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Hitachi Set Free mini-HNRQ1 Series, Service Manual

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Hitachi Set Free mini-HNRQ1 Series Service Manual Download Page 53

                                                                                                     46 

1.2 Location of Printed Circuit Boards

(1) Model: RAS-3.0~6.5HNBRKQ1

Symbol

PCB

Purpose

PCB1

Outdoor Unit Board

(Driver Board)

1. Communicating between Indoor Unit and Outdoor Unit;
2. Processing Sensor Input;
3. Operation Control for Above Items 1 to 2. Compressor Operation Control, Fan2 Control, 
    Electrical Expansion Valve, 4-Way Valve, Solenoid Valve, and Overcurrent Control;
4. Processing of Safety Device Input;
5. Processing of Relay Output.

PCB2

Service Board

1. Processing DIP Switch Input;
2. 7-Segment Indication.

PCB3

Reactor Board

Used for the Power Factor Correction.

PCB4

Fan Motor Driver Board

Drive Fan1 Motor.

a. Outdoor Unit Board (PCB1) 

Part name

Function Information

LED1 (Red)

Power source indicator for main control of the PCB1 (5V)
Normal Condition: Activated /ON;      Abnormal Condition: Deactivated /OFF. 

LED2 (Red)

It indicates: “Alarm”.

LED3 (Yellow)

It indicates: “Alarm”.

LED4 (Green)

It indicates: “Alarm”.

LED5 (Red)

Indicator for DC Bus Voltage
Normal Condition: Activated /ON;      Abnormal Condition: Deactivated /OFF.

LED6 (Red)

Power source indicator for Precharge Relay
Normal Condition: Activated /ON;      Abnormal Condition: Deactivated /OFF.

LED7 (Green

）

Power source indicator for inverter control of the PCB1 (3.3V)
Normal Condition: Activated /ON;      Abnormal Condition: Deactivated /OFF.

LED8 

（

Red

）

Power source indicator for Main Relay
Normal Condition: Activated /ON;      Abnormal Condition: Deactivated /OFF.

LED9 (Orange)

It indicates: “Alarm”.

LED10 (Yellow)

It indicates the communication state between the indoor unit and outdoor unit. 
Normal Condition: Activated /Flash;    Abnormal Condition: Deactivated /OFF.

LED11 (Green)

It indicates the communication state between the main control and inverter control of PCB1. 
Normal Condition: Activated /Flash;    Abnormal Condition: Deactivated /OFF. 

TROUBLESHOOTING

Summary of Contents for Set Free mini-HNRQ1 Series

Page 1: ...RAS 3 5HNBRKQ1 RAS 4 0HNBRKQ1 RAS 4 5HNBRKQ1 RAS 5 0HNBRKQ1 RAS 6 0HNBRKQ1 RAS 6 5HNBRKQ1 380 415V 3Ph 50Hz RAS 7 0HNBRMQ1 RAS 8 0HNBRMQ1 RAS 10HNBRMQ1 RAS 11HNBRMQ1 RAS 12HNBRMQ1 HS2019266A SERVICE MANUAL HEAT PUMP AIR CONDITIONERS SET FREE mini HNRQ1 SERIES VRF CONDITIONERS SYSTEM ...

Page 2: ... Electrical Wiring Connection 32 4 3 Electrical Wiring for Outdoor Unit 34 5 DIP Switch Setting of Outdoor Unit 36 6 Test Run 38 6 1 Before Test Run 38 6 2 Test Run by DIP Switch of Outdoor Unit 38 6 3 Test Run by Wired Controller 39 7 Safety and Control Device Setting 40 8 Drain Adapter DC 01Q Optional Parts 41 Troubleshooting 43 1 Initial Troubleshooting 44 1 1 Checking Electrical Wiring and Pow...

Page 3: ...ompressor 144 2 3 Scroll Compressor 145 2 4 Thermistor 146 2 5 Electronic Expansion Valve for Outdoor Units 147 2 6 Pressure Sensor 148 2 7 High Pressure Switch 149 2 8 Noise Filter NF1 149 2 9 Reader DCL 150 External Input Output and Function Setting 151 1 External Input Output Setting Method 152 2 Exteral Input and Output Settings 154 2 1 Definition of External Input and Output Settings 154 2 2 ...

Page 4: ...the drain pan and splashed water runs into electrical box In the end water leakage or electrical devices failure may occur Pay attention to the following points when the unit is installed in a hospital or other facilities where electromagnetic wave generates from medical equipment Do not install the unit in the place where the electromagnetic wave is directly radiated to the electrical box wired c...

Page 5: ...dents may occur Refrigerant leakage can cause difficulty with breathing due to insufficient air If a refrigerant leakage is found immediately turn OFF the main power supply extinguish any open flame and then contact the service dealer Make sure to perform air tight testing The refrigerant R410A used in this product fluorocarbon is not flammable non toxic and odourless If there is refrigerant leaka...

Page 6: ...rwise it will cause an electrical malfunction or fire Make sure that the terminals are tightened with the specified torque Otherwise it will cause a fire or electrical fault at the terminal block If the supply cord is damaged it must be replaced by the manufacturer its service agent or similarly qualified persons in order to avoid a hazard If there is fire please cut off the power supply immediate...

Page 7: ...er Power supply for high power equipment is too close to the power wire of the air conditioner Device Ex Lift container crane rectifier for electric railway inverter power device arc furnace electric furnace large sized induction motor and large sized switch It consumes a large quantity of electrical power In the case mentioned above the power wire of the air conditioner generates a large induced ...

Page 8: ...1 Installation ...

Page 9: ...harging Cylinder 4 Refrigerant Gas Hose 15 Gauge Manifold 5 Megohmmeter 16 Wire Cutters 6 Copper Pipe Bender 17 Gas Leak Detector 7 Manual Water Pump for Indoor Unit 18 Leveller 8 Pliers 19 Crimper for solderless Terminals 9 Pipe Cutter 20 Hoist for Indoor Unit 10 Brazing Kit 21 Ammeter 11 Hexagon Wrench 22 Voltage Meter It is recommended to use specially designated tools for handling R410A refrig...

Page 10: ...against pollution Blow nitrogen during brazing Prevention from Oxidation during Brazing Lubrication Oil for Flare Surface Use a synthetic oil which is equivalent to the the oil used in the refrigeration cycle Synthetic oil absorbs moisture quickly Applying Oil to the Flared Surface Vacuum Drying Refrigerant Charge Refrigerant Cylinder Check refrigerant cylinder color Liquid refrigerant charging is...

Page 11: ...or 2 Vibration Absorder 8 High Pressure Sensor 14 Low Pressure Sensor 20 Air Outlet 3 Crankcase Heater 9 High Pressure Switch 15 4 Way Valve 21 Propeller Fan 4 Compressor 10 Oil Separator 16 Check Joint 22 Fan Motor 5 Liquid Stop Valve 11 Electronic Expansion Valve 17 Check Valve 23 Air Inlet 6 Gas Stop Valve 12 Electrical Box 18 Filter 24 Heat Exchanger ...

Page 12: ...ration Absorder 8 High Pressure Sensor 14 Check Joint 20 Propeller Fan 3 Crankcase Heater 9 High Pressure Switch 15 Low Pressure Sensor 21 Fan Motor 4 Compressor 10 Filter 16 4 Way Valve 22 Air Inlet 5 Liquid Stop Valve 11 Check Valve 17 Accumulator 23 Heat Exchanger 6 Gas Stop Valve 12 Solenoid Valve 18 Electronic Expansion Valve 24 Oil Separator ...

Page 13: ...bration Absorder 8 High Pressure Sensor 14 Low Pressure Sensor 20 Air Outlet 3 Crankcase Heater 9 High Pressure Switch 15 4 Way Valve 21 Propeller Fan 4 Compressor 10 Oil Separator 16 Check Joint 22 Fan Motor 5 Liquid Stop Valve 11 Electronic Expansion Valve 17 Check Valve 23 Air Inlet 6 Gas Stop Valve 12 Electrical Box 18 Filter 24 Heat Exchanger ...

Page 14: ...1 Distributor 20 Filter 4 3 High Pressure Switch 12 Filter 1 21 Solenoid Valve 4 High Pressure Sensor 13 Electronic Expansion Valve 22 Low Pressure Sensor 5 Check Valve 14 Filter 2 23 Crankcase Heater 6 4 Way Valve 15 Liquid Stop Valve 24 Filter 5 7 Check Joint 16 Gas Stop Valve 25 Bypass Capillary Tube 8 Gas Collector 17 Filter 3 26 Heat Exchanger 9 Propeller Fan 18 Accumulator 27 Y shaped Joint ...

Page 15: ...n 10 C during the outdoor unit heating operation 3 When operating the outdoor unit under low heating load conditions and the outdoor temperature is 15 C WB or more only one indoor unit is in the operation the outdoor unit will be Thermo OFF to protect the compressor from failure 4 When RAS 7 0 12HNBRMQ1 outdoor units are connected with the RCIM 0 8FSN4 or RCD 0 8 1 0FSN3 or RCS 0 8 1 0FSN if only ...

Page 16: ...nit ensure the safety and lift up smoothly a Do not unwrap the package until the hanging work is finished b The hanging work can be followed the next figure More than 60 Wire Rope 0 7m 1 0m Apply rope through the square hole Do not remove corrugated paper frame and plastic band Notes Make sure the unit is in horizontal while lifting Do not hook with the plastic bands If the unit is lifted after un...

Page 17: ... that nothing remains there prior to installation and test run Ignoring the instructions can lead to damage and fire incidents 1 6 Factory Supplied Accessories The accessories are packed in the outdoor unit please check that in the package Accessory Appearance Quantity Remarks Plastic Bag 1 RAS models IOM 1 Wire Clamp big 1 Only for RAS 3 0 6 5HNBRKQ1 Wire Clamp small 3 Magnetic Ring big 2 Magneti...

Page 18: ... Where corrosive gases such as chlorine bromine or sulphide can accumulate such as near a hot tub or hot spring Where dense salt laden airflow is heavy such as in coastal regions Where the air quality is of high acidity Where harmful gases can be generated from decomposition Do not install the indoor unit where such dripping can cause moisture damage or uneven locations Use a raised concrete pad o...

Page 19: ...ir inlet or outlet of the outdoor unit Make sure to provide sufficient space around the outdoor unit for operation and maintenance Notes If strong wind blows to the air outlet directly the needed airflow volume cannot be maintained and the outdoor unit may be difficult to operate normally If excessively strong wind blows to the air outlet consecutively it may cause the propeller fan or the fan mot...

Page 20: ...it may result in a performance drop off and mechanical issues due to insufficient air intake Additionally adequate srvice space is required for service maintenance access 1 Obstacles on the inlet side a There is no obstacle in the upper side Unit mm Single Installation Multiple Installation b There are obstacles upper side Unit mm Single Installation Multiple Installation ...

Page 21: ...14 INSTALLATION 2 Obstacles on the outlet side and no obstacle in the upper side Unit mm Single Installation Multiple Installation ...

Page 22: ... the upper side Unit mm 4 Multi row and multiple installations Unit mm Note If L is larger than H mount the units on a base so that H is greater or equal to L Be sure to seal up every surface of the base If the base allows the airflow to go it may cause a short circuit L A mm B mm 0 L 1 2H 600 or more 300 or more 1 2H L H 1400 or more 350 or more ...

Page 23: ... the base of the unit the 5 10mm thickness of rubber gaskets field supplied should be placed under the feet of the outdoor unit which could decrease the vibration into the room a Model RAS 3 0 6 5HNBRKQ1 b Model RAS 7 0 12HNBRMQ1 2 Installation positions of feet air inlet and drain holes are shown in the following figures Model RAS 3 0 6 5HNBRKQ1 Unit mm Concrete ...

Page 24: ...r gaskets have been adopted they should also be positioned under the feet of the outdoor unit 6 When the outdoor unit is installed on a metal frame the metal plates should be used to adjust the frame width for stable installation Metal Plate Outdoor unit is stable of Outdoor Unit Foot Frame Outdoor unit is unstable Foot of Outdoor Unit Frame Recommended Metal PlateSize Field Supplied Material Hot ...

Page 25: ... or saw which could produce metal particles 3 Take special care to prevent pollution or moisture settling from going into the interior pipe during piping work 4 Avoid performing the piping connection work for outdoor unit in the rain 5 Refrigerant pipe ends 6 Piping Thickness and Material The thickness of refrigerant pipe differs depending on design pressure For copper tube pay attention to pipe s...

Page 26: ... work Note To avoid oxidation and scaling perform brazing at the appropriate temperature D To prevent gas leakage at the brazing connection refer to the table for the insertion depth and the gap for joint pipe Unit mm Diameter ΦD Min Insertion Depth B Gap A D 5 D 8 6 0 05 0 35 8 D 12 7 12 D 16 8 0 05 0 45 16 D 25 10 8 Cautions for Flaring Work A Perform the flaring work as shown below Unit mm Diam...

Page 27: ...igerant oil field supplied on the flare surface of the pipe and flare nut before performing flaring work Tighten the flare nut to specified torque settings using two wrenches Perform flaring work to the liquid piping side before treating the gas piping side Verify that no gas leakage has oc curred after completing flaring work E Be sure to use two wrenches as shown Stop Valve Flare Nut Do not appl...

Page 28: ...ipe straight and the length of the straight pipe is no less than 0 5 meter Keep Horizontal To Indoor Unit To Indoor Unit Branch Connection To Outdoor Unit Keep Vertical Secure the Branch Pipe to the surface of Pillar or Wall Keep K e e p Horizontal H o r i z o n t a l Secure the Branch Pipe to Ceiling surface or Beam Upper side Upper side Upper side Upper side Branch Pipe Branch Pipe Branch connec...

Page 29: ... b c RAS 11 12HNBRMQ1 Φ19 05 Φ12 7 Φ25 4 Φ12 7 a b c Notes Mark represent that if the liquid pipe which is between the outdoor unit and the 1st branch is over than 70 meters its diameter should be up size Thus the Φ9 52 diameter pipe is converted to Φ12 7 diameter pipe Mark represent that there are pipe adapters in the outdoor unit which is used to adjust the gas pipe between the outdoor unit and ...

Page 30: ...RAS 7 0 12HNBRMQ1 180 meters Between the 1st branch pipe and the farthest indoor unit b c d 40 meters Between branch pipes and connected indoor units L1 L2 L3 d 15 meters Allowable Height Difference Outdoor unit is higher than indoor unit H1 RAS 3 0 6 5HNBRKQ1 30 meters RAS 7 0 12HNBRMQ1 50 meters Outdoor unit is lower than indoor unit H1 RAS 3 0 6 5HNBRKQ1 30 meters RAS 7 0 12HNBRMQ1 40 meters He...

Page 31: ...rant Piping Work for Outdoor Unit 1 The refrigerant piping can be installed in four directions front right bottom or rear side as shown in the following figures Model RAS 3 0 3 5HNBRKQ1 Model RAS 4 0 6 5HNBRKQ1 RAS 7 0 12HNBRMQ1 ...

Page 32: ...ant leakage may occur Controlling torque of hexagonal wrench Model Gas side stop valve Liquid side stop valve RAS 3 0 6 5HNBRKQ1 11 14 N m 7 9 N m RAS 7 0 8 0HNBRMQ1 12 15 N m 7 9 N m RAS 10 12HNBRMQ1 12 15 N m 8 12 N m 3 If the direction of the refrigerant piping has been chosen please remove the piping cover from the unit punch out the holes following the guide line with a screwdriver and a hamm...

Page 33: ...te the gas piping side and liquid piping side individually 5 Connect the pressure gauge and the charging hoses to the check joints of the stop valves with a nitrogen tank Perform the air tight test at 4 15 MPa for the test pressure 6 For the air tight test please use a leak detector or forming agent to detect the joints and stop valves for the piping connection If there is leakage please solve it ...

Page 34: ... more than one hour 3 After that turn off the vacuum pump and then observe the pressure for more than two hours 4 If the pressure is over than 0 1MPa obviously a gas leak is suspected Please check the leak position and eliminate it Then repeat the vacuuming work again The vacuuming should be performed on the gas stop valve and the liquid stop valve simultaneously Otherwise air may be left in the s...

Page 35: ...er Refrigerant charge per meter Additional charge kg W W11 W12 W13 W21 W22 W23 Φ6 35 W11 0 020kg m Φ9 52 W12 0 059kg m Φ12 7 W13 0 120kg m For the 4 way cassette indoor units Model Symbol Numbers Q ty Refrigerant charge per unit Additional charge kg RCI 1 0 1 5 W21 0 23kg pcs RCI 2 0 2 5 W22 0 29kg pcs RCI 3 0 6 5 W23 0 47kg pcs For the other indoor units 0 Note Ensure the total additional charge ...

Page 36: ...of refrigerant follow the procedure below A Fully open the gas stop valve B Operate the compressor in the cooling mode and charge the additional refrigerant from the check joint of the liquid stop valve At this time keep the liquid stop valve slightly open C After the refrigerant is charged fully open the liquid stop valve and the gas stop valve D Carefully calculate any additional refrigerant qua...

Page 37: ...he indoor unit and the outdoor unit then wait for more than 10 minutes before electrical wiring work or a periodical check is performed Ensure that the indoor fan and the outdoor fan have been stopped before electrical wiring work or a periodical check is performed Protect the wirings electrical parts and so on from rats or other small animals If not rats may gnaw at unprotected parts and which ma...

Page 38: ...Stranded Copper Shielded cable must be considered for applications and routing in areas of high EMI and other sources of potentially excessive electrical noise to reduce the potential for communication errors When shielded cabling is applied proper bonding and termination of the cable shield is required as per guidelines Plenum and riser ratings for transmission cables must be considered per appli...

Page 39: ...2 Electrical Wiring Connection Connect the electrical wiring according to the following figures Figure 4 1 Electrical Wiring Connection for RAS 3 0 6 5HNBRKQ1 Figure 4 2 Electrical Wiring Connection for RAS 7 0 12HNBRMQ1 ...

Page 40: ...e magnetic rings in the package of the outdoor unit should be used on the power supply wire and transmission cable For the power supply wire two magnetic rings should be paralleled and the wire should through them by one cycle For the transmission cable between the outdoor unit and indoor units the cable should be through the magnetic ring by 3 cycles 4 Connect the transmission cables between the ...

Page 41: ...will cause an electric shock or fire Check that the ground wire is securely connected Otherwise it may lead to an electrical shock Do not connect the ground wiring to gas piping water piping lightning conductor or telephone ground wirings In the electrical wiring connection for RAS 7 0 12HNBRMQ1 do not connect the live wires L1 L2 L3 to the terminals N of the terminal block TB1 Otherwise printed c...

Page 42: ...l characteristics again 3 If the distribution box or pull box is adopted to the power supply for air conditioning the size of the power supply wire should be chosen according to the following table Total Ampacity A Power Supply Wiring mm2 1 If the total ampacity is over than 63A the power supply wires must not be connected in series I 6 2 5 6 I 10 2 5 10 I 16 2 5 16 I 25 4 25 I 32 6 32 I 40 10 40 ...

Page 43: ...DIP switches inside the outdoor unit 2 Setting for Transmitting It is required to set the refrigerant cycle No of outdoor unit 3 Setting End Terminal Resistance Before shipment No 1 pin of DSW5 is set at the ON side If there are 2 or more units in the same communication system set No 1 pin of DSW5 at the OFF side from the 2nd refrigerant group outdoor unit If only one outdoor unit is used no setti...

Page 44: ...w The range of refrigerant cycle No is between 0 and 63 Refrigerant Cycle No The value of the DSW4 System Address Setting Double Digit The value of the RSW1 System Address Setting Single Digit DSW4 System Address Setting Double Digit RSW1 System Address Setting Single Digit DIP Switch Setting Value DIP Switch Setting Value 0 0 10 1 20 2 30 3 40 4 50 5 60 6 7 8 9 ...

Page 45: ... scalded Do not touch any electrical components otherwise it may cause an electrical shock 3 Turn off the main power switch to the indoor unit and the outdoor unit and wait for more than 10 minutes before electrical wiring work or a periodical check is performed 6 2 Test Run by DIP Switch of Outdoor Unit 1 Turn on the power supply of the outdoor and indoor units for more than 12 hours the 7 segmen...

Page 46: ...the ON OFF to turn on the air conditioning The default setting for the test run time is a 120 minutes OFF timer It can be adjusted by pressing the INCREASE and DECREASE The range of the timer is between 30 minutes and 600 minutes with an interval of 30 minutes 4 After setting the test run menu the LCD will be displayed as follow Notes Louver angle switch is in auto swing mode If the multiple indoo...

Page 47: ... screws for the terminal block are loosen Less than the actual connected Power supply for indoor unit is not turned on Disconnect the transmission cables between outdoor unit and indoor units 7 Safety and Control Device Setting The compressor is protected by the following devices and their combinations 1 High Pressure Switch This switch cuts out the operation of the compressor when the discharge p...

Page 48: ...outdoor unit on a flat foundation or block and secure it at least 100mm higher than the ground For smooth drainage install the outdoor unit with a slight incline on the drainage side rear side The Drain Adaptor is for the drain pipe connection for use on the outdoor unit bottom base as a drain pan A Put the rubber cap in the drain adaptor to the upper part of the drain adaptor projection in the di...

Page 49: ...lization in Cold Area Do not use the Drain Adaptor in an area where drain water may be frozen If the drain water in the drain pipe is frozen and then the drain pipe may crack A In a snow area water from the heat exchanger may be frozen on the surface of the bottom base This may lead to poor drainage Therefore do not use the drain adaptor in this type of area B In the drainage method according to t...

Page 50: ...43 Troubleshooting ...

Page 51: ... current Rated Current Input MOP MCA Voltage PH Hz Max Min Cooling Heating V Φ Hz V V A A A A A RAS 3 0HNBRKQ1 220 240 1 50 264 0 198 8 7 9 5 9 9 32 21 RAS 3 5HNBRKQ1 220 240 1 50 264 0 198 8 7 12 9 12 3 32 21 RAS 4 0HNBRKQ1 220 240 1 50 264 0 198 10 6 12 6 14 0 40 31 RAS 4 5HNBRKQ1 220 240 1 50 264 0 198 10 6 14 8 16 1 40 31 RAS 5 0HNBRKQ1 220 240 1 50 264 0 198 10 6 18 3 19 2 40 31 RAS 6 0HNBRKQ...

Page 52: ...vidual Operation Setting The maximum quantity of the indoor units can be controlled by one wired controller is 16 c Connecting Wired Controller if Connecting between Individual Systems Notes Thermo ON The outdoor unit and some indoor units are running Thermo OFF The outdoor unit and some indoor units stay on but don t run TROUBLESHOOTING ...

Page 53: ...al Condition Deactivated OFF LED2 Red It indicates Alarm LED3 Yellow It indicates Alarm LED4 Green It indicates Alarm LED5 Red Indicator for DC Bus Voltage Normal Condition Activated ON Abnormal Condition Deactivated OFF LED6 Red Power source indicator for Precharge Relay Normal Condition Activated ON Abnormal Condition Deactivated OFF LED7 Green Power source indicator for inverter control of the ...

Page 54: ... Test Run 7 PSW1 Manual Defrosting 2 DSW2 Function Setting 8 PSW2 Decrease 3 DSW3 Model Setting 9 PSW3 Increase 4 DSW4 System Address Setting Double Digit 10 RSW1 System Address Setting Single Digit 5 DSW6 Function Setting 11 SEG1 7 segment Display 6 DSW7 Function Setting 12 TP1 Test Port for Factory TROUBLESHOOTING ...

Page 55: ...reen It indicates Alarm LED7 Green Power source indicator for inverter control of the PCB1 3 3V Normal Condition Activated ON Abnormal Condition Deactivated OFF LED9 Orange It indicates Alarm LED11 Green This indicates the communication state between the PCB1 and PCB4 Normal Condition Activated Flash Abnormal Condition Deactivated OFF TROUBLESHOOTING ...

Page 56: ...and Overcurrent Control 5 7 Segment Indication 6 Processing of Safety Device Input 7 Processing of Relay Output 8 Reverse Phase Detection for Power Source PCB2 Driver Board for Inverter 1 Compressor is driven by Driver Board 2 Overcurrent Control 3 Protection Control PCB3 Fan Motor Driver Board 1 Fan motors are driven by Fan Motor Driver Board 2 Overcurrent Control 3 Protection Control NF1 Noise F...

Page 57: ...ator for Outdoor Unit PCB 280VDC Normal Condition Activated ON Abnormal Condition Deactivated OFF LED6 Red Power Source Indicator for Outdoor Unit PCB from PCB2 Normal Condition Activated ON Abnormal Condition Deactivated OFF SEG SEG1 It indicates Alarm Protective Safety Device has Tripped or Checking Items Definition of DIP Switch No DIP Switch Code Definition No DIP Switch Code Definition 1 DSW1...

Page 58: ...LED6 Red Power Source Indicator for Precharge Relay Normal Condition Activated ON Abnormal Condition Deactivated OFF LED4 Green LED3 Yellow LED2 Red Compressor is Working ON OFF OFF Frequency Decrease for Overcurrent ON ON OFF Frequency Limit for Overcurrent ON ON ON Frequency Limit for Overheat ON Flash OFF Frequency Decrease for Overheat ON Flash Flash Compressor is Ready to Operate The Main Rel...

Page 59: ...ON Abnormal Condition Deactivated OFF LED9 Orange ON Fan1 Motor Driver is error Flash Fan2 Motor Driver is error LED4 Green LED3 Yellow LED2 Red Fan Motor is Working ON OFF OFF Frequency Decrease for Overcurrent ON ON OFF Frequency Limit for Overcurrent ON ON ON Frequency limit for Overheat ON Flash OFF Frequency Decrease for Overheat ON Flash Flash Fan Motor is Ready to Operate The Main Relay is ...

Page 60: ...53 d Noise Filter Board NF1 TROUBLESHOOTING ...

Page 61: ...e unit will start in in 1 minute after the switch adjustment is made To simplify service and maintenance number this outdoor unit to help distinguish it from the other outdoor units Record the unit number in the right of the electrical box Setting is required Setting item Pin No Setting before 1 Shipment 2 3 4 5 6 Function Setting External Input Output Setting DSW2 No setting is required 21 Functi...

Page 62: ...tting is required Setting Before Shipment Setting Position For End Terminal Resistance Cancellation Set No 1 pin of DSW5 correctly in the same H LINK system DSW4 RSW1 otherwise it may cause abnormal transmission Refer to Setting of End Terminal Resistance Setting Before End Resistance DSW4 DSW5 21 21 21 0 1 2 3 4 5 6 7 8 9 No Setting is required No Setting is required Setting Before Setting Before...

Page 63: ...On No 2 pin Set Dial No 5 Notes DSW and RSW setting before shipment is 0 Maximum in setting refrigerant system No is 63 For installing the outdoor unit and the indoor unit on the same communication cable maximum number of connectable indoor units is 160 3 Setting of End Terminal Resistance Before shipment No 1 pin of DSW5 is set to ON If the quantity of outdoor units in the same H LINK II is 2 or ...

Page 64: ...interface If one wired controller is connected to only one indoor unit the step is skipped Check Mode 2 Check Mode 1 Press and hold and simultaneously for five seconds during the normal mode Select the check mode 1 or 2 with pressing or Ⱦ And confirm it by pressing Switch the items with pressing or Ⱦ ƹ Press and hold and simultaneously for five seconds ƹ Press ON OFF Normal Mode Interface Check Me...

Page 65: ...r I U 25 J1 I U Capacity 5 b5 Wireless Controller Temp 26 J2 O U Code 6 b6 Outdoor Air Temp 27 J3 Refrigerant System No 1 7 b7 Gas Pipe Temp for I U 28 J4 Refrigerant System No 2 8 b8 Evaporating Temp at Heating for O U 29 L1 I U Expansion Valve 9 b9 Condensing Temp at Cooling for O U 30 L2 O U Expansion Valve 1 10 bA Comp Discharge Temp 31 L3 O U Expansion Valve 2 11 bb Wired Controller Temp 32 L...

Page 66: ...ndensing Temp at Cooling for O U 15 qF Comp Current 8 q8 Comp Discharge Temp Note I U Indoor Unit O U Outdoor Unit 3 Alarm History Display The Alarm History Display is accessed from the Check Menu A The figure shows the normal mode interface B Press and hold for five seconds during the normal mode and the history alarm code would display The codes can be checked by pressing or C Press the for five...

Page 67: ...No of error the No of indoor unit and the error code will display 00 as shown in the following figure Press the for five seconds or press ON OFF the alarm history display is disappeared and it will show the normal mode interface Note The maximum history alarm codes can be recorded by the wired controller is 30 Press and hold and simultaneously for five seconds TROUBLESHOOTING ...

Page 68: ...ng conditions and each part of the refrigerant system temperature condition by 7 segment display SEG1 on the service board 3 6 5HP or outdoor unit PCB 7 12HP and push switches PSW A To start the checking mode Press PSW2 for 3 seconds B To move the checking item forward Press PSW2 C To move the checking item backward Press PSW3 D To cancel the checking mode Press PSW2 for 3 seconds WARNING 剱 剱 剱 剱 ...

Page 69: ...an 2 if there are two fan motors it indicates the software No of fan 1 Inverter Order Frequency to Comp 06 1 0 140 Hz Outdoor Fan Step 07 0 18 step Speed of Outdoor Fan 1 08 2 0 1000 rpm Speed of Outdoor Fan 2 09 2 0 1000 rpm Outdoor Electronic Expansion Valve Opening 10 0 100 High Pressure Discharge Pressure 11 0 1 4 9 MPa Low Pressure Suction Pressure 12 0 0 1 9 MPa Discharge Temp 13 1 1 142 C E...

Page 70: ...Alarm Code or Cause Code of I U Stoppage Cause Code of Inverter Fan Stoppage Abnormal Data Record No 9 Capacity of Outdoor unit 157 Capacity Code of Outdoor Unit For example 40 represent that 40 8 5 HP Besides the 3HP its capacity code is 22 Total Capacity of Indoor Unit Connected 158 1 0 199 Connected Indoor Unit Number 159 0 64 pcs System Refrigerant Address 160 0 63 Refrigerant System No Notes ...

Page 71: ...rigerant Charge Failure of Thermistor Incorrect Wiring Incorrect Piping Connection Expansion Valve Locking at Opened Position Disconnect Connector 08 Increase in Discharge Gas Temperature Insufficient Refrigerant Charge Pipe Clogging Failure of Thermistor Incorrect Wiring Incorrect Piping Connection Expansion Valve Locking at Closed Position Disconnect Connector 11 Sensor on Indoor Unit Abnormalit...

Page 72: ...Heating Expansion Valve Locking at Open Position Loose Connector 45 Activation of High Pressure Increase Protection Overload Operation Heat Exchanger Clogging Short Circuit of Airflow Pipe Clogging Excessive Refrigerant Inert Gas Mixing 47 Activation of Low Pressure Decrease Protection Insufficient Refrigerant Piping Clogging Expansion Valve Locking at Close Position Loosen Connector 48 Activation...

Page 73: ...apacity Code Setting DSW3 of Combination Excessive or Insufficient Indoor Unit Total Capacity Code The allowable scope is 45 150 3 When SEG1 displays 35 the condition of activation This alarm code is displayed in 3 to 5 minutes after powering on outdoor unit when the indoor unit No set by DSW6 and RSW1 on I U PCB in the same refrigerant system No duplicates When the refrigerant system No and the a...

Page 74: ...itching Failure Retry due to Pd Increase Retry after Defrosting Operation Retry due to Discharge Gas Temperature Increase Retry due to Low Pressure Decrease Forced Thermo OFF for the Indoor Units Rotation Retry due to Discharge Gas SUPERHEAT Decrease Forced Thermo OFF for the Outdoor Unit Control Notes The cause code of indoor unit stoppage is not always Alarm during stoppage by the abnormality If...

Page 75: ...lure Detection Reset of Micro Computer for Inverter Ground Fault Detection from Compressor Open Phase Detection Inverter Malfunction Communication Error Protection Device Actuation PSH Abnormal Protective Device Early Return Protective Device Step Out Detection Abnormal PCB Setup EERPOM Error Abnormal Comp Frequency Beyond Frequency Scope DC BUS Pre charge Malfunction Phase Default of Comp Inverte...

Page 76: ...tection Activation Electronic Thermal Protection Inverter Voltage Decrease Overvoltage Abnormal Communication Abnormal Current Detection Reset of Micro Computer for Inverter Ground Fault Detection from Compressor Inverter Malfunction Step Out Detection EERPOM Error Abnormal Fan Motor Frequency Beyond Frequency Scope Phase Default of Inverter Output Error of IPM Temp Sensor Abnormal of MCU RAM Abno...

Page 77: ...peration time when abnormality happened alarm code cause code of I D stoppage and cause code of inverter fan stoppage are recorded For example No of Abnormal Data n1 Accumulated Operation Time 1278h Alarm Code 48 Cause Code of Inverter Stoppage 2 Item Content Alarm Code Cause code of I D stoppage item Content ITC Cause Code of Comp Stoppage FTC Cause Code of Fan Stoppage Fan Motor 1 Stoppage Fan M...

Page 78: ...and outdoor unit 38 Abnormality of picking up circuit for protection in outdoor unit 45 Activation of high pressure increase protection d1 13 47 Activation of low pressure decrease protection d1 15 48 Activation of overcurrent protection 2 4 d1 17 51 Abnormality of current sensor for inverter 8 d1 17 53 Activation of inverter PCB protection device 1 12 21 d1 17 54 Activation of inverter fin temper...

Page 79: ...3 Inverter Current Protection Control 4 P4 Inverter Fin Temperature Increase Protection Control 5 P5 Discharge Temperature Increase Protection Control 6 P6 Low Pressure Decrease Protection Control 7 PA Demand Current Control 8 Pd Low Pressure Increase Protection Control 9 P9 High Pressure Decrease Protection Control Lower Rank Order of Protection Control Function Forced Decrease Forced Increase Pr...

Page 80: ...ncy for prevention of low pressure decrease High Pressure Decrease Protection Control To control the compressor frequency for prevention of high pressure decrease which would interrupt smooth refrigerant distribution to indoor units with different height and oil supply to the compressor Demand Current Control To control the compressor frequency for fixing the inverter primary current around the se...

Page 81: ...mple of 4 way Cassette Type This alarm code is displayed when the contact between 1 and 2 of CN14 on the I U PCB is opened for more than 120 seconds during the cooling dry fan or heating operation I U PCB Indoor Unit PCB Alarm Code 02 Activation of Protection Device High Pressure Switch in Outdoor Unit The alarm code is flashed on the 7 segment display of the outdoor unit The alarm code is display...

Page 82: ...ort circuited air Heating Remove short circuited air Check for other heat source Remove heat source Excessively High Temp Air to Indoor Unit Heat Exchanger Check for clogging of heat exchanger Remove clogging Check for dust on air filter Remove dust Check for any obstacles at inlet or outlet of heat exchanger Remove obstacles Check service space is sufficient Secure sufficient service space Check ...

Page 83: ...ure resistance between wires and insulation resistance Failure of Comp Motor Measure resistance between wires and insulation resistance Replace outdoor unit fan motor and fuse Replace O U PCB if faulty Failure of Outdoor Unit Fan Motor Blown Fuse on O U PCB Check for breakage of insulation Remove cause of short circuit and replace fuse Short Circuit between Wires Disconnected Wires Contact Failure...

Page 84: ...he inverter PCB Driver Board and the outdoor unit PCB Main Board Event Cause Check Item Action Turn OFF Main Switch Abnormal communication between inverter PCB and outdoor unit PCB Incorrect setting of DSW1 DIP3 of outdoor unit board 3 6 5HP or driver board 7 12HP Re power ON to check if the cause is eliminated Replace the outdoor unit board 3 6 5HP or driver board 7 12HP if faulty The outdoor uni...

Page 85: ...the operation is automatically retried Start Operation Check if the wiring of reactor is looseϋ Fasten the wiring Is the power supply voltage within the range of 10 of the rated voltage Replace the damaged driver board or fan motor driver board if faulty Check the power supply voltage and remove the fault to avoid the voltage too low or too high Is the power supply voltage higher than 85 of the ra...

Page 86: ... installation position of the discharge thermistor is correct Is the electronic expansion valve of indoor not connected correctly Is the unit heating or cooling when the failure occurs Avoid sudden fluctuations in air flowθ such as airflow short circuiting or thermo ON OFF frequently Connect the valve again Yes No Yes Yes Yes No No Is No No Yes Yes Replace temperature thermistor Install at the cor...

Page 87: ...The alarm code is flashed on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when the discharge temperature is too high during cooling heating operation TROUBLESHOOTING ...

Page 88: ...display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 24kΩ or less or disconnection 840kΩ or more of the thermistor is detected during a heating or cooling operation The operation automatically restarts when the malfunction is removed TROUBLESHOOTING ...

Page 89: ... display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 24kΩ or less or disconnection 840kΩ or more of the thermistor is detected during a heating or cooling operation The operation automatically restarts when the malfunction is removed TROUBLESHOOTING ...

Page 90: ...ed on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 24kΩ or less or disconnection 840kΩ or more of the thermistor is detected during a heating or cooling operation The operation automatically restarts when the malfunction is removed TROUBLESHOOTING ...

Page 91: ...the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 24kΩ or less or disconnection 840kΩ or more of the thermistor is detected during a heating or cooling operation The operation automatically restarts when the malfunction is removed TROUBLESHOOTING ...

Page 92: ...s flashed on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 24kΩ or less or disconnection 840kΩ or more of the thermistor is detected during a heating or cooling operation TROUBLESHOOTING ...

Page 93: ...e 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 9kΩ or less or disconnection 5946kΩ or more of the thermistor is detected during a heating or cooling operation TROUBLESHOOTING ...

Page 94: ...on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when output voltage of the high pressure sensor decreases to 0 1V or less or increases to 4 9V or more during operation TROUBLESHOOTING ...

Page 95: ...is flashed on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 2kΩ or less or disconnection 500kΩ or more of the thermistor is detected during heating or cooling operation TROUBLESHOOTING ...

Page 96: ...rmistor The alarm code is flashed on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when a short circuit 0 2kΩ or less or disconnection 500kΩ or more of the thermistor is detected during heating or cooling operation TROUBLESHOOTING ...

Page 97: ...on the 7 segment display of the outdoor unit The alarm code is displayed on the wired controller of the indoor unit This alarm code is displayed when output voltage of the low pressure sensor decreases to 0 1V or less or increases to 4 9V or more during operation TROUBLESHOOTING ...

Page 98: ...his alarm code is displayed when an undefined setting is set to DSW3 for capacity and power supply setting on the service board 3 6 5HP or O U PCB 7 12HP This alarm code is displayed when the total indoor unit capacity is outside the range of connectable indoor unit capacity ratio Connectable Indoor Unit Capacity Outdoor Unit Model Connectable Indoor Unit Capacity Ratio Minimum Maximum 3HP 12HP 45...

Page 99: ...are 64 or more The alarm code b1 is displayed on the wired controller This alarm code is displayed when refrigerant system No set by DSW4 and RSW1 on service board 3 6 5HP or outdoor unit PCB 7 12HP in in the same H LINK ll system duplicates Note In the case of H LINK ll system this alarm code may be displayed when DSW4 and RSW1 for refrigerant system No setting on the outdoor unit and DSW5 and RS...

Page 100: ...displayed on the wired controller of the indoor unit This alarm code is displayed when the outdoor unit PCB detects that the protection device PSH is activated Note This alarm code may be displayed at starting the operation when the high pressure switch PSH is connected incorrectly or fails open fault The item for alarm code 02 should be checked as well TROUBLESHOOTING ...

Page 101: ...wired controller of the indoor unit If the pressure ratio ε 1 is less than 1 5 for a minute the compressor stops The operation automatically restarts after three minutes If this occurs again twice in the next 30 minutes this alarm code is displayed 1 Pressure Ratioε Pd MPa 0 1 Ps MPa 0 1 Pd high pressure discharge pressure Ps low pressure suction pressure TROUBLESHOOTING ...

Page 102: ...r unit The alarm code is displayed on the wired controller of the indoor unit If the suction pressure Ps of the compressor is more than 1 4 MPa for a minute the compressor stops The operation automatically restarts after three minutes If this occurs again twice in the next 30 minutes this alarm code is displayed TROUBLESHOOTING ...

Page 103: ...oor unit The alarm code is displayed on the wired controller of the indoor unit If the high pressure Pd of the compressor is more than 3 8 MPa for a minute the compressor stops The operation automatically restarts after three minutes If this occurs again twice in the next 30 minutes this alarm code is displayed TROUBLESHOOTING ...

Page 104: ...correct Connection Excessively Decreasing Low Pressure Internal Thermostat for Outdoor Fan is Activated in Heating Operation Measure coil resistance and insulation resistance Replace outdoor fan motor if faulty Faulty Outdoor Fan Motor Check charged ref volume or check for leakage Repair leakage and correctly charge ref Shortage of Refrigerant Check electrical system and ref system Correctly conne...

Page 105: ...s alarm code is displayed Condition of Activation 1 Instantaneous overcurrent Main causes Compressor damage output U V W are connected in reverse 2 Electronic thermal Main causes Heavy compressor load and so on 3 PFC_A hardware overcurrent Main causes Short circuited PFC electric reactor L1 driver hardware is abnormal 4 PFC_B hardware overcurrent Main causes Short circuited PFC electric reactor L2...

Page 106: ...ric reactor wiring secure Replace compressor if faulty Is the power supply voltage within the range of the rated voltage Is refrigerant overcharged Is the power supply voltage higher than 85 of the rated voltage during operation Is there any other high power equipment starting during the operation Is the power voltage higher than 85 of the rated voltage No Yes No Yes Yes Yes No Is electronic expan...

Page 107: ... code is displayed Condition of Activation 1 Picking up circuit for inverter current is not central value before the compressor starts operation 2 Inverter secondary current is excessively low when the compressor starts operation Abnormal Replace comp Restart operation No Inverter PCB is faulty Replace it Compressor stops immediately at low frequency P7 indication appears without compressor operat...

Page 108: ...d RHV DODUP FRGH GLVSOD LPPHGLDWHO DIWHU FRPSUHVVRU VWDUWHG RSHUDWLRQ Correct refrigerant charging amount Fasten the wiring Check the power supply voltage remove the fault to avoid the voltage too low or too high Is electric reactor wiring loose Is crank case heater ON Yes Yes Yes Yes No No No No Yes Check if compressor wirings are connected reversely Is electric reactor wiring secure Replace comp...

Page 109: ...m code is displayed If this occurs less than three times in 30 minutes the operation automatically restarts Condition of Activation 1 Fin temperature increases Main causes Increased temperature of the fins of the heat dissipation module 2 Thermistor failure Main causes Abnormality of driver temperature sampling circuit and so on Restart operation Does it trip soon Is heat exchanger of outdoor unit...

Page 110: ...es MCU RAM abnormality driver MCU abnormality 3 MCU Register abnormality Main causes Driver MCU abnormality 4 MCU clock abnormality Main causes Driver MCU abnormality driver crystal oscillator circuit abnormality 5 MCU FLASH abnormality Main causes Driver MCU abnormality 6 Reference voltage abnormality Main causes Driver MCU abnormality driver reference voltage circuit abnormality 7 Software prote...

Page 111: ... electrical abnormality of the fan motor Restart operation Does fan motor run when inverter failure occurs Yes No Yes Replace driver of fan motor Turn OFF outdoor unit power supply and disconnect compressor and fan motor wiring Short circuit TCN10 FCT connector Does it fail No Is the power supply voltage higher than 85 of the rated voltage during operation Turn OFF power supply and check if the fa...

Page 112: ...f the setting is not correct it may cause failure of O U PCB and circuit tester 1 The following table shows the check points and the normal range of voltage in case that the voltage on O U PCB is measured by a circuit tester The setting of circuit tester shall be set within the DC voltage measurement range when the following voltages are measured Check Point Normal Range V Side of Tester Side of T...

Page 113: ... LED Connector PCN CN Fuse FU1 FU2 Check Point 5V 12V GND Checking Item for Fuse The purpose capacity and causes of fuse melted are shown as below Fuse Capacity Purpose FU1 40A 3 3 5HP Protection for short circuiting of control circuit 220 230 240V 50A 4 6 5HP FU2 3 15A FU4 5A FU1 FU2 LED1 5V GND 12VD FU2 FU4 TROUBLESHOOTING ...

Page 114: ... voltage still exists in the inverter PCB after power is disconnected When the unit is operated LED5 is turned ON At the time of powering off the unit LED5 is turned OFF In this case the residual voltage is less than DC50V If LED5 is turned ON while powering off the unit please wait for about five minutes LED5 will turn OFF CAUTION TROUBLESHOOTING ...

Page 115: ... L COM AC L1 AC N More than 100k Ohm Overload N AC L1 AC N More than 1k Ohm 0 5V or smaller U V W P More than 1k Ohm 0 5V or smaller U V W N More than 100k Ohm Overload P U V W More than 100k Ohm Overload N U V W More than 1k Ohm 0 5V or smaller APFC Circuit of Inverter Module If all the items below table are performed and all items are satisfied the inverter module is non defective Test Point Ana...

Page 116: ...rrect it may cause failure of O U PCB and circuit tester 1 The following table shows the check points and the normal range of voltage in case that the voltage on O U PCB is measured by a circuit tester The setting of circuit tester shall be set within the DC voltage measurement range when the following voltages are measured Check Point Normal Range V Side of Tester Side of Tester 5V GND 4 8VDC 5 1...

Page 117: ...nector PCN CN Fuse EFR1 EFS1 Check Point P1 GND VCC05 VCC13 VDC 1 Checking Item for Fuse The purpose capacity and causes of fuse melted are shown as below Fuse Capacity Purpose EFR1 EFS1 5A Protection for short circuiting of control circuit 220 230 240V LED4 LED1 LED3 LED2 LED6 VCC13 GND VCC05 VDC1 P1 EFR1 EFR1 EFS1 TROUBLESHOOTING ...

Page 118: ...ned ON while powering off the unit please wait for about ten minutes LED7 will turn OFF APFC Circuit of Driver Board In case of using Digital Tester Rectifier and Inverter Circuit of Driver Board Remove all the terminals of the driver board before check If all the items below table are performed and all items are satisfied the driver board is non defective Test Point Digital Tester Result side of ...

Page 119: ...0k Ohm Over Load OL CN28 P U0 More than 1k Ohm 0 5V or smaller CN28 N U0 More than 100k Ohm Over Load OL CN28 N U0 More than 1k Ohm 0 5V or smaller CN28 P V0 More than 100k Ohm Over Load OL CN28 P V0 More than 1k Ohm 0 5V or smaller CN28 N V0 More than 100k Ohm Over Load OL CN28 N V0 More than 1k Ohm 0 5V or smaller CN28 P W0 More than 100k Ohm Over Load OL CN28 P W0 More than 1k Ohm 0 5V or small...

Page 120: ...F In this case the residual voltage is less than DC50V If LED7 is turned ON while powering off the unit please wait for about ten minutes LED7 will turn OFF IPM Circuit of Fan Motor Driver Board In case of using Digital Tester Rectifier and Inverter Circuit of Fan Motor Driver Board Remove all the terminals of the fan motor driver board before check If all the items below table are performed and a...

Page 121: ...or smaller CN28 P CN901 U2 More than 100k Ohm Over Load OL CN28 P CN901 U2 More than 1k Ohm 0 5V or smaller CN28 N CN901 U2 More than 100k Ohm Over Load OL CN28 N CN901 U2 More than 1k Ohm 0 5V or smaller CN28 P CN901 V2 More than 100k Ohm Over Load OL CN28 P CN901 V2 More than 1k Ohm 0 5V or smaller CN28 N CN901 V2 More than 100k Ohm Over Load OL CN28 N CN901 V2 More than 1k Ohm 0 5V or smaller C...

Page 122: ...eze protection thermistor becomes lower than the inlet air temperature when the unit under checking is stopped and other units are under the cooling operation It is abnormal if the liquid pipe pressure does not increase and the outlet temperature of the expansion valve decreases after the cooling operation is started Locked with Fully Opened It is abnormal under under the following conditions Afte...

Page 123: ...121 Maintenance ...

Page 124: ... refrigerant by water or foreign materials do not expose the refrigerant parts open to atmosphere for long periods If necessary seal pipe ends using caps or tape 1 1 Removing Service Cover Remove the service cover by drawing it downward after removing the securing screws for the service cover When removing the service cover take special care not to drop it Tool Gloves Phillips Screwdriver Model 3 ...

Page 125: ...123 MAINTENANCE 1 2 Removing Air Outlet Grille Remove the securing screws for each air outlet grille molded plastic Tool Gloves Phillips Screwdriver Model 3 3 5HP Model 4 6 5HP Model 7 12HP ...

Page 126: ...124 MAINTENANCE 1 3 Removing Upper Cover After removing the securing screws for the upper cover lift the upper cover up Tool Gloves Phillips Screwdriver Model 3 3 5HP Model 4 6 5HP Model 7 12HP ...

Page 127: ...e service cover 2 Remove the securing screws for the side cover and remove the side cover pulling it downward 3 Remove the securing screws for rear cover and remove the rear cover by pulling it downward Tool Gloves Phillips Screwdriver Model 3 3 5HP Model 4 6 5HP Model 7 12HP ...

Page 128: ... a corrosion or puller may be needed 4 Removing Fan Motor a Remove the service cover b Disconnect the connectors for the fan motors from the outdoor unit PCB in the electrical box c Remove the spacer screws securing the fan motor Tool Gloves Phillips Screwdriver Adjustable Wrench Puller Nipper Model 3 6 5HP Model 7 12HP Upper Cover Propeller Fan Washer Closing Nut Motor Clamp Screw with Spacer Fan...

Page 129: ... motor with the provided clamp taking care to route and secure the wiring away from the propeller fan 3 Mount the fan motor so that the gap of wiring harness is at lowest position 4 Reinstalling Propeller Fan Carefully align the D cut hole of propeller fan to match the shaft and slide on slowly Once the propeller fan hits the stop on motor shaft using figures start closing nut and tighten to appro...

Page 130: ... Way valve coil the expansion valve coil and the solenoid valve coil 2 Disconnect the fasten terminals from high pressure switch and pressure sensor 3 Disconnect the fan motor connectors and thermistors from the outdoor unit PCB 4 Disconnect the compressor wires and loosen all cord clamps 5 When mounting the electrical box join and fit the electrical box and the partition plate into the outdoor un...

Page 131: ...xpansion valve coil and the solenoid valve coil 2 Disconnect the fasten terminals from high pressure switch and pressure sensor 3 Disconnect the fan motor connectors and thermistors from the outdoor unit PCB 4 Disconnect the compressor wires and loosen all cord clamps 5 When mounting the electrical box join and fit the electrical box and the partition plate into the outdoor unit ...

Page 132: ...NTENANCE Remove the electrical box from the top of outdoor unit Remove the electrical box from the front of outdoor unit Remove the securing screws for electrical box Remove the securing screws for Front Plate ...

Page 133: ... the fasten terminals from high pressure switch and pressure sensor 3 Disconnect the fan motor connectors and thermistors from the outdoor unit PCB 4 Disconnect the compressor wires and loosen all cord clamps 5 When mounting the electrical box join and fit the electrical box and the partition plate into the outdoor unit Remove the securing screws for electrical box Remove the hook ...

Page 134: ...pen the sound proof cover wrapped around the compressor Remove the terminal box cover for the compressor and disconnect the lead wiring Notes Write down or photograph wiring and terminal designations to prevent mis wiring of replacement compressor as shown below If the read wiring is connected incorrectly to the terminal the compressor may be damaged due to reverse rotation 5 Remove the rubber cap...

Page 135: ...es with tape to prevent water and foreign particles entering the compressor and remove it right before brazing work 6 Disconnect the suction pipe and discharge pipe from the compressor with a torch Ensure that wiring and electrical parts are kept away from the brazing area If not they may catch fire at brazing work 7 Remove all securing to the compressor Tilt the compressor forward lift it up and ...

Page 136: ...e cover 2 Recover the refrigerant from check joints 3 Disconnect the fasten terminals of the high pressure switch and pressure sensor 4 Carefully unsolder the high pressure switch and the pressure sensors Tool Phillips Screwdriver Charging Hose Torch Model 3 3 5HP Model 4 6 5HP Model 7 12HP ...

Page 137: ...securing screw for 4 Way valve Note For model of 3 3 5HP remove the front plate of the electrical box before removing the 4 Way valve coil 4 To replace the 4 Way valve coil reverse the removal procedure Tool Phillips Screwdriver Stubby Phillips Screwdriver Model 3 3 5HP Model 4 6 5HP Model 7 12HP Securing Screw for 4 Way Valve Coil 4 Way Valve 4 Way Valve Securing Screw for 4 Way Valve Coil ...

Page 138: ...onnector on the outdoor unit PCB 3 Pull the expansion valve coil upward until it slides off from valve body 4 To attach the new expansion valve coil reverse the removal procedure Tool Phillips Screwdriver Nipper Band Model 3 3 5HP Model 4 6 5HP Model 7 12HP Top side view Pull the expansion valve coil upward Release Lock Expansion Valve Coil ...

Page 139: ...Disconnect the connector on the outdoor unit PCB 3 Remove one securing screw for solenoid valve coil SVA and slide the solenoid valve coil SVA upward 4 To install a new solenoid valve coil reverse the removal procedure Tool Phillips Screwdriver Model 3 3 5HP Model 4 6 5HP Model 7 12HP ...

Page 140: ...and the gas stop valve while cooling the valve bodies with a wet cloth b Perform the brazing work while keeping the flame away from electrical wiring and piping insulation 5 Remove the 4 Way valve from the assemblies four parts Remove Attach the 4 Way valve while cooling the valve bodies with a wet cloth 6 To attach the new 4 Way valve after replacement reverse the removal procedure Tool Phillips ...

Page 141: ...xpansion valve and the solenoid valve after cooling the valve bodies with a wet cloth b Perform the brazing work while keeping the flame away from electrical wiring and piping insulation 5 To attach the new valves after replacement reverse the removal procedure Tool Phillips Screwdriver Charging Hose Torch Wet Cloth Adjustable Wrench Model 3 3 5HP Model 4 6 5HP Model 7 12HP Expansion Valve EVO Sol...

Page 142: ...nternal IPM 2 Instantaneous Overcurrent Trip It is detected when current value is Over Demagnetization current 90 3 Instantaneous Overcurrent Trip It is detected when current value is Over Demagnetization current 85 4 Electronic Thermal Trip It is detected when current value is over rate current Condition is maintained longer than 10 seconds Protection of IPM of Inverter PCB The transistor module ...

Page 143: ...f Protection Function When the wired controller is off or main power supply is cut off iii Protection of IPM of Inverter a Level of Detection When some of the output terminals between U and V V and W W and U of DIPIPM of inverter PCB are short circuited an abnormality is detected When the running current of DIPIPM of inverter PCB reaches the maximum rated current an abnormality is detected When th...

Page 144: ... current is smaller than 396V an abnormality is detected b Function When an abnormality is detected the inverter compressor is stopped and the cause code of inverter stoppage is communicated to outdoor unit PCB c Cancellation of Protection Function When the wired controller is off or main power supply is cut off ii Overcurrent Protection for Inverter a Level of Detection When the current detected ...

Page 145: ...erter stoppage is communicated to main control c Cancellation of Protection Function When the wired controller is off or main power supply is cut off v Pre charge Protection a Level of Detection When the pre charge time of the relay is over than 5 seconds the relay is not activated then an abnormality is detected b Function When an abnormality is detected the inverter compressor is stopped and the...

Page 146: ...w noise design i The twin rotor crankshaft is arranged in a symmetrical type which counteracts the centrifugal force produced by the rotation and the vibration is smaller ii Unique low noise structure design and high efficiency DC motor is adopted The operation can be smooth and low noise at the full frequency 2 Principle of Compression 3 Structure ...

Page 147: ...el of 7 12HP It has the following advantages 1 Reliable Mechanism for Low Vibration and Low Sound i The rotating direction is definite ii The pressure inside of the chamber is high pressure and the surface temperature of the chamber is 60 C to 110 C 2 Principle of Compression 3 Structure ...

Page 148: ...4 Thermistor 1 Position of Thermistor Model 3 3 5HP Model 4 6 5HP Model 7 12HP Gas 4 5HP 6 6 5HP Thermistor for Discharge Gas Tem perature Thermistor for Outdoor Ambient Temperature Thermistor for Evaporating Temperature ...

Page 149: ... decreasing compressor temperature If the discharge gas temperature of compressor increases exceeding 132 C even if an electronic expansion valve opens the compressor is stopped in order to protect the compressor 3 Thermistor for Outdoor Ambient Temperature The thermistor resistance characteristics are shown in the figure below 4 Thermistor for Evaporating Temperature of Outdoor Unit The character...

Page 150: ...ating capacity of indoor units or PID Control for Compressor Frequency so that the high pressure is controlled in an appropriate range The output characteristics of the high pressure sensor are as follows Output Characteristics of High Pressure Sensor Output Characteristics of Low Pressure Sensor 3 Low Pressure Sensor The low pressure during operation is detected by a low pressure sensor for prote...

Page 151: ...4HP 6 5HP Model 7HP 12HP 2 8 Noise Filter NF1 The noise filter decreases the leakage of noise made by the outdoor unit to the power supply The individual noise filter is adopted in the model of 7HP 12HP Item Specifications Model NF167W Rated Voltage AC 3Ph 380V 415V Rated Current 30A Fuse FU1 FU2 FU3 690V 40A Brazing Part High Pressure Switch Brazing Part High Pressure Switch ...

Page 152: ...rent for the inverter Model 3HP 6 5HP Reactor 400V 50Hz 380 415V 50Hz 380V 60Hz Items Specifications Character 0 41mH 40KHz DC 16A Rated Current 16A Direct Current Resistance 50 0mΩ Max 25 C Model 7HP 12HP Items Specifications Character 1mH Rated Voltage AC 380V 415V Rated Current 30A Red Red Black Black ...

Page 153: ...External Input Output and Function Setting 151 ...

Page 154: ... No Function No Input Setting 3 Output Setting 1 Output Setting 2 Start DSW1 No 4 is ON DSW2 No 6 is ON The menu indication is changed by pressing PSW2 or PSW3 and PSW1 as shown by arrows below End DSW2 No 6 is OFF DSW1 No 4 is OFF NOTES 1 Record the function No of each setting when setting the optional function The example is for setting 1 2 The same function cannot be set to a different input te...

Page 155: ...21 C8 814 814 R31MA1 814 814 R176 C98 D 5 2 Q1 C99 CN8 CN6 CN100 THM9 THM81 THM11 THM8 CN101 CN2 LED3 DSW5 R140 R138 Q28 R141 R82 R59 R62 R58 R60 R88 R92 R91 R87 Q32 Q34 R147 R143 D34 C81 R156 R157 Q40 C89 C88 ON 2 1 THM10 THM7 CN102 CN7 CN1 LED6 R206 R205 D58 D57 D11 D12 Q12 D16 Q17 CN405 CN406 CN404 CN5A CN5B TP1 SEG1 1 ON 2 4 3 DSW1 1 6 2 5 ON 3 4 DSW2 1 6 2 5 ON 3 4 DSW3 1 6 2 5 ON 3 4 DSW4 0 ...

Page 156: ... 5 Forced Stoppage 6 Demand Current Control 40 7 Demand Current Control 60 8 Demand Current Control 70 9 Demand Current Control 80 10 Demand Current Control 100 11 1 No Setting 1 Control Function No 11 is valid only when applied to Input Setting 3 Output Control Function No Setting Function for Output 1 Operation Signal 2 Alarm Signal 3 Compressor ON Signal 4 Defrosting Signal Input Output Termina...

Page 157: ...ation at Input 1 between 1 and 2 pins of CN17 Fixing Cooling Operation at Input 2 between 3 and 2 pins of CN17 3P Connector X1 Auxiliary Relay X2 Auxiliary Relay SS3 Operation mode fixing switch SS2 Changeover switch Outdoor unit PCB Heat Cool Heat Cool Control circuit Power sopply 2 Input Demand Stoppage Control Function No 3 When the input terminals for Demand Stoppage on the outdoor unit PCB ar...

Page 158: ...e Outdoor Fan Motor Start Stop Input 2 is set to 2 and 3 pins of CN1 by an external signal is shown below Notes This is an auxiliary function to protect the unit from snow In snowy regions make sure to protect the unit with a snow prevention roof fence field supplied or snow protection hood optional Otherwise abnormal vibrations because of an imbalanced propeller fan will be caused This function c...

Page 159: ...some indoor units are running Thermo OFF The outdoor unit and some indoor units stay on but don t run 5 Input Demand Current Control 40 60 70 80 100 Control Function No 6 to 10 When the input terminals for Demand Current Control on the outdoor unit PCB are short circuited the compressor frequency is controlled so that the maximum limit of the outdoor running current is set to 100 80 70 60 or 40 of...

Page 160: ...Change Over Switch SS2 SS3 Manual Switch 220V 3 Pin Connector Cord Model PCC 1A Connected to JST Connector XARP 3 Five Cords with Connectors as One Set Electric Wiring Inside of Unit Low Volt AWG22 Lower than 24V 220V AWG18 20 Electric Wiring Outside of Unit Low Volt AWG18 20 Lower than 24V 220V AWG14 Notes Make the wiring to the terminals as short as possible Do not run the wirings too closely to...

Page 161: ...signal will be sent to output terminals when the indoor units are operating Even when one indoor unit is operating the signal will be sent This function can be used for circulator or humidifier operation 2 Output Alarm Signal Control Function No 2 This function is utilized to receive the alarm signal Auxiliary relay contacting RYa is closed when the alarm occurs The alarm signal will be sent to ou...

Page 162: ...ntacting RYa is closed during the compressor operation 4 Output Defrosting Signal Control Function No 4 This function is utilized to receive the defrosting signal Auxiliary relay contacting RYa is closed during the defrosting Specifications of Required Auxiliary Relay Parts Specifications Auxiliary Relay High Power Relay LY2F DC12V made by OMRON Do not use the relay with diode built in ...

Page 163: ...peration 6 0 Cancellation of Hot Start No setting 1 Cancellation of hot start 7 0 Priority Capacity Mode No setting 1 Change of correction factor for compressor frequency pattern1 2 Change of correction factor for compressor frequency pattern2 3 Change of correction factor for compressor frequency pattern3 8 0 Compressor Frequency Control Target Value for Cooling No setting 1 Change of upper limit...

Page 164: ...g No setting 1 Valid demand function all time 16 0 Demand Function Setting No setting 1 Valid wave function 20min 100 demand 10min minimum setting 17 0 Protection of Decrease in Outlet Temperature of Cooling No setting 1 Cooling outlet temperature decrease protection1 2 Cooling outlet temperature decrease protection1 18 0 Outlet Temperature Control DOAS No setting 1 Restrain capacity control 2 Out...

Page 165: ...tting Preheating during outdoor unit stoppage 1 Power saving during outdoor unit stoppage without preheating by crankcase heater 29 0 Invalid Motion Sensor during Prepare Defrost Prepared 9 No Setting 1 Invalid starting defrosting by motion sensor detecting no human activity absent 30 0 Convert Unit in Checking Mode Valid for North America No setting indication unit o F or psi 1 Convert indication...

Page 166: ...Opening Eo High Pressure Discharge Pressure Pd Low Pressure Suction Pressure Ps Discharge Temperature Td Evaporating Temperature TE Ambient Air Temperature To Inverter Fin Temperature TF Inverter Primary Current A1 Inverter Secondary Current A2 Checking for Indoor Unit Indoor Unit Address n Indoor Expansion Valve Opening E Liquid Pipe Temperature of Indoor Unit L Gas Pipe Temperature of Indoor Uni...

Page 167: ...Field Work Instructions 165 ...

Page 168: ...or any accidents caused by charging non specified refrigerants or others as noted above 3 Maintenance Work 1 For Outdoor Unit and Indoor Unit a Fan and Fan Motor Lubrication All fan motors are pre lubricated and sealed at the factory Therefore no lubricating maintenance is required Sound and Vibration Inspect for abnormal sounds or vibration Rotation Check that the fan rotates counterclockwise and...

Page 169: ...ing operation b 4 Way valve Activation Inspect for any abnormal activating sound c Strainer Clogging Check that there is no temperature difference between the ends d Ground Wiring Ground Line Inspect for continuity to the earth ground e Crankcase Heater Activation Apply power to the outdoor unit s at least 12 hours prior to operation of the system for preheating of the compressor oil 3 For Indoor ...

Page 170: ... C WB C Outlet DB C WB C 7 Check Refrigerant Temperature Liquid Temperature C Discharge Temperature C 8 Check Pressure Discharge Pressure MPa Suction Pressure MPa 9 Check Voltage Rated Voltage V Operating Voltage L N V Starting Voltage V 10 Check the Input Running Current of the Compressor Running Current A 11 Is the refrigerant charge correct 12 Do the operation control devices operate correctly ...

Page 171: ...RK INSTRUCTIONS 5 Saturation Curve for Refrigerant 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 30 20 10 0 10 20 30 40 50 60 70 G a p M d i u q i L e r u s s e r P n o i t a r u t a S Saturation Temperature Liquid oC R410A ...

Page 172: ...Service Parts List 170 ...

Page 173: ...0C STRAINER H17G62701B QU030010 4 4 4 4 4 4 4 U030K STRAINER H17G55723A QU030007 1 1 1 1 1 1 1 U034 PROTECTION NET H7D10106A 1 1 U034 PROTECTION NET H7D10108A 1 1 1 1 1 U040 HEAT EXCHANGER H7D10015A 1 1 U040 HEAT EXCHANGER H7D10017A 1 1 1 U040 HEAT EXCHANGER H7D10018A 1 1 U042Q CHECK VALVE H7D00022A QU042003 1 1 1 1 1 1 1 U051 PROPELLER FAN H7A03833C QU051009 1 1 2 2 2 2 2 U055 OIL SEPARATOR H7C05...

Page 174: ...COMPRESSOR H7B04846A QU311018 ATL232SDNC9AUY 1 1 U311 COMPRESSOR H7B02183B QU311019 ATH356SDPC9FQ HITACHI 1 1 1 U311 COMPRESSOR H7B04848A QU311022 ATH420SDPC9EQ 1 1 U318 STOP VALVE H7C00434B QU027009 1 1 1 1 1 1 1 U320 STOP VALVE H7C00436A QU027010 1 1 1 1 1 1 1 U405 MAIN PCBA H7C05653C QU407010 IMB 001 045B AC AC690V 40A 1 1 U405 MAIN PCBA H7C05653D QU407011 IMB 001 065B AD AC690V 50A 1 1 1 1 1 U...

Page 175: ...173 SERVICE PARTS LIST RAS 3 0HNBRKQ1 RAS 3 5HNBRKQ1 ...

Page 176: ...174 SERVICE PARTS LIST RAS 3 0HNBRKQ1 RAS 3 5HNBRKQ1 ...

Page 177: ...175 SERVICE PARTS LIST RAS 4 0HNBRKQ1 RAS 4 5HNBRKQ1 RAS 5 0HNBRKQ1 ...

Page 178: ...176 SERVICE PARTS LIST RAS 4 0HNBRKQ1 RAS 4 5HNBRKQ1 RAS 5 0HNBRKQ1 ...

Page 179: ...177 SERVICE PARTS LIST RAS 6 0HNBRKQ1 RAS 6 5HNBRKQ1 ...

Page 180: ...178 SERVICE PARTS LIST RAS 6 0HNBRKQ1 RAS 6 5HNBRKQ1 ...

Page 181: ... H7C05724A 1 1 U040A HEAT EXCHANGER H7C05726A 1 1 1 U040B HEAT EXCHANGER H7C05719A 1 1 U040B HEAT EXCHANGER H7C05721A 1 1 1 U042U CHECK VALVE H7C01709A QU042001 1 1 1 1 1 U051 PROPELLER FAN H7A03833C QU051009 2 2 2 2 2 U055 OIL SEPARATOR H7C04486A QU055007 1 1 1 1 1 U071 FAN MOTOR H7D09834B QU071143 1 1 1 1 1 U071A FAN MOTOR H7D09834A QU071144 1 1 1 1 1 U077H SOLENOID VALVE 17C77098A QU077003 1 1 ...

Page 182: ...318 STOP VALVE 3 8 H7C00434A QU027003 1 1 U319 STOP VALVE 1 2 H7C00435A QU027004 1 1 1 U321 STOP VALVE 3 4 H7C03201A QU027012 1 1 1 1 1 U405 MAIN PCBA H7B04866B QU409040 PO141W 1 1 1 1 1 U406 PRINTED CIRCUIT BOARD H7C05661A QU407006 DRV 180A A 1 1 U406 PRINTED CIRCUIT BOARD H7C05661B QU407007 DRV 180B A 1 1 1 NOTE The parts without the order numbers are the custom ordered and these are not include...

Page 183: ...181 SERVICE PARTS LIST RAS 7 0HNBRMQ1 RAS 8 0HNBRMQ1 ...

Page 184: ...182 SERVICE PARTS LIST RAS 7 0HNBRMQ1 RAS 8 0HNBRMQ1 ...

Page 185: ...183 SERVICE PARTS LIST RAS 10HNBRMQ1 RAS 11HNBRMQ1 RAS 12HNBRMQ1 ...

Page 186: ...184 SERVICE PARTS LIST RAS 10HNBRMQ1 RAS 11HNBRMQ1 RAS 12HNBRMQ1 ...

Page 187: ...HS2019266A ...

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