the outdoor and indoor uni...

Page 15: ...is available 3 In this emergency operation frequency of the compressor is not controlled at each 1Hz Therefore alarm code 07 43 44 45 or 47 may be indicated on LCD Details of alarm codes are shown in the alarm code table page 1 18 4 This emergency operation does not provide sufficient cooling and heating capacity 5 This method is an emergency operation temporarily when the inverter compressor is d...

Page 16: ...he fuse Melted Fuse at Control Circuit Short Circuit of Control Circuit to Earth Measure insulation resistance Remove the cause of short circuit and replace the fuse Failure of Transformer at Indoor Unit Side Measure voltage at secondary side Replace the transformer Disconnected Cable of Remote Control Switch Connect the cable Replace cable or repair It Insufficient Connection or Incorrect Connect...

Page 17: ...ct Polarity Check wiring and connections Repairing Failure of Remote Control Switch Check it by self check mode 1 Replace it if remote control switch is faulty Disconnected Wire to PCB Check connectors Correctly connect Wires Failure of PCB In Indoor Unit and Remote Control Switch Failure of PCB Check it by self check mode 2 Replace PCB if failed 1 Refer to Item 1 3 2 2 Refer to Item 1 3 1 3 This ...

Page 18: ...omp Check for abnormal sound from Comp Replace compressor Failure of Magnetic Switch for Comp Insufficient Contacting Check magnetic switch activates correctly or not Replace magnetic switch Disconnec ted Wiring to PCB Check connections Correctly connect wiring RUN light is ON and LCD is indicated However the system does not operated ex The indoor outdoor fans or compressor does not operate Failur...

Page 19: ...ir and Thermostat of Remote Control Switch In case that thermostat of remote control switch is not used set at 00 1 Refer to Item 1 3 1 1 3 4 2 Refer to Item 1 3 1 3 Even if controllers are normal the compressor does not operate under the followings conditions 1 Indoor Air Temp is lower than 21 C or Outdoor Air Temp is lower than 5 C during cooling operation 2 Indoor Air Temp is higher than 30 C o...

Page 20: ...l Measure resistance of coil Failure of 4 Way Valve º Incorrect Activation of 4 way valve Enforced power supply Replace 4 Way valve Disconnected Control Wires between Indoor Unit and Outdoor Unit Check connectors Correctly connect wiring Disconnected Wiring to PCB Check connectors Correctly connect wiring Failure of Outdoor units of PCB Failure of PCB Check PCB by self checking 1 Replace it when c...

Page 21: ...rmistor on compressor normal Replace thermistor Failure or Malfunction of Expansion Valve Is thermistor installed correctly on compressor Correctly install it Clogged Capillary Tube in Indoor Unit Is there dewing after capillary tube Replace capillary tube in indoor unit Clogged Strainer in Indoor Unit Clogging at Low Pressure Piping Check temp difference at inlet and outlet of strainer Replace st...

Page 22: ...g Clogging of Discharge Piping Check for Clogging Remove Clogging Check for clogging Remove clogging Check for connecting cord and connector Replace connector Is there operation sound from coil Replace coil Is thermistor on compressor normal Replace thermistor Excessively High Discharge Pressure Failure or Malfunction of Expansion Valve Is thermistor installed correctly on compressor Correctly ins...

Page 23: ...alled correctly on compressor Correctly install it Clogging of I U O U Strainer Check Temp Difference between Inlet and Outlet of Strainer Replace Strainer for Outdoor Unit or Indoor Unit Clogging of Suction Piping Check Temp Difference of each Part Remove Clogging Is Outdoor Unit Heat Exchanger Clogged Remove Clogging Is there any Obstacles at Inlet or Outlet of Outdoor Unit Remove Obstacles Is S...

Page 24: ...gerant after vacuum pumping Excessively High Discharge Pressure Clogging of Discharge Pr Piping Check for clogging Remove clogging Malfunction or Internal Leakage of 4 Way Valve Check temp difference at inlet and outlet of 4 way valve Replace 4 way valve Malfunction of Check Valve of Outdoor Unit Check temp difference at inlet and outlet of check valve Replace check valve Failure of Bypass Solenoi...

Page 25: ...sor No Heating by Oil Heater Check Resistance Oil Heater Fuse Replace oil heater or fuse Hamming Sound from Magnetic Conductor Check surface of contacts Replace magnetic switch Cooling or Heating Operation with Abnormal Sound Abnormal Vibration of Cabinets Check each fixing screws Tightly fix it Obstacle at Outdoor Fan Check obstacles Remove obstacles Outdoor Fan is Not Operated When Compressor is...

Page 26: ...tting of Outdoor and Indoor Unit Incorrect Setting of Capacity Code 32 Abnormal Transmission of Other Indoor Unit Failure of Power Supply PCB in Other Indoor Unit Failure of Other Indoor Unit of the same refrigerant cycle 35 Incorrect Setting in Indoor Outdoor Unit No Existence of the same Indoor Unit No in the same refrigerant cycle 38 Abnormality of Protective Circuit in Outdoor Unit Failure of ...

Page 27: ...FSG E RCI FSGE RCD FSG RPI FSGE 1 RPC FSGE Series Is DC24V applied both ends of R24 No Activation of Safety Device such as Float Switch FS or Incorrect Wiring Yes Faulty PCB Phenomenon Cause Check Item Action Turn OFF main switch High Drain Level Clogging of Drainage Check drain pan Remove clogged foreign particles Fault Check continuity when drain level is low Replace float switch if faulty Fault...

Page 28: ...s ON when in check mode SC No Faulty PCB1 Yes No Yes Is the voltage between PCN3 1 and faston terminal N 220V or 240V during Y52C1 ON No Faulty PCB1 Yes No No Looseness Faulty PCB1 Is the protective device still operating No continuity between 1 and 3 of PCN2 No Is PCN3 or PCN2 loosened Yes Restart after connecting PCN3 or PCN 2 correctly Yes Does CMC1 turn ON for more than 3 seconds No Voltage Fa...

Page 29: ...econnect connector Expansion Valve Trouble Fully opened and locked see page 1 93 Replace expansion valve Calculate heat load Reduce heat load or use a bigger unit Check for hot air near the ceiling Heating Make good circulation Check for short circuited air Heating Remove short circuited air Excessively High Temp Air to Indoor Unit Heat Exchanger Check for other heat source Remove heat source Faul...

Page 30: ...ss Solenoid Valve Check for clogging Replace gas bypass solenoid valve Overcharged Refrigerant Check cycle operating temp Charge refrigerant correctly Mixture of Non Condensable Gas in Refrigeration Cycle Check ambient temp and pressure Recharge refrigerant after vacuum pumping Clogging of Discharge Piping Check for clogging Remove clogging Liquid Line Stop Valve or Gas Line Stop Valve are not in ...

Page 31: ...er is automatically reset The alarm is indicated when the abnormal transmitting is maintained for 30 seconds from starting of the outdoor unit Investigate the cause of overcurrent and take necessary action when fuses are melted or the breaker for the outdoor unit are activated See next page Note from next page 1 In case that terminal resistance DSW10 1P is OFF when H Link Connection is performed S...

Page 32: ... yellow on PCB1 flickering more than once in 10 seconds No Faulty PCB1 Yes Connect CN2 of PCB1 PCB1 Outdoor Unit Printed Circuit Board PCB1 Indoor Unit Printed Circuit Board Yes Is LED3 on PCB1 ON Yes Is LED3 yellow ON even if CN2 of PCB1 is removed Yes Faulty PCB1 No No Check other Indoor Units Is LED3 yellow on PCB1 flickering more than once in 10 seconds No Check wiring between outdoor unit and...

Page 33: ...esistance Remove short circuit and replace fuse Faulty Solenoid Coil for Magnetic Switch for Comp Motor Measure resistance of coil Replace magnetic switch and fuse Failure of Outdoor Unit Fan Motor Measure resistance between wires and insulation resistance Replace outdoor unit fan motor and fuse Melted Fuse for Control Circuit or Activation of Outdoor Unit Breaker Failure of AC Chopper for Outdoor...

Page 34: ...yellow on PCB3 flickering Is LED2 green on PCB1 flickering Yes Check PCB3 and check the wiring between PCB1 and PCB3 No No Check PCB3 No Is LED4 yellow on PCB3 OFF Yes Check the wiring between PCB1 and PCB3 Faulty PCB1 PCB1 Control PCB in Outdoor Unit PCB3 Inverter PCB High Voltage Phenomenon Cause Check Item Action Turn OFF main switch Between Control PCB and Inverter PCB Disconnected Wires Insuf...

Page 35: ...tly connect each phase of power source No Reverse Phase Connection Yes PCB1 is normal Correctly connect each phase of power source No Is there any excessively voltage decrease at power source Yes PCB1 is normal Abnormality witch Power Source No Faulty PCB1 or other cause Refer to next page Note PCB1 Outdoor Unit Printed Circuit Boaed Voltage for unit to be suspended Running Voltage 342 to 456V Sta...

Page 36: ...on by operation of other apparatus Yes No Frequency can increase higher than 60Hz Does LED2 on PCB3 ON after compressor s electromagnetic switches CMC turn on Yes How is compressor operation Compressor stops immediately lower than 30Hz Faulty PCB3 for Inverter Replace it No No Compressor stops when frequency increase Approx 30Hz to 60Hz Is connection correctly between PCB3 and transistor module Co...

Page 37: ...arge gas temperature and calculate superheat value by outdoor unit PCB No Is superheat value under10 C Superheat under 10 C No Yes Yes Is the opening of the outdoor unit heat exchanger s expansion valve under 12 No Yes Remove sudden changes of load like short path of outgoing air to the air intake of the outdoor unit or the cause of frequent thermo ON OFF Match the refrigerant piping and electric ...

Page 38: ... Ex Valve Refer to 1 3 6 Replace ex valve if faulty Fault Replace PCB and check operation Replace PCB if faulty Faulty PCB Disconnected Wires for Ex Valve Control Check connections Repair wiring connection Fault Measure resistance Replace thermistor if faulty Incorrect Mounting Check mounting state Correctly mount thermistor Decrease of Discharge Gas Superheat Faulty Discharge Gas Thermistor Incor...

Page 39: ...ating Operation Cooling Cooloing Operation Yes Check the outdoor unit PCB if the compressor discharge gas temperature is over 132 C Check the outdoor unit PCB to see if the compressor discharge gas temperature is over 132 C No Yes No Yes Is the opening of all the operating indoor unit ex valve 100 No Is the opening of the outdoor unit ex valve 100 No Yes Yes Remove sudden changes of load like shor...

Page 40: ...and check operation Replace PCB if faulty Faulty PCB Disconnected Wires for Ex Valve Control Check connections Repair wiring connection Faulty Gas Bypass Solenoid Valve Ref Leakage Replace solenoid valve if faulty Fault Measure resistance Replace thermistor if faulty Incorrect Mounting Check mounting state Correctly mount thermistor Excessively High Discharge Gas Temperature at Top of Compressor F...

Page 41: ...Yes Correct connection Replace the connector No Common Is 220V or 240V applied across R2 and S2 on PCB2 Is 220V or 240V applied across EF5 1 and N of TB1 No If the voltage is over 264V or under 187V check the power source and check the wiring around the outdoor unit PCB Yes Replace the outdoor fan motor if faulty Or check outdoor temperature If it is unusual take suitable action to reduce it Pheno...

Page 42: ...connected to THM1 intake of PCB No Connect it Yes Is resistance of THM1 between 0 24kW and 840kW No Faulty Thermistor Yes Faulty PCB Phenomenon Cause Check Item Action Turn OFF main switch Fault Check resistance Replace thermistor if faulty Faulty Intake Air Thermistor Incorrect Connection Check connection Repair wiring and connections Faulty PCB Replace PCB and Check operation Replace PCB if faul...

Page 43: ... 24 kW or cut greater than 840 kW during the cooling or heating operation The system is automatically restarted when the fault is removed Is it connected to THM2 intake of PCB No Connect it Yes Is resistance of THM2 between 0 24kW and 840kW No Faulty Thermistor Yes Refer to page 1 34 for thermistor resistance Faulty PCB Phenomenon Cause Check Item Action Turn OFF main switch Fault Check resistance...

Page 44: ...circuited less than 0 24 kW or cut greater than 840 kW during the cooling or heating operation The system is automatically restarted when the fault is removed Is it connected to THM3 intake of PCB No Connect it Yes Is resistance of THM3 between 0 24kW and 840kW No Faulty Thermistor Yes Refer to page 1 34 for thermistor resistance Faulty PCB Phenomenon Cause Check Item Action Turn OFF main switch F...

Page 45: ...uited less than 0 24 kW or cut greater than 840 kW during the cooling or heating operation The system is automatically restarted when the fault is removed Is it connected to THM5 intake of PCB No Connect it Yes Is resistance of THM5 between 0 24kW and 840kW No Faulty Thermistor Yes Refer to page 1 34 for thermistor resistance Faulty PCB Phenomenon Cause Check Item Action Turn OFF main switch Fault...

Page 46: ...an motor No Is fan motor hot No Replace the motor Yes Yes Is connection bad at the connector No Repair wiring and connections Yes Is the coil resistance of fan motor normal No Replace the motor Yes Check indoor temperature If it is unusual take suitable action to reduce it Phenomenon Cause Check Item Action Turn OFF main switch Faulty Indoor Unit Fan Motor Measure coil resistance and insulation re...

Page 47: ...fuse EF1 EF2 cut out Yes Replace the PCB Yes Yes No Replace the motor Is connection bad at the connector No Repair wiring and connections Yes Is the coil resistance of fan motor normal No Replace the motor Yes Check the dislocation of motor shaft and the obstacle of current of air Phenomenon Cause Check Item Action Turn OFF main switch Faulty Indoor Unit Fan Motor Measure coil resistance and insul...

Page 48: ...s 12 VDC applied across 1 and 3 of the connector CN7 of the outdoor unit PCB1 No PCB1 defective Yes Is voltage under 0 1 VDC or over 4 9 VDC across 2 and 3 of the connector CN7 of the outdoor unit PCB1 No Faulty PCB1 Yes Yes Clogged Check Joint Replace check joint No Abnormality of High Pressure Sensor Phenomenon Cause Check Item Action Turn OFF main switch Fault Check output voltage is correct Re...

Page 49: ...this alarm occurs during test running mode only In the case that the thermistor is abnormal during running operation continues based on the assumption that the outdoor temperature is 35 C Cooling 6 C Heating Is it connected to THM7 TA of PCB1 No Connect it Yes Is resistance of THM7 between 0 24kW and 500kW No Faulty Thermistor Yes Refer to page 1 34 for thermistor resistance Faulty PCB1 Phenomenon...

Page 50: ... THM8 TD1 THM9 TD2 THM12 TD3 and THM13 TD4 No Connect them Yes Is resistance of THM8 THM9 THM12 and THM13 same with characteristic in below figure No Faulty Thermistor Yes Faulty PCB1 Resistance of Thermistor KW Faulty TD1 Faulty TD2 Faulty TD3 Faulty TD4 Ambient temperature Characteristics Of Thermistor 1 Indication on the display of the outdoor unit PCB Phenomenon Cause Check Item Action Turn OF...

Page 51: ... shown below figure If this thermistor is faulty this alarm is indicated The position is indicated below RAS 5FSG FS3 RAS 8FSG FS3 RAS 10FSG FS3 RAS 16FSG FS3 RAS 20FSG FS3 Is CN105 or CN106 on PCB1 connected to THM10 Te or THM11 Te No Connect it Yes Is resistance of the thermistor between 0 2kW and 500kW No Faulty Thermistor Faulty Te1 Faulty Te2 Yes Refer to page 1 34 for thermistor resistance F...

Page 52: ... VDC applied across 1 and 3 of the connector CN8 of the outdoor circuit board PCB1 No Faulty PCB1 Yes Is voltage under 0 1 VDC or over 4 9 VDC across 2 and 3 of the connector CN8 of the outdoor unit PCB1 No Faulty PCB1 Yes Yes Is the Check Joint clogged Replace check joint No Abnormality with low Pressure Sensor Phenomenon Cause Check Item Action Turn OFF main switch Fault Check output voltage is ...

Page 53: ... Yes Total capacity of the indoor units is wrong Phenomenon Cause Check Item Action Turn OFF main switch Incorrect Capacity Setting of Indoor Unit Check combination of indoor units and capacity setting on PCB Correctly set dip switch DSW3 Incorrect Capacity Setting of Outdoor Unit Check capacity setting on outdoor unit PCB Correctly set dip switch DSW2 Total Indoor Unit Capacity Connected to the O...

Page 54: ...ween the indoor unit and outdoor unit Yes No Check the power source fuse and transformer of the indoor unit Is LED3 OFF Yes Check connections of the PCB of indoor unit or connector CN1 No Is still LED3 ON Yes Faulty indoor unit PCB Phenomenon Cause Check Item Action Turn OFF main switch Abnormal Transmitting Indoor Unit Outdoor Unit Outdoor Unit Indoor Unit Check indoor unit showing alarm code 03 ...

Page 55: ...indicated on the remote control switch n The unit No alarm code and the unit code is alternately indicated on the set temperature section and the unit No and alarm code are indicated on the display of the outdoor unit PCB This alarm code is indicated when AC 220V or 240V is supplied to voltage between terminal 3 of PCN14 on PCB1 and faston terminal N on PCB1 in the outdoor unit during inverter com...

Page 56: ...n during operating The running current of the constant compressor is detected 0A and retry when 3 minutes are passed after all compressors are stopped and this phenomenon occurs three times within 30 minutes Does the CMC2 4 turn ON No Check wiring connection around PCB1 Yes Does the constant compressor operate No Check fuses and wiring between CMC2 4 and constant compressor Yes Is the running curr...

Page 57: ...wer Source Replace the fuses Looseness of Screws for Power Source Tightly fix screws Single Phase Operation Deterioration of Contact of Magnetic Switch for Compressor Replace magnetic contactor Seizure of Compressor Bearing Locked up Replace compressor Insulation Failure of Compressor Motor Measure insulation resistance Replace compressor Fault Check continuity during stoppage Replace CT when faul...

Page 58: ...high pressure sensor and the low pressure sensor good No Replace the high pressure sensor or the low pressure sensor if faulty Yes Is there a leak in the Solenoid Valve for Hot Gas Bypass SVA Yes Replace the Solenoid Valve SVA if faulty No Check if the intake air temperature is too low at the indoor or outdoor units Phenomenon Cause Check Item Action Turn OFF main switch Inverter is not Functionin...

Page 59: ... way valve spindle mounted at the middle position Yes Replace the four way valve if faulty No Is the low presuure sensor good No Replace the low pressure sensor if faulty Yes Check if the indoor outdoor intake air temperature is too high Phenomenon Cause Check Item Action Turn OFF main switch Leakage of Solenoid Valve SVA Check outlet pipe temp of solenoid valve SVA Check connecting wires Replace ...

Page 60: ...e the electronic expansion valves if faulty No Check the outdoor electronic expansion valve during cooling and the indoor electronic expansion valve during heating Are electric wiring and refrigerant piping between the indoor and outdoor unit incorrectly connected Yes Correctly connect it No Check if indoor or outdoor intake air temperature is too high No In the case of H LINK connection check the...

Page 61: ... G for an hour Discharge Pressure Voltage between 2 and 3 of CN7 Outdoor Air Temperature C Is the amount of refrigerant correct No Correctly charge refrigerant Yes Connect pressure gauge at the check joint of the compressor discharge pipe Yes Is the high pressure in the alarm area Yes Check for leakage of refrigerant No Is the connector CN7 of outdoor unit PCB1 loose yes Plug the connector CN7 cor...

Page 62: ...e electronic ex valves fully closed and locked Yes Check connection of the connectors and the circuit board Replace the electronic ex valves if faulty No Check the indoor ex valve during cooling and the outdoor ex valve during heating Check if connections of electric wiring and refrigerant piping between the indoor and outdoor unit are wrong Note In the case of H LINK system check the refrigerant ...

Page 63: ...compressor is maintained at 15 18Hz after compressor is started one of the absolute value of running current at each phase U U V and V is less than 0 5A including 0 5A Restart operation Power wiring of Comp is not through CT Pass the wires through CT Compressor stops immediately nearly 18Hz Faulty PCB3 and Replace PCB3 2 How is compressor operation when restarted Compressor is not operated P17 is ...

Page 64: ...hes up to 3 5 minutes in 10 minutes Rated Current Model 380 415V 50Hz RAS 5FS3 G RAS 8FS3 G RAS 10FS3 G 14 0 25 0 RAS 16FS3 G RAS 20FS3 G 16 5 30 0 Is the cause of stoppage óC of troubleshooting by 7 segments display 2 or 4 2 Refer to next page 4 Restart operation Is the compressor current larger than activation current Yes The circuit board is normal Is discharge pressure high Check pressure and ...

Page 65: ...use of instantaneous voltage decrease No Check the compressor It trips after a certain period Yes Check the power source capacity It trips occasionally Check the transistor module 2 Faulty Replace the transistor module Good Replace the inverter circuit board Is the compressor running current as same as rated current Yes Check the compressor No Check the diode module 1 Faulty Replace the diode modu...

Page 66: ...tor Module or Control Voltage Decrease Turn off power disconnect U V W from compressor terminals and restart Does the protecting function activate 3 No Check the compressor If there is a short circuit between phase lines replace the compressor Yes Yes Check the transistor module 1 Faulty Check the inverter circuit board 2 Good Replace the transistor module Good Faulty Replace the transistor module...

Page 67: ... AC chopper circuit board PCB2 No Is outdoor unit fan operated for more than 2 seconds when the unit is restarted Yes Is the connection of CT5 at outdoor circuit board PCB1 right No Connect CT5 correctly Yes No Abnormality of CT5 Is the connection of CN13 at outdoor unit circuit board PCB1 and CN201 at AC chopper circuit board right No Connect correctly Yes Is the connection of S3 R3 at outdoor un...

Page 68: ...he unit No and unit code are as below regardless of the indoor unit Unit No 00 Cycle System 00 Unit Code E00 Is wiring among indoor units right No Repair the wiring among indoor units Yes Turn off the main powerswitch and cut the wire JP4 at remote control switch then turn on the main power switch again Phenomenon Cause Check Item Action Turn OFF main switch Wiring Trouble Incorrect Wiring Check t...

Page 69: ...perature 39 Abnormality of Running Current at Constant Comp 43 Pressure Ratio Decrease Protection Activating 44 Low Pressure Increase Protection Activating 45 High Pressure Increase Protection Activating 46 High Pressure Decrease Protection Activating 47 Low Pressure Decrease Protection Activating These alarms are able to be checked by the CHECK Mode 1 Follow the action indicated in each alarm cha...

Page 70: ...mber and Alarm Code Displayed A Perform within 7 seconds to check another unit Alarm code identifying the last fault that has occurred in the indicated unit Unit number of connected unit or unit number for which checking mode was selected previously ADDS Number of Indoor Unit in No Cycle RN No Refrigerant Cycle After 7 seconds Check Mode 1 See page 1 63 for details n Forward Press the switch to ri...

Page 71: ...tion for the remote control switch In case of SET FREE this indication shows the operating compressor quantity In case that temperature is higher than 100 C two digits blinks Ex During more than one compressors operation average temperature of two compressors is indicated In case that temperature is higher than 126 C 126 is always shown Normal Abnormal Temperature displayed 129 Thermistor Open cir...

Page 72: ...High Temperature of Discharge Gas Excessively Low Suction Pressure 16 Retry due to Decrease of Discharge Gas Superheat 17 Retry due to Inverter Tripping 18 Retry due to Voltage Decrease 19 Expansion Valve Opening Change Protection 20 Operation Mode Changeover of Indoor Unit Note 5 Note 1 Explanation of Terms Thermo ON A condition than an Indoor Unit is requesting compressor to operate Thermo OFF A...

Page 73: ...DWXUH QGLFDWLRQ This is an indication for internal information for the remote control switch This does not have any specific meaning The total frequency is indicated when plural compressors are running The capacity of the Indoor Unit is indicated as shown in the table below Capacity Code of Indoor Unit Indication Code Equivalent Capacity HP 06 0 8 08 1 0 10 1 3 13 1 5 14 1 8 16 2 0 18 2 3 20 2 5 2...

Page 74: ...ting Temp at Heating C 97 7 Control information 98 45 8 Discharge Gas Temp at the Top of Comp Chamber C to next page Normal Abnormal Temperature displayed 129 Thermistor Open circuited or PCB defected Temp for Top of Comp FF or Thermistor Open circuited or PCB defected 255 or 127 or Temp for Top of Comp Indication of Category Code Indication of Temperature etc See 1 3 1 Self Checking of PCB s usin...

Page 75: ...nit Expansion Valve MV1 Opening VWLPDWHG OHFWULF XUUHQW QGLFDWLRQ 9F 20 15 Compressor Running Current A Returns to Temperature Indication 7HPSHUDWXUH QGLFDWLRQ This is an indication for internal information for the remote control switch This does not have any specific meaning The total frequency is indicated when several compressors are running The total value is indicated when several compressors...

Page 76: ...ceed reversely press the PSW3 for less than 2 seconds n To cancel this checking press the PSW2 switch for more than 3 seconds The display will be changed to the indication one step before Then press the PSW2 switch once again for more than 3 seconds Checking Item Checking contents 1 Output State of Outdoor Micro Computer S C ì ö 2 Total of Thermo ON Indoor Units Capacity o P 2 6 000 240 X 1 8 HP 3...

Page 77: ...5 Short circuited 12 Discharge Gas Temp on the Top of Compressor MC3 TD3 ó d 3 For 16 20HP 1 0 0 1 142 C 0 Open Circuited 255 Short circuited 13 Discharge Gas Temp on the Top of Compressor MC4 TD4 ó d 4 For 20HP 9 0 1 142 C 127 Open Circuited 127 Short circuited 14 Evaporating Temperature 1 at Heating ó E 1 6 42 88 C 127 Open Circuited 127 Short circuited 15 Evaporating Temperature 2 at Heating ó ...

Page 78: ... ó L 0 1 2 No 0 Unit 62 127 C 22 No 0 Unit Indoor Unit Heat Exchanger Liquid Pipe Temp Freeze protection No F Unit ó L F Indicates only the units number connected 1 2 No F Unit 62 127 C ó 0 1 7 No 0 Unit 62 127 C 23 No 0 Unit Indoor Unit Heat Exchanger Gas Pipe Temp No F Unit ó F Indicates only the units number connected 1 7 No F Unit 62 127 C ó ú 0 2 7 No 0 Unit 62 127 C 24 No 0 Unit Indoor Unit ...

Page 79: ...peration 1 Restricted Control is in Operation 29 High Pressure Rise Protection restricted Control c 1 3 1 0 Restricted Control is not in Operation 1 Restricted Control is in Operation 30 Discharge Gas Temp Decrease Protection Restricted Control c 1 5 0 0 Restricted Control is not in Operation 1 Restricted Control is in Operation 31 Discharge Gas Temp Increase Protection Restricted Control c 1 6 0 ...

Page 80: ...f Compressor MC4 U J 4 For 20HP 3 1 2 0 9999 x 10 times hours 37 The Latest Alarm Code Cause of Stoppage at Outdoor Unit A C 0 2 Refer to page 1 73 for code indication 38 Cause of Stoppage at Inverter ú ó C 9 0 11 39 Total Capacity Setting of Indoor Unit C P 5 2 000 240 x 1 8 HP 40 Total Number of Combined Indoor Unit A A 8 000 016 sets 41 Address os Refrigerant System A 1 0 F Return to START SC P...

Page 81: ...urrent of Compressor MC1 indicated on 7 segment n Cause of Stoppage for Inverter Content of Check Item ó C Remark Code Cause Cause of Stoppage for Corresponding Unit Indication during Retry Alarm Code 1 Automatic Stoppage of Transistor Module IPM Error Over Current Decrease Voltage Increase Temperature 17 P 17 53 2 Instantaneous Over Current 17 P 17 52 4 Electronic Thermal Activation 17 P 17 52 5 ...

Page 82: ... Protection Control Code Protection Control p 0 1 Pressure Ratio Control p 1 1 Pressure Ratio Falling Retry p 0 2 High Pressure Rise Protection p 1 2 Low Pressure Rising Retry p 0 3 Current Protection p 1 3 High Pressure Rising Retry p 0 5 Discharge Gas Temperature Rise Protection p 1 4 Over Current Retry of Constant Compressor p 0 6 Low Pressure Fall Protection p 1 5 Vacuum Discharge Gas Temperat...

Page 83: ...o Pd Ps 1 3 1 8 When activating 3 times in an hour 43 alarm is indicated P12 Low Pressure Rising Retry Ps 0 9MPa 9kgf cm2 G When activating 3 times in an hour 44 alarm is indicated P13 High Pressure Rising Retry Ps 2 7MPa 27kgf cm 2 G In case of 20 30Hz Pd 2 5MPa 25kgf cm 2 G When activating 3 times in an hour 45 alarm is indicated P14 Overcurrent Retry of Constant Compressor Current Maximum Value...

Page 84: ...cover LED1 Red This LED1 indicates the transmission state between the indoor unit and remote control switch Normal Condition Flickering Abnormal Condition Activated or Deactivated LED2 Green This LED2 indicates the transmission state between the indoor unit and central station When disconnected Deactivated Normal Condition Flickering Abnormal Condition Activated or Deactivated LED3 Yellow This LED...

Page 85: ...nufacturing U4NG1001 EF7 EF8 CT3 CMC3 NF11 Only for RAS 16FSG RAS 16FS3 RAS 20FSG and RAS 20FS3 After Manufacturing U4NG1002 EF7 EF8 CT3 CMC3 NF11 Only for RAS 16FSG RAS 16FS3 RAS 20FSG and RAS 20FS3 Front Side The Interior of the Electrical Control Box Front Side The Interior of the Electrical Control Box Front Side The Interior of the Electrical Control Box Front Side The Interior of the Electri...

Page 86: ... Control 5 7 Segment Indication 6 Processing of Safety Device Input 7 Processing of Relay Output 8 Reverse Phase Detection for Power Source PCB2 for Fan Fan Speed Control PCB3 for Inverter 1 Inverter power part is driven by instruction of PCB1 and compressor is driven 2 Overcurrent Control 3 Protection Control for Inverter Part PCB5 for SNUBBER 1 Restraining of Surge Voltage added to Transistor Mo...

Page 87: ...n 380V OFF 415V ON DSW6 Setting of Piping Length The total piping length between the outdoor unit and indoor unit is set DSW7 Setting of Emergency Operation µ DSW8 Test Operation and Service Setting II No setting is required DSW9 Optional Function 2 DSW10 Transmitting Setting PSW1 Manual Defrosting Switch The defrosting operation is manually available under the forced defrosting area PSW2 º PSW3 C...

Page 88: ...ed Circuit Board Function LED1 Red This indicates the state of transmission Flickering Normal Transmission Activated or Deactivated Abnormality in Transmission Circuit LED2 Red This indicates the voltage between both terminal of capacitor CB1 and CB2 for inverter part Activated The voltage between both terminals of capacitor CB is 50V 20V or greater Deactivated The voltage between both terminals o...

Page 89: ... U4NG1001 LED3 LED Function on Outdoor Unit Printed Circuit Board Name of Printed Circuit Board Function LED3 Red This indicates the voltage between both terminal of capacitor CB1 and CB2 for inverter part Activated The voltage between both terminals of capacitor CB is 50V 20V or greater Deactivated The voltage between both terminals of capacitor CB is 50V 20V or smaller ...

Page 90: ...FF the power supply 2 Disconnect the connector CN25 on PWB M 3 Connect PC 2H2 to the connectors CN12 or CN13 4 Turn ON the power supply After completion of checking turn OFF the power supply again and make connectors as before checking RUN STOP Indi cation Contents 00 Normal Abnormality Open circuit Shor circuit etc in circuit for 01 Intake Air Temp Thermistor 02 Discharge Air Temp Thermistor 03 L...

Page 91: ...or unit 2 In this troubleshooting procedure checking of the following part of the PCB s is not available PCB in Indoor Unit Relay Circuit Dip Switch Option Circuit PCB in Outdoor Unit Relay Circuit Dip Switch Option Circuit 3 If no result is given using this troubleshooting procedure J1 there is a possibility of abnormal transmission of the central station short circuit TL TG 4 In the case that th...

Page 92: ...tion of A part in the figure below increases one by one Notes Any order of depressing switches is available Depressing two or more switches simultaneously is invalid and not counted Unless all the switches are depressed the checking do not proceed to the next item 6 The LCD indication changes as shown below The remote control switch automatically starts to check the transmission circuit In case th...

Page 93: ...ormal The number indicated at the A part is 99 the checking do not proceed to the next time Cancellation of EEPROM 11 The LCD indication changes as shown below and the EEPROM is automatically cancelled by the remote control switch 10 When the remote control switch is activated again the RUN indicator is ON and the operation is started Therefore depress RUN STOP switch and stop operation Notes 1 In...

Page 94: ...cking Function Procedure Refer to page 1 76 for location and function of DSW and LED Turn OFF the main power switch Disconnect connectors CN5 and CN8 and set dip switch DSW2 as shown below 21 2 Note Before turning ON the power see checking procedure mentioned in next page Turn ON the main power switch Check Mode starts See next page A Analog Test B Relay Test After completion of self checking turn...

Page 95: ...UN CN6 ALARM CN7 COOL CN5 3 COOL Thermo ON CN5 2 HEAT CN8 2 HEAT Thermo ON CN8 3 Check ON OFF sound of relays and LED lamp Termination Turn OFF and reset all dip switches as they were For RPK FSGM Check Item State of Mode Confirmation Method A Initialize Exp Valve and Auto Louver Exp Valve fully open fully closed Auto Louver is horizontally stopped B Analog Test If each thermistor for intake air d...

Page 96: ... the LCD indications activated for 5 seconds All the LCD indications deactivated for 1 second By depressing a particular touch type switch the corresponding segment is activated 3 Checking of Touch Type Switch Function Depress all the touch type switches one by one Any one of the switches can be depressed Normal After 15 Seconds 4 Completion of self checking 77 is indicated for 3 seconds 5 Return ...

Page 97: ...econds All the LCD indications deactivated for 1 second By depressing a particular touch type switch the corresponding segment is activated 3 Checking of Touch Type Switch Function Depress all the touch type switches one by one Any one of the switches can be depressed Normal After 15 Seconds Normal Abnormal 4 Checking of Transmission Circuit Automatically checked and the result will be indicated a...

Page 98: ...rcuit between terminal P and N Manufacturing A Case Before U4NG1001 LED3 on PCB5 1 a Turn OFF the main switches and wait for three minutes Check to ensure that no high voltage exists If A is ON after start up and A is OFF after turning OFF power source the voltage will decrease lower than DC50V b Connect connecting wires to an electrical brazer After U4NG1002 LED2 on PCB3 2 d Wait for 2 or 3 minut...

Page 99: ...sure it under 1 kW range of a tester Do not use a digital tester a By touching the side of the tester to the P terminal of transistor module and the side of tester to U V and W of transistor module measure the resistance If all the resistances are from 1 to 5 kW it is normal b By touching the side of the tester to the P terminal of transistor module and the side of tester to U V and W of transisto...

Page 100: ...measure the resistance If all the resistances are greater than 100 kW it is normal c d n Checking Procedures on Diode Module Outer Appearance and Internal Circuit of Diode Module Case1 Case2 If items a to d are performed and the results are satisfactory the diode module is normal Measure it under 1 kW range of a tester Do not use a digital tester a By touching the side of the tester to the termina...

Page 101: ...Valve Locked with Fully Closed Check for the liquid pipe temperature during heating operation It is abnormal if the temperature does not increase It is abnormal if the liquid pipe pressure does not increase during cooling operation Locked with Slightly Open It is abnormal if the liquid pipe pressure does not increase and the outlet temperature of the expansion valve decreases after the cooling ope...

Page 102: ... DC Motor Fan Motor for Indoor Unit for RPF 1 0FSG RPFI 1 0FSG TNO KPPA 75W BLK óRED REDó ìWHT 127 90 102 70 at 20 C Fan Motor for Indoor Unit for RPF 1 5FSG RPFI 1 5FSG TNO KPPA 35W BLK óRED REDó ìWHT 127 90 102 0 at 20 C Fan Motor for Indoor Unit for RPI 0 8FSGE RPI 1 0FSGE RPI 1 5FSGE 45W BLK óRED REDó ìBLU BLUì öYEL YELö úGRN GRNú GRY REDó øWHT 58 36 14 87 14 87 18 88 18 88 124 91 at 20 C Fan ...

Page 103: ... öGRY REDó úWHT 19 65 7 29 5 66 20 71 at 20 C Fan Motor for Indoor Unit for RCI 1 0FSGE 5W Fan Motor for Indoor Unit for RCI 1 5FSGE 17W BLK óRED REDó ìBLU BLUì öORN ORNö úYEL REDó WHT 167 10 47 30 46 70 58 70 249 00 at 25 C Fan Motor for Indoor Unit for RCI 2 0FSGE RCI 2 5FSGE RCI 3 0FSGE 60W BLK óRED REDó ìBLU BLUì öORN ORNö úYEL REDó WHT 117 10 28 50 40 35 39 60 210 65 at 25 C Fan Motor for Ind...

Page 104: ... RPC 2 5FSGE RPC 3 0FSGE 65W BLK óRED REDó ìYEL YELì öGRY GRYö úBLU REDó WHT 59 90 16 90 15 80 15 80 63 60 at 20 1 C Fan Motor for Indoor Unit for RPC 4 0FSGE RPC 5 0FSGE 180W BLK óRED REDó ìYEL YELì öGRY REDó WHT 32 10 24 50 24 50 44 70 at 25 C Fan Motor for Outdoor Unit for RAS 5FSG RAS 5FS3 NF4501 160W ó ó ì 8 17 7 97 Fan Motor for Outdoor Unit for RAS 8FSG RAS 8FS3 RAS 10FSG RAS 10FS3 NF7001 2...

Page 105: ...A 2 018 at 20 C RAS 5FSG RAS 5FS3 CHV 0407 CHV 01AJ503C1 1 435 at 20 C 4 Way Valve for RAS 5FSG RAS 8FSG RAS 10FSG RAS 5FS3 RAS 8FS3 RAS 10FS3 RAS 8FSG RAS 8FS3 RAS 10FSG RAS 10FS3 LB6451C VH60100 2 000 at 20 C 4 Way Valve for RAS 16FSG RAS 20FSG RAS 16FS3 RAS 20FS3 CHV 0717 CHV 01AJ503H1 1 435 at 20 C Inverter Compressor Motor for RAS 5FS3 401DHV 1 746 at 75 C Inverter Compressor Motor for RAS 8F...

Page 106: ...401DHM 4 006 at 75 C Fix Compressor Motor for RAS 10FSG G501DHM 3 222 at 75 C Fix Compressor Motor for RAS 16FSG RAS 20FSG G601DHM 2 775 at 75 C Contactor for Compressor Motor for RAS 5FSG RAS 8FSG RAS 10FSG RAS 5FS3 RAS 8FS3 RAS 10FS3 A25 FC 1S A25 501 FC 1S 656 at 20 C Contactor for Compressor Motor for RAS 16FSG RAS 20FSG RAS 16FS3 RAS 20FS3 A35 FC 1S A35 501 FC 1S 656 at 20 C ...

Page 107: ...y viewing 7 Are power source wires U and V inserted correctly into current sensor Check to ensure that wires are correctly inserted 8 Are ex valves MV1 and MV2 correctly connected Check to ensure that MV1 CN10 and MV2 CN11 are correctly connected 9 Are ex valve coils MV1 and MV2 correctly mounted Check to ensure that each coil is correctly mounted on the valve 10 Are the refrigeration cycle and el...

Page 108: ...tor winding resulting in winding insulation failure 8 9 During a cooling operation Pd is controlled by fan revolution of outdoor unit and Td and SH are controlled by MV of each indoor units During a heating operation Td and SH are controlled by MV1 and MV2 If expansion valves are incorrectly connected correct control is not available resulting in compressor seizure depending on liquid refrigerant ...

Page 109: ... a The TEST RUN operation will be started The TEST RUN operation will be finished after 2 hours unit operation or by depressing the RUN STOP switch again b IF the unit do not start or the operation lamp on the remote control switch is flickered some abnormalities exist Go to Remote Control Switch Indication Unit Condition Fault Inspection Points after Power Source OFF The operation lamp flickers 1...

Page 110: ...ever the test run function of the outdoor unit is not cancelled In case that the plural indoor units are connected with one remote control switch all the units start test run operation at the same time therefore turn the power source OFF for the indoor units not to operate test run In this case the TEST RUN indication of the remote control switch may flicker and this is not abnormal The setting of...

Page 111: ...contacting to power lines 4 Was an earth wire connected 5 Is there any short circuit 6 Is there any voltage abnormality among each phase L1 L2 L2 L3 L3 L1 L1 N 2 Refrigeration Cycle a Operation Cooling Heating No Check Item Result 1 Operate all the indoor units TEST RUN mode 2 Operate all the indoor units at HIGH speed 3 In case that the constant compressor is turned ON and OFF repeatedly stop one...

Page 112: ... ORVHG 6KRUW FLUFXLW 6 Is TG Gas Pipe Temp of I U Heat Exchanger lower than Ti Intake Air Temp of I U It is normal when TG Ti 5 7 7KHUPLVWRU DLOXUH 9DOYH XOO ORVHG RU 6OLJKWO 2SHQ 6KRUW FLUFXLW 7 Is there any excessive difference among I U at SHTG TL of I U heat exchanger It is applicable when Intake Air Temp is 3 deg higher than Setting Temp It is normal if the difference among units is within 7 ...

Page 113: ...LYH 3LSH 5HVLVWDQFH 4 Is Ps Î0 2à to Î0 5à Only under the condition that electrical expansion valve SVA is OFF RZ 2 8 6KRUW FLUFXLW RZ LJK 2 8 DQ 7K ULVWRU DLOXUH RU 2XWGRRU LU 6HQVRU DLOXUH 5 Is the temperature difference between I U more than 15 deg when iE I U Ex Valve is 100 The temperature difference between I U means the following b3 Discharge Gas Temp b2 Intake Air Temp indicated on the rem...

Page 114: ......

Page 115: ...the air intake grille by pulling and unhooking four 4 hooks at both sides 2 1 2 REMOVING FRONT SERVICE PANEL 1 Remove five 5 screws Slightly lift the panels upwards and remove them Note When removing screws for front service panel remove the screw at the lower part of panel firstly 2 1 3 REMOVING FAN GUARD NETS 1 Remove four 4 screws and remove the fan guard net Hook Screw Hook Screw Screw Fan Gua...

Page 116: ...Notes 1 Make the cord outlet of the motor directing downward when mounting the motor 2 Firmly fix the motor wires onto the motor clamp with the plastic tie not to touch the propeller fans 3 Mounting Propeller Fan Put and push the propeller fan by identifying the mark with the cut part of the motor shaft Firmly fix the propeller fan twice with a tightening torque of 30N m 300 kg cm after the head o...

Page 117: ... them in a box so that the parts are stored correctly 4 Release the lace for the water proof cover open the water proof cover from the front side Note Remove the water proof cover in the arrow mark direction as shown by paying attention to the cut part of the water proof cover in order to avoid any damages 5 Remove the terminal cover for the compressor and disconnect the wiring to the compressor t...

Page 118: ...t foul If foul replace it with new one 9 Remove three nuts fixing the compressor and remove the compressor Note When lifting the compressor hold the discharge pipe vertically and turn it to the right and pull the compressor towards the front side by paying attention to the compressor leg not to touch the suction pipe 10 Regarding remounting the compressor work perform the above work in the reverse...

Page 119: ...d again when reassembling Keep them in a box so that the parts are stored correctly 4 Release the lace for the water proof cover open the water proof cover from the front side Note Remove the water proof cover in the arrow mark direction as shown by paying attention to the cut part of the water proof cover in order to avoid any damages 5 Remove the terminal cover for the compressor and disconnect ...

Page 120: ... of the oil pipe Therefore prepare an oil pan etc to collect the oil Notes 1 Completely wipe off the oil if the oil is spread to the other parts such as the compressor cover wiring bottom base etc If not this will cause many problems to the unit 2 If the oil is spilt charge new oil equivalent to the spilt oil 3 Check to ensure that the oil is not foul If foul replace it with new one 9 Remove the s...

Page 121: ...ollect all refrigerant from the low pressure side check joint when the high pressure switch is removed Use two spanners when removing the pressure sensors Note The figures are viewed from the front side RAS 5FSG and RAS 5FS3 RAS 8FSG RAS 10FSG RAS 8FS3 RAS 10FS3 RAS 16FSG RAS 20FSG RAS 16FS3 RAS 20FS3 Pull out towards front Side Special Nut Vibration proof Rubber Discharge Pipe Suction Pipe Pay at...

Page 122: ...e hole B Removing High Pressure Sensor and Low Pressure Sensor Remove the water proof caps Note The water proof caps are used after replacing pressure sensors Remove the pipe of the high pressure sensor or low pressure sensor using two spanners Firstly remove the check joint at the manin pipe side Remove the connector for the pressure sensors Remove the high pressure sensor or low pressure sensor ...

Page 123: ... solenoid valve coil after removing the fixing screw 1 piece for the solenoid valve In Case of SVA for Gas Bypass 2 1 10 REMOVING THERMISTOR FOR LIQUID PIPE DANGER Do not touch the electrical parts when the LED3 Red on the SNUBBER PCB PCB5 or the LED2 Red on the Inverter PCB PCB3 is lit since the voltage is higher than 50V 1 Remove the front service panel according to the item 2 1 2 Removing Front...

Page 124: ... control between the indoor and outdoor units and electrical wiring terminal board 4 Disconnect the wiring connections and check to ensure that two stop valves are open 5 Disconnect the following to remove the reversing valve a Brazing Portion between Reversing Valve and Discharge Pipe b Brazing Portion of the Right and the Left Pipes of Three Pipes from the Reversing Valve c Brazing Portion of th...

Page 125: ...ill occur 4 Do not clamp electrical wires between a mounting electric component and plates or electric parts when a PCB is remounted 5 Screws bushes and collars are used to fix the inverter PCB Check to ensure that the bushes and collars are used when fixing the inverter PCB again If not used it may cause malfunction 6 In the case that the control PCB is replaced set all the dip switch at the same...

Page 126: ...te towards the front side b Remove two 2 screws fixing the magnetic contactor for inverter compressor 2 2 IN THE CEILING TYPE Models RPI 0 8FSGE RPI 1 0FSGE RPI1 5FSGE RPI 2 0FSGE RPI 2 5FSGE RPI 3 0FSGE RPI 4 0FSGE and RPI 5 0FSGE 2 2 1 REMOVING PRINTED CIRCUIT BOARD PCB 1 Remove the screw 1 pc fixing the electrical box cover and remove the electrical box cover 2 Disconnect the connectors Remove ...

Page 127: ... Motor and Capacitor 3 Remove the Fan Motor mounted on the fixing plate according to the process shown beside 4 Loosen the screw fixing each fan runner by a hexagon wrench 5 Remove the screws 4 pcs fixing each casings and pull out each casings 6 Remove the holding band for the motor and remove the motor carefully Service Access Motor Shaft Runner Casing ...

Page 128: ...the float switch Do not drop it on the floor If dropped malfunction may occur When mounting do not use a motor driven screwdriver 2 2 4 REMOVING FLOAT SWITCH 1 Remove the screws 4 pcs fixing the service cover and remove the service cover 2 Remove the screws 2 pcs of the plate fixing the float switch and remove the float switch Gas Pipe Thermistor Cork Tape Liquid Pipe Thermistor Cork Tape Fixing P...

Page 129: ...e the electrical box can be seen Remove two 2 screws fixing the electrical box cover and remove the cover 2 3 4 REMOVING OPTIONAL AIR PANEL 1 By opening the intake air grille the electrical box can be seen Remove two 2 screws fixing the electrical box cover and remove the cover 1 Disconnect the connector Red 2 Pins for the dew protection heater on the indoor PCB 2 Disconnect the connector Red 7 Pi...

Page 130: ...D FAN MOTOR 1 Remove the intake air grille according to the item 2 3 2 Removing Intake Air Grille 2 Drawing Electrical Box 1 Remove the discharge air thermistor from the PCB 2 Disconnect the connector of each lead wire 3 Remove two 2 fixing screws for the electrical box and pull the electrical box towards the front then the electrical box will turn with an angle of approximately 90 3 Removing Bell...

Page 131: ...n absorbing rubber onto the turbo fan when assembling 2 3 6 REMOVING PRINTED CIRCUIT BOARD PCB 1 Remove the intake air grille according to the item 2 3 2 Removing Intake Air Grille 2 Remove the electrical box cover according to the item 2 3 3 Removing Electrical Box Cover 3 There is a printed circuit boards PCB in the electrical box Disconnect the connectors The PCB is supported by six 6 holders R...

Page 132: ...ch Do not drop it on the floor If dropped malfunction may occur When mounting do not use a motor driven screwdriver 2 3 8 REMOVING DRAIN UP MECHANISM 1 Remove the service access cover near the pipes according to the item 2 3 7 Removing Float Switch 2 Remove two 2 screws A fixing the fixing plate for the drain up pump after removing the wiring connector Loosen the fixing screw B remove the fixing p...

Page 133: ...e connectors between indoor unit and outdoor unit and in the electrical box after opening the electrical box cover according to the item 2 3 3 Removing Electrical Box Cover 3 Remove the bell mouth according to No 3 of item 2 3 5 Removing Turbo Fan and Fan Motor 4 Remove drain water 5 Remove the drain pan after removing four 4 screws fixing the drain pan onto the indoor unit Fixing Plate for Drain ...

Page 134: ... spanners Hold the part of the valve body with one spanner and loosen the lock nut with another spanner by turning the lock nut counterclockwise NOTE Do not hold the motor part when loosening the lock nut by spanner The base of the drive part may turn idle and be broken 5 Turn the lock nut by a few turn and the drive part is separated from the screw and can be removed 6 Prepare the new drive part ...

Page 135: ...ed if the position of the motor is moved toward the rotating direction after replacement as shown in Figure 2 However pay attention to the direction of the motor for the coil of the electronic expansion valve not to touch other pipings and the side plate of the electrical box 9 After completion of the replacement attach the electronic expansion valve in the reverse procedures for removing 2 3 12 R...

Page 136: ...ove the long life filter after opening the intake air grille The long life filter can be removed from the intake air panel by supporting the lower side of the intake air grille lifting the long life filter and unhooking it from the extrusion part 2 4 2 REMOVING INTAKE AIR GRILLE 1 Open the intake air grille at an angle of approximately 30 45 lift it upwards with inclined draw it towards the front ...

Page 137: ...6DWA H 6pcs fixing the optional air panel onto the indoor unit 3 Remove the optional air panel by unhooking the hook of the suspension bracket Electrical Box Cover Indoor Unit Indoor Unit Plates for Fixing Air Panel Long Screw M6x50 Hook Wire Long Flocked Screw Only for P G23 G46 type Orange Colored Mark of Air Panel 2 Connector for Auto Swing Motor Low Voltage 7pin RED 3 Connector for Wireless re...

Page 138: ...d loosen the fixing screw A 3 slide the motor toward the P direction and remove the motor In Case of 2 0 5 0HP 1 Remove the partition plate R and the partition plate L 2 Remove the screws B and C fixing the motor and loosen the fixing screw A 3 Slide the motor toward the P direction and remove the motor 4 Remove the casing by pushing four 4 extruded parts at the lower part of the casing which cons...

Page 139: ... Fan Motor 3 Remove the bearing according to the item 2 4 6 Removing Bearing 4 Remove the coupling and the turbo fan after removing the fan assembly 2 4 8 REMOVING PRINTED CIRCUIT BOARD PCB 1 Remove the intake air grille according to the item 2 4 2 Removing Intake Air Grille 2 Remove the electrical box cover according to the item 2 4 3 Removing Electrical Box Cover 3 Pull out the PCB holders Holde...

Page 140: ...hose by holding the drain up mechanism not to fall remove the drain hose from the drain up mechanism and remove the drain up mechanism with the fixing plate 2 4 11 REMOVING DRAIN PAN 1 Remove the intake air grille according to the item 2 4 2 Removing Intake Air Grille 2 Remove the fan assembly according to the item 2 4 5 Removing Fan Motor 3 Remove the electrical box cover according to the item 2 ...

Page 141: ... to the item 2 4 5 Removing Fan Motor 3 Remove the drain pan according to the item 2 4 11 Removing Drain Pan 4 Remove the CORK TAPE for gas pipe or the butyl sheet for liquid pipe fixing the thermistors remove the thermo clip for the the thermistors from the pipes and remove the thermistors 2 4 13 REMOVING ELECTRONIC EXPANSION VALVE COIL 1 Remove the optional air panel according to the item 2 4 4 ...

Page 142: ...n by hand The motor assembly can be removed from the optional air panel by removing the connectors for wiring 4 Remove one 1 screw fixing the crank and cut the plastic tie fixing the motor cord 5 Remove the motor after removing two fixing screws 2 5 WALL TYPE 2 5 1 REMOVING AIR FILTER 1 Press two 2 portions right and left of the air intake grille as shown beside 2 Slowly pull the lower side of the...

Page 143: ...t body and the front panel can be removed toward the front side NOTE DO NOT hit the front panel when removing the front panel It may break the unit body 6 For attaching the front panel attach the front panel at the air outlet side firstly and attach three 3 hooks at the upper part of the front panel 7 Open the front panel as the procedure 1 and fix the screw 1 piece at the center of the front pane...

Page 144: ...move the front panel according to the item 2 5 2 Removing Front Panel 2 Remove the electrical box according to the item 2 5 5 Removing Electrical Box 3 Removing Thermistor for Liquid Pipe Remove the butyl sheet protecting the thermistor for liquid pipe and remove the thermistor from the holder 4 Removing Thermistor for Gas Pipe Remove the piping insulation protecting the thermistor for gas pipe by...

Page 145: ...pansion valve fan motor thermistor for liquid pipe and gas pipe AS motor X 2 and remote control switch from the connectors And also remove earth wires x2 of the heat exchanger 5 Remove the thermistor for discharge air from the holder fixed at the vertical louver of the air outlet 6 Draw out the electrical box toward the front side after removing two 2 screws fixing the electrical box 7 For attachi...

Page 146: ...l box according to the item 2 5 5 Removing Electrical Box Cover 3 Remove the drain pan from the unit by detaching the hooks A and B from the left side of the drain pan and detaching the hook C by pulling the right side of the air panel toward the front side 4 For attaching the drain pan perform the reverse procedures for removing drain pan NOTE Check to ensure that the hooks A B and C are hooked c...

Page 147: ...t and the left sides of the heat exchanger are correctly attached 2 5 9 REMOVING FAN AND FAN MOTOR 1 Remove the heat exchanger according to the item 2 5 8 Removing Heat Exchanger 2 Remove the supporting plate for the bearing by pushing the knobs at both sides of the supporting plate toward the inside and detaching the hooks 3 Remove the motor holders 1 and 2 fixing the fan motor For removing the m...

Page 148: ...d loosen the lock nut with another spanner by turning the lock nut counterclockwise NOTE Do not hold the motor part when loosening the lock nut by spanner The base of the drive part may turn idle and be broken Turn the lock nut by a few turn and the drive part is separated from the screw and can be removed Prepare the new drive part for replacement service part with the position of the driver driv...

Page 149: ...ire 2 However pay attention to the direction of the motor for the coil of the electronic expansion valve not to touch other pipings and the side plate of the electrical box 5 Attach the removed butyl sheet to the electronic expansion valve again 6 After completion of the replacement attach the electronic expansion valve in the reverse procedures for removing 2 6 FLOOR TYPE 2 6 1 REMOVING INTAKE AI...

Page 150: ...n be removed 2 6 4 REMOVING FRONT COVER 1 Remove the air filter according to the item 2 6 2 Removing Air Filter 2 Remove the front cover from the slit after removing four 4 fixing screws at the lower part and pulling it out downwards 2 6 5 REMOVING FAN MOTOR 1 Remove the intake air grille according to the item 2 6 1 Removing Intake Air Grille 2 Remove the air filter according to the item 2 6 2 Rem...

Page 151: ...fter removing the fixing plate Pay attention not to drop it 2 6 6 REMOVING PRINTED CIRCUIT BOARD PCB 1 Remove the intake air grille according to the item 2 6 1 Removing Intake Air Grille 2 Remove the air filter according to the item 2 6 2 Removing Air Filter 3 Remove the front cover according to the item 2 6 4 Removing Front Cover 4 The side cover can be removed by removing three 3 fixing screws a...

Page 152: ...ig force to the PCB If applied the PCB will be faulty 2 When reassembling check to ensure that each terminal is correctly connected by referring to the wire marks and terminal codes If incorrectly connected malfunction or damage of electrical parts will occur 2 6 7 REMOVING THERMISTORS FOR LIQUID PIPE AND GAS PIPE 1 Remove the intake air grille according to the item 2 6 1 Removing Intake Air Grill...

Page 153: ...or after removing the thermo clip for the thermistors Seal the thermistor with CORK TAPE Mount it as shown beside 2 7 FLOOR CONCEALED TYPE 2 7 1 REMOVING AIR FILTER 1 The air filter is located at the inner upper part of the inlet 2 Remove the air filter by pulling the center knob and bending the filter Piping Cover Partition Plate Screw Thermistyor for Gas Pipe Cork Tape Liquid Pipe Thermistor The...

Page 154: ...nt Covers 3 Remove the fan motor as same as indicated in No 4 to No 8 of the item 2 6 5 Removing Fan Motor 2 7 4 REMOVING PRINTED CIRCUIT BOARD PCB 1 Remove the front covers according to the item 2 7 2 Removing Front Covers 2 Remove the PCBs as same as indicated in No 5 to No 7 of the item 2 6 6 Removing Printed Circuit Board PCB 2 7 5 REMOVING THERMISTORS FOR LIQUID PIPE AND GAS PIPE 1 Remove the...

Page 155: ...pwards the filter can be removed 2 8 2 REMOVING SIDE COVER 1 Pull the side cover towards you 2 Unhook the hook at the lower part of the side cover 3 Lift it upwards 2 8 3 REMOVING DISCHARGE AIR GRILLE 1 Remove the side covers according to the item 2 8 2 Removing Side Cover 2 Remove the crank assembly mounted on the right side shaft of the air deflector Hook at Front Part of Side Cover ó ì Side Cov...

Page 156: ...ing to the item 2 8 1 Removing Air Filter 2 Remove the stay at the air inlet 3 Disconnect the connector for the indoor fan motor 4 Hook the electrical box on the lower frame after removing the screws fixing the electrical box NOTE During this work support the electrical box by hands not to drop it Fixing Screw Air Deflection Bearing Air Deflection Intake Air Panel Stay Fixing Screw Wiring Cover El...

Page 157: ...s after removing the fixing band Pay attention not to drop it 2 8 5 REMOVING BEARING 1 Remove the side covers according to the item 2 8 2 Removing Side Cover 2 Loosen two 2 screws fixing the bearing and shaft by a hexagon wrench 3 Remove the bearing after removing two 2 fixing screws M8 1 Hook Casing Motor To Loosen Allen Key Coupling Fixing Screw Fixing Band Fixing Screw for Bearing Fixing Screw ...

Page 158: ...de Cover 2 Remove the M4 screws and remove the AS motor assembly from the right shaft of the discharge air grille Pay attention not to damage the AS motor assembly 3 Remove two 2 screws A fixing the motor for auto louver and remove the motor from the AS motor fixing plate Remove one 1 screw B fixing the shaft of the motor for auto louver and pinion AS NOTE When assembling tighten two 2 screws A wi...

Page 159: ...x not to drop it 5 The PCB is supported by four 4 holders Pinch the expanded part of the holder with long nose pliers NOTE Do not touch the electrical components Do not apply big force to the PCB If applied the PCB will be faulty 2 9 TOTAL HEAT EXCHANGER 2 9 1 REMOVING AIR FILTER 1 Turn off the power source for the total heat exchanger 2 Remove the check panel at the side of the unit and the air f...

Page 160: ...rtition plate The supply air side partition plate is fixed with one 1 screw and the exhaust air side partition plate with three 3 screws at the check hole side Remove these screws and remove these plates by drawing towards the center of the unit 4 When removing the fan assembly remove the eight 8 M6 bolts fixing the motor base to the unit and suction bell mouth fixed to the fan casing together The...

Page 161: ...h dust remove it with this brush The length of brush should be 25 35mm 5 Hose for Water Pan Select a hose according to site requirements 6 Bucket 2 Nos for 5 liters 7 Phillips Screwdriver 1 No 8 Nipper 1 No 9 Adjustable Wrench 1 No 10 Megohm Tester 500V 11 Cleaning Agent Select a neutral type cleaning agent 12 Spray To spray cleaning water 13 Tape with Adhesive To fix the vinyl sheet to protect th...

Page 162: ...with Support B and Magnet 1 4 Sheet B Vinyl Chloride Sheet 1t with Support B and Magnet 1 5 Sheet C Vinyl Chloride Sheet 1t with Support B and Magnet 1 6 Sheet D Vinyl Chloride Sheet 1t with Support B and Magnet 1 7 Motor Cover Vinyl Chloride Sheet 1t with Magnet 1 8 Motor Band Vinyl Chloride Sheet 1t Magic Tape 1 9 Wiring Cover Vinyl Chloride Sheet 1 10 Gloves Rubber 1 11 Sling Rope 1 m 4 18 Bar ...

Page 163: ...g drain water on the drain pan 1 Remove the drain water on the drain pan after pulling out the rubber plug Check to ensure that water can flow smoothly through the hole by pricking it with a pencil 2 Remove the drain pan after removing four fixing screws Carefully remove the drain pan since drain water may remain at the bottom of the drain pan 3 Clean and dry the drain pan after removing Carefully...

Page 164: ...ort bars into the holes of the water collector c Tie the rope on the support bar of the water collector and suspend the water collector d Connect a hose to the boss and put the end of the hose in a bucket 4 Put approximately 15 liters of cleaning agent for aluminum fins in a supply tank Cleaning Water Collector Support Bar 8 Nos Boss Hose Blucket Indoor Unit Suspension Bolt Rope Suspension Bracket...

Page 165: ... cleaning water Adjust the pressure of the water pump so as not to damage the fins NOTE If the cleaning water remains fins will be corroded Adjust the pressure of the pump at 2 5 to 5 0 kg cm so as not to damage fins 6 After cleaning mount the drain pan by extending the rope downwards NOTE In the case that the cleaning water collector is removed wipe off the drops from the indoor unit Cleaning Spr...

Page 166: ...t Switch according to page 2 26 and the item 2 4 9 Removing Float switch 3 Remove Drain Up Mechanism according to page 2 26 and the item 2 4 10 Removing Drain Up Mechanism 4 Removing Dust on Heat Exchanger Remove dust on the fins at the inlet side of the heat exchanger by scratching off downwards Collect all dust in a bucket or carton box 5 Put a vinyl sheet around the heat exchanger so that clean...

Page 167: ...mp pressure so as not to damage the fins NOTE If the cleaning water remains fins will be corroded Adjust the pressure of the pump at 2 5 to 5 0 kg cm so as not to damage fins 9 Attach the fan assembly and drain pan after cleaning is completed and dropping of cleaning water is stopped 10 Check the insulation of drain up pump by megohm meter Check to ensure that the insulation is greater than 1 MW w...

Page 168: ...ean water completely d Adjust the pressure of the pump so as not to damage fins 7 Neutralization Treatment after Cleaning The cleaning agent specified in the item 2 10 1 is of the neutral type However the cleaning water after use may be not neutral Collect all cleaning water and make necessary neutralization treatment for the cleaning water NOTES If the cleaning water remains fins will be corroded...

Page 169: ...n a bucket or carton box 6 Spray cleaning water over the fins of the heat exchanger 7 Cleaning with Clean Water Cover the wiring connectors with insulation tape Operate the pump and clean the heat exchanger with clean water completely Adjust the pressure of pump so as not to damage fins NOTES If the cleaning water remains fins will be corroded Adjust the pressure of the pump at 2 5 to 5 0 kg cm so...

Page 170: ... the item 2 8 1 Removing Air Filter 4 Remove the lower cover and drain pan according to page 2 44 and the item 2 8 8 Removing Thermistors for Liquid Pipe and Gas Pipe 5 Remove the indoor fan motor and fan assembly according to page 2 42 and 2 8 4 Removing Fan Motor 6 Remove the partition plate 2 after removing two fixing screws 7 Remove the fixing plate for the fan after removing two screws at the...

Page 171: ...for the cleaning water 2 11 REMOVING REMOTE CONTROLER 2 11 1 REMOVING REMOTE CONTROL SWITCH 1 Remove the panel from the bracket a Snap out the bottom part of the panel from the bracket and b unhook the top part 2 Remove the connector with the cable from the panel 3 Disassemble the panel by removing two screws NOTES When holding the printed circuit board by hand hold the edge and do not touch the e...

Page 172: ... be equivalent to half of the total refrigerant capacity Check the refrigerant quantity by measuring the weight 6 Close the liquid line stop valve on the cylinder gradually during the cooling operation 7 Fix the opening of the liquid line stop valve at a slightly opened position Continue the cooling operation 8 Finally close the liquid line stop valve and then gas line stop valve and stop the unit...

Page 173: ... Control subject Cooling Operation Heating Operation Fan Revolution of Outdoor Unit For controlling Discharge Pressure Pd For Controlling Pressure Based on outdoor Air temperature Opening Degree of Exp V of Outdoor Unit Fully Open For Controlling Temperature of Discharge super Heat Td SH Opening Degree of Exp V of Indoor Unit MV 1 For Controlling Temperature difference between Air Inlet and Air ou...

Page 174: ...ncy 0 01Hz Accuracy of Output Voltage 10 at Applicable Frequency Range Output Characteristics Conditons 1 Power Source Voltage AC380 415V 2 Non Loading Free Output 3 Ammeter Type Volt Meter 31 1 Refer to the follow note Soft Start Stop 0 5Hz S 1Hz S 3Hz S 6Hz S 30Hz S 5 Steps Protection Function Excessive High or Low Voltage for Inverter Excessive Low Voltage at a Voltage is lower than 350V Excess...

Page 175: ... minutes sampling time Protection of Transistor Module Transistor module has four protection function for self protection Some of the output terminals between U and V V and W W and U has a short circuit Running current reaches the maximum rated current Temperature is measured by internal thermistor exceeds 150 C Control voltage decreases to 12 5V overload Control Overload control at a current grea...

Page 176: ...3 4 MAIN PARTS 3 1 3 ARRANGEMENT OF INVERTER POWER UNIT Model No Parts 380 415V 50Hz Name 1 Fin mm 2003255350 2 Transistor Module PM25RSB120 IPM 3 Diode Module DF40AA160 DM 4 Diode Module RM201 1A 20F D ...

Page 177: ...3 MAIN PARTS 5 Model No Parts 380 415V 50Hz Name 1 Fin mm 2003255350 2 Transistor Module 6MBP25RA120 05 IPM 3 Diode Module 6RI30G 160 DM ...

Page 178: ...t Stop Frequency Failure Signal Activation of Protection Device Overload Signal Charged Indication Red LED5 on PCB5 or LED2 on PCB2 Activation Recovery 10 sec Transmit Error 30sec Protection Activation Output The changing speed depends on the outer setting Frequency HIGH Frequency LOW All bit 1 All bit 1 Operation ...

Page 179: ...toppage cause to PCB1 c Cancellation of Protection Function Transmission for signal code of stoppage cause is canceled by stopping order is issued or main power source is cut off n Protection of Transistor Module a Level of Detection 1 When some of the output terminals between U and V V and W W and U of transistor module are short circuited an abnormality is detected 2 When the running current of ...

Page 180: ...THM13 for Constant Speed Compressor Thermistor for Outdoor Ambient temperature THM7 Thermistor for Evaporating temperature THM10 and THM11 Thermistor for Air Oulet Temperature THM2 Thermistor for Air Inlet Temperature THM1 Thermistor for Indoor Heat Exchanger Liquid Pipe Temperature for Freeze Protection THM3 Thermistor for Indoor Heat Exchanger Gas Pipe Temperature THM5 ...

Page 181: ...r temperature 2 If the compressor upper part temperature increases exceeding 127 C for 10 minutes even if an electronic expansion valve opens the compressor is stopped in order to protect the compressor Thermistor resistance characteristics are shown in Fig 3 1 d If compressor upper part temperature increases exceeding 127 C for 10 minutes during cooling operation the compressor is stopped Refer t...

Page 182: ...m is 34 C because suction air temperature during heating operation has a tendency to become higher than that of the occupied zone intending comfortable heating operation n Thermistor for Discharge Air Temperature Control Indoor Unit Discharge Air Temperature Thermistor THM2 This thermistor THM2 has been installed to prevent cold blow during heating operation The characteristics of the thermistor r...

Page 183: ...AS 20FSG RAS 20FS3 Type EKV 10 0USRT Series Refrigerant Used R22 or R407 Working Temperature Range 30 C 65 C Operating Time of Coil less than 50 Mounting Direction Drive shaft in Vertical Direction within an Angle of 45 as Maximum Flow Direction Reversible Drive Method 4 Phase Canned Motor Method Rated Voltage DC12V 1 8V Drive Condition 83PPS Pulse Width at ON 36mm sec OFF 60mm sec 1 2 Phase Excit...

Page 184: ...ot Electrified Mounting Direction Drive shaft in Vertical Direction Motor Upside and 90 in Four Direction Flow Direction Reversible Rated Electricity Drive Method 4 Phase Pulse Motor Rated Voltage DC12V 1 2V Drive Condition 100W 250PPS Pulse Width Over 3mm 2 Phase Excitation Coil Resistance each Phase 150W 10 at 20 C Wiring Diagram Drive Circuit And Activation mode Magnet Gear Coil Bellows Valve D...

Page 185: ...lled by the proportional controlling method with operating capacity of indoor units so that the suction pressure is controlled in an appropriate range If the suction pressure reaches excessively low the cooling can be insufficient and parts composing the refrigeration cycle can be damaged For this reason if the output of the low pressure sensor indicates vacuum and the valve is maintained 12 minut...

Page 186: ...the inverter to the power supply side Terminals indicated with OUT are connected to the inverter side and terminals indicated with IN to the power supply side Specifications Items Specifications Model HF4020 DV Rated current AC415V 20A Permissible Temperature Range 20 C 65 C Circuit Diagram ...

Page 187: ...3 MAIN PARTS 15 Items Specifications Model 20PTT10 H Rated current AC415V 20A Permissible Temperature Range 20 C 85 C Circuit Diagram LINE DATE CODE LOAD Units mm ...

Page 188: ...ifications Model 400LGN2700M Capacity of Static Electricity 2700mF Rated Voltage 400V Permissible Temperature Range 20 C 95 C 3 7 REACTOR DCL This part is used for changing the alternative current to the direct current for the inverter Specifications Items Specifications Character 1mH 10 at 1kHz Rated current 33A Direct Resistance 25 1mW 20 at 20 C Permissible Temperature Range 20 C 60 C ...

Page 189: ...3 MAIN PARTS 17 Items Specifications Character 0 5mH 10 at 1kHz Rated current 37A Direct Resistance 12 2mW 20 at 20 C Permissible Temperature Range 20 C 65 C 17C 0 5mH 37A MAX 80 66 2 86 2 74 2 ...

Page 190: ......

Page 191: ...3 MAIN PARTS 19 3 8 CIRCUIT DIAGRAM FOR PRINTED CIRCUIT BOARD OF OUTDOOR UNIT n Control Board 1 PCB1 1 2 ...

Page 192: ...3 20 MAIN PARTS n Control board 1 PCB1 2 2 ...

Page 193: ...3 MAIN PARTS 21 n Fan Control Board PCB2 ...

Page 194: ...3 22 MAIN PARTS n Inverter Board PCB3 n Snubber Board PCB5 ...

Page 195: ...3 MAIN PARTS 23 3 9 CIRCUIT DIAGRAM FOR PRINTED CIRCUIT BOARD OF INDOOR UNIT n Control Board PCB of Indoor unit Except for RPK Model n Fan Control Relay Board PCB of indoor Unit ...

Page 196: ...3 24 MAIN PARTS n Control Board PCB of Indoor Unit Only for RPK Model ...

Page 197: ...3 MAIN PARTS 25 3 10 CIRCUIT DIAGRAM FOR PRINTED CIRCUIT BOARD OF REMOTE CONTROL SWITCH n PC 2H2 ...

Page 198: ...3 26 MAIN PARTS n PC 5H ...

Page 199: ...3 MAIN PARTS 27 3 11 CIRCUIT DIAGRAM FOR PRINTED CIRCUIT BOARD OF RECEIVER ...

Page 200: ......

Page 201: ...turned ON is not available due to initializing of components n Remote Control 2 Pulse Signal Input This is an ON OFF function from a remote place by using pulse signal The basic wiring and time chart are shown below Ö CAUTION Turn OFF the power source before setting the dip switch Wiring Diagram Example of Remote Control 2 NOTE When the unit is started by the remote ON OFF switch the fan speed is ...

Page 202: ...within 10 seconds after power supply is turned ON is not available due to initializing of components n Cancellation of Commands from Remote Control Switch after Forced Stoppage Level Signal Input By using the signal from a building management system the air conditioners can be stopped and the commands from the remote control switch are canceled The basic wiring and time chart are shown below The r...

Page 203: ...e condition that there is no person to operate the unit make the system with monitoring for disaster prevention Ö CAUTION Turn OFF the power source before setting the dip switch NOTE The unit is started and stopped according to the power supply ON OFF due to the power failure When the power failure is occurred during stoppage by the remote control switch operation the unit is started again automat...

Page 204: ...emperature exceeds 60 C the fan speed increases from Medium to High or Low to Medium Remote Temperature Sensor THM R2 NOTES The remote temperature sensor can not be used together with the remote control thermistor Refer to the item 4 3 5 10 During the heating operation Heating Temperature Calibration is automatically cancelled Refer to the item 4 3 5 1 4 1 6 COOLING OR HEATING OPERATION MODE SETTI...

Page 205: ...safety devices is activated n Picking Up Heating Operation Signal RPK FSGM is not available This function is utilized to pick up the heating operation signal The contact of RYa is closed when heating operation signal is ON despite Thermo ON or Thermo OFF Connect the wires as shown below Connector No Indoor Unit CN8 RCD FSG E RPF I FSG E CN21 RCI FSGE RPI FSG E RPC FSGE n Picking Up Thermo ON Signa...

Page 206: ...terminals to send signals outwards These signals are available by setting as shown below Function No Input Output 1 Fixing Heating Mode Operation Signal 2 Fixing Cooling Mode Alarm Signal 3 Demand Compressor ON Signal 4 Snow Sensor Defrosting Signal 5 Enforced Stoppage Each input terminal and output terminal are set before shipment as shown below Input Output Name Connector Pin No Setting Function...

Page 207: ...urce lines are disconnected The connecting details of each function are described below and the required parts are also indicated below 4 2 1 DEMAND In the case that the demand input terminals on the outdoor unit printed circuit board are short circuited compressor s is stopped In this case the indoor unit s is put under thermo OFF condition The stoppage code No 10 is given By disconnecting the de...

Page 208: ...eration is changed to the normal operation If the input terminal is opened the fan s is stopped This function protects the outdoor units from a condition covered with snow Wiring Diagram Example of Snow Sensor Table 4 4 Specifications of Required Main Parts Parts Specifications Remarks Auxiliary Relay X1 X2 Mini Power Relay MY1F or 2F made by OMRON 220 240V Changeover Switch SS2 SS3 Manual Switch ...

Page 209: ...the dip switch Operation Conditions Operation Under compressor running except defrosting operation When the indoor unit is at thermo OFF during the heating operation the indoor fan operates for 2 minutes and stops for 6 minutes within cycles NOTE When the indoor fan is stopped by another control it is not available to operate indoor fans 4 2 7 ALL SEASON HEATING OPERATION By setting the dip switch...

Page 210: ...ight shift operation shall be applied only in case that the cooling capacity has the margin to be allowed for the capacity decrease and the low sound operation is required especially in the nighttime n Outdoor Fan NOTE The maximum rotation is always 100 rotation ratio for the standard unit no limitation of the outdoor temperature n Frequency Range Outdoor Unit Capacity HP Minimum Frequency Maximum...

Page 211: ...ing Up Compressor ON Signal With this procedure the compressor signal can be picked up The method is explained in the figure below The required part is indicated in Table 4 5 Connecting relay contactors RYa are closed at the time of compressor running This signal can be applied to the check of signals at the time of remote controlling and to the fan interlock of outdoor fresh air n Picking Up Defr...

Page 212: ...ss the RESET button The filter indication will disappear and the next filter cleaning time is reset It also stops the run procedure TEMP Temperature Setting Switch T RUN Test Run Indication Check Check Indication These Tests appears when TEST RUN or CHECK is being performed ABNML Alarm Indicator FILTER Indicator SET TEMP Set Temperature Indicator ON OFF Timer Timer Operation Indicator Alarm Code I...

Page 213: ... pipes c Set rotary switches RSW on the printed circuit boards of respective units as shown in the following figure DANGER Turn off all power sources Setting of Rotary Switches When indoor units are connected to the same outdoor unit it is unnecessary to set rotary switches because they are automatically addressed Unit nº 0 Unit nº 1 Unit nº 2 Unit nº 3 Unit nº 4 Unit nº 5 Unit nº 6 Unit nº 7 Unit...

Page 214: ...de and the sub remote control switch is changed to the check mode CAUTION When a main remote control switch malfunctions unit operation stops Units cannot be operated with only a sub remote control switch When a main switch and a sub switch are simultaneously operated the units will operate according to either one of the modes after 30 seconds 4 3 4 OPTIONAL FUNCTION SETTING The remote control swi...

Page 215: ...s and Setting Conditions a At the optional setting mode the indication on the remote control switch is changed as shown in the right figure The indications of ADDS and RN are turned OFF The item number of the optional function is indicated at the segment for the setting temperature indication Refer to the table in the next pages for the item numbers and the contents of the optional functions The s...

Page 216: ...As for optional functions with 5 at the individual setting only when the All Rooms is selected to set the optional function the setting condition can be changed As for the items not indicated in the above table the optional function is not available Do not change the setting 4 3 5 OPTIONAL FUNCTIONS OF REMOTE CONTROL SWITCH Removal of Heating Temperature Calibration This function is utilized when ...

Page 217: ...when changes in operation modes are not required When this function is valid the operation mode which has been set cannot be changed Fixing of Setting Temperature This function is utilized when changes in setting temperature are not required When this function is valid the setting temperature which has been set cannot be changed Fixing of Operation as Exclusive Cooling Unit This function is utiliz...

Page 218: ...nds The indication of the above items for all the indoor units connected the remote control switch is completed the remote control switch is returned to the normal condition b Indication of Address and Refrigerant Cycle Number The indication of the address and the refrigerant cycle number of the indoor unit shown in the below figure The address of the indoor unit is indicated at the segments for t...

Page 219: ...selected by this switch The operation mode is changed in the following order by pressing this switch AUTO HEAT DRY COOL FAN The mark indicates the selected mode No indication for FAN operation FAN SPEED Select Switch The fan speed can be selected by this switch The fan speed is changed in the following order by pressing this switch HIGH MEDIUM LOW The mark indicates the selected mode the fan speed...

Page 220: ...d d Set the rotary switch RSW on the indoor PCB of the indoor unit B as shown in the right figure e When the above procedures b c and d are performed only the identified indoor unit corresponds to the commands from the identified wireless remote control switch f When canceling the identification of the unit set the dip switches of the receiver part and the setting of the rotary switch RSW on the i...

Page 221: ...be put into grounded metal pipes d Set the Rotary Switches RSW on the printed circuit boards of respective units as shown in the next table Unit nº 0 Unit nº 1 Unit nº 2 Unit nº 3 Unit nº 4 Unit nº 5 Unit nº 6 Unit nº 7 Unit nº 8 Unit nº 9 Unit nº 10 Unit nº 11 Unit nº 12 Unit nº 13 Unit nº 14 Unit nº 15 CAUTION If the setting of the Rotary Switches RSW is not performed correctly the operation LED...

Page 222: ...ing Heating Setting Temperature 21 C 30 C Air Flow Mode High High When operating the unit by the wireless remote control switch again set the switch emergency operation switch to the NORMAL position NOTE For stopping the unit operated by the wireless remote control switch the unit can be stopped by setting the switch emergency operation switch to the STOP position instead of turning OFF the power ...

Page 223: ...SS REMOTE CONTROL SWITCH n Change of Filter Cleaning Time The filter sign LED Yellow of the receiver part is set to turn ON after the total operation period is over 1 200 hours approximately Factory Setting In case of the RPK model the factory setting is 200 hrs However this filter cleaning time can be changed depending on the condition of the filter n Removal of Heating Temperature Calibration Re...

Page 224: ...g days of a week are selected by this switch The mark blinks at the position of the required running day µ Set Reset Switch for Running Day of a Week By depressing this switch the selected running days of a week are set or reset Set Cancel Switch for ON OFF Time By depressing the SET switch after adjusting the ON TIME or OFF TIME switch to the required time the ON TIME or OFF TIME is set Monitor S...

Page 225: ... RESET switch the mark will be turned ON at the required running day When the unit is not required to be started mark should be turned OFF Setting 7 Setting or canceling ON OFF Time The ON OFF TIME is adjustable by depressing the HOUR and MINUTE switches of the ON OFF TIME switch after depressing the ON TIME or OFF TIME switch of the MONITOR switch In the case that ON TIME is set or cancelled depr...

Page 226: ...Control Remote by Remote Control Switch Setting whether 7 Day timer control is required or not Note When monitoring mode is selected the above mentioned operation modes and setting temperature are indicated INDVL MNTR Switch By pressing this switch operation status of the selected group or unit is indicated n ON o OFF During individual monitoring operation indication of UNIT is OFF RMT SW AVL NAVL...

Page 227: ...e 7 Unit number setting of each indoor unit is not available n System of up to 16 units st n Setting of Rotary Switches Set the unit number of all the units using the rotary switch DSW1 of indoor unit PCB WARNING Do not set the same indoor unit number in the same refrigeration cycle If the same number exists an alarm code of 35 appears Always start from no 1 for the main indoor unit Unit nº 0 Unit...

Page 228: ...by one However please note that the unit number for the main unit in group 2 should be set from the next number as shown below Repeat this work for the remaining units WARNING Do not set the same indoor unit number in the same refrigeration cycle If the same number exists an alarm code of 35 appears Do not set the same indoor unit number in the main indoor units Always start from No 1 for the main...

Page 229: ... 1 Press the mode selection switch MNTR SET to select the SET mode 2 Press the unit selection switch UNIT or to select the unit number to be set When setting all the units simultaneously select the AA indication 3 Press one of the operation switches FAN COOL HEAT or DRY to select the operation mode 4 Press the temperature adjustment switch TEMP or to set the temperature In the FAN mode there is no...

Page 230: ...oring One or more air conditioners in the group are operated All units in the group are stopped or not connected Blinking One or more air conditioners in the group are faulty The ALARM lamp on the lower right of the display section lights simultaneously This indicates when a fault exist in the group 3 OPERATION STATUS IN GROUP Mode Monitoring Press the unit selection switch UNIT to set the unit nu...

Page 231: ...he additional refrigerant is charged from the check joint of the liquid stop valve discharge side during the cooling operation If the liquid valve is fully open it is difficult to charge the additional refrigerant Do not charge refrigerant from the gas stop valve 5 2 INSUFFICIENT COOLING PERFORMANCE WHEN A LONG PIPING IS APPLIED n Question and Answer for Field Work Example 2 insufficient Cooling P...

Page 232: ...s added Remarks Please note that running current is increased when no external pressure is given to the indoor unit resulting in overheating 5 4 ALARM CODE 31 n Question and Answer for Field Work Example 4 Alarm Code 31 Phenomenon Alarm code 31 sometimes occurred and the system was stopped Cause Combination of the indoor and outdoor unit was as follows This system was used in a tenant building One...

Page 233: ...llation space the hot discharge air from other outdoor units was circulated In this case though the outdoor temperature was 35 C the actual suction air temperature was nearly 50 C and Protection System from Excessively High Suction Pressure was activated the frequency of the compressor was decreased and the cooling capacity was also decreased accordingly As the outdoor units in line were installed...

Page 234: ...tration of H C FC gas R407C in air is 0 3 kg m according to the refrigeration and air conditioning facility standard KHK S 0010 by the KHK High Pressure Gas Protection Association Japan Therefore some effective measure must be taken to lower the R407C concentration in air below 0 3 kg m in case of leakage n Calculation of Refrigerant Concentration 1 Calculate the total quantity of refrigerant R kg...

Page 235: ...contactor auxiliary relay PCB and etc Line Condition Pay attention to working voltage amperage and phase balance Inspect for faulty contact caused by loosened terminal connections oxidized contacts foreign matter and other items Inspect for electrical insulation resistance 6 Control and Protective Devices Setting Do not readjust the setting in the field unless the setting is maintained at a point ...

Page 236: ...e at 4 way valve ditto Good Not Good 17 Check for Leakage at check valve ditto Good Not Good 18 Check for Leakage at accumulator ditto Good Not Good No Check Item Action Judgement 19 Check for Leakage at Strainer ditto Good Not Good 20 Check for Leakage at electronic Ex Valve ditto Good Not Good 21 Check for Leakage at piping ditto Good Not Good 22 Check for direction of fans by Viewing or Air Flo...

Page 237: ...mperature To A1 A2 A3 Compressor Running Current A4 Indoor Unit Unit No Expansion Valve Opening iE Heat Exchanger Liquid Temp TL Heat Exchanger Gas Temp TG Intake air Temp Ti Outlet Air Temp To Capacity 1 8HP CA Indoor unit Soppage Cause Code d1 Restricted Control for Prevention of Compression Ratio Decrease c11 Restricted Control for Prevention of High Pressure Increase c13 Restricted Control for...

Page 238: ...rol Top Temp bA 98 C Micro Computer state Indication I U Micro Computer C1 O U Micro Computer C2 D Stopping Cause Stopping Cause state Indication d1 E Alarm Occurrence Times of Abnormality E1 Times of Power Failure E2 Times of Abnormal Transmitting E3 Times of Inverter Tripping E4 F Automatic louver State Louver Sensor State F1 H Pressure Frequency State indication Discharge Pressure H1 99 Suction...

Page 239: ......

Page 240: ...SMGB0001 06 01 Printed in Spain ...

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