Hitachi Summit RAC-60YH5 Service Manual Download

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NO. 0299E

SPECIFICATIONS AND PARTS ARE SUBJECT TO CHANGE FOR IMPROVEMENT

ROOM AIR CONDITIONER

INDOOR UNIT + OUTDOOR UNIT

DECEMBER 2005

Refrigeration & Air-Conditioning Division

SERVICE MANUAL

REFER TO THE FOUNDATION MANUAL

TECHNICAL INFORMATION

FOR SERVICE PERSONNEL ONLY

(W)

(A)

(kW)

(B.T.U./h)

(W)

(A)

(kW)

(B.T.U./h)

(kg)

RAS-60YH5

RAC-60YH5

DC INVERTER (WALL TYPE)

TYPE

MODEL

POWER SOURCE

TOTAL INPUT

TOTAL AMPERES

CAPACITY

TOTAL INPUT

TOTAL AMPERES

CAPACITY

DIMENSIONS
(mm)

NET WEIGHT

SPECIFICATIONS

1,030

295

191

RAS-60YH5

CONTENTS

SPECIFICATIONS ------------------------------------------------------------------- 4

HOW TO USE ------------------------------------------------------------------------ 6

CONSTRUCTION AND DIMENSIONAL DIAGRAM --------------------- 28

MAIN PARTS COMPONENT --------------------------------------------------- 30

WIRING DIAGRAM ---------------------------------------------------------------- 33

CIRCUIT DIAGRAM --------------------------------------------------------------- 35

PRINTED WIRING BOARD LOCATION DIAGRAM --------------------- 41

BLOCK DIAGRAM ----------------------------------------------------------------- 43

BASIC MODE ----------------------------------------------------------------------- 45

REFRIGERATING CYCLE DIAGRAM --------------------------------------- 59

AUTO SWING FUNCTION ------------------------------------------------------ 60

DESCRIPTION OF MAIN CIRCUIT OPERATION ----------------------- 61

SERVICE CALL Q & A ---------------------------------------------------------- 92

TROUBLE SHOOTING ----------------------------------------------------------- 95

PARTS LIST AND DIAGRAM ------------------------------------------------- 115

RAS-60YH5/RAC-60YH5

RAC-60YH5

COOLING

HEATING

INDOOR UNIT

OUTDOOR UNIT

2,300

10.60 – 9.70

6.05 (0.90 – 6.50)

20,660

2,400

11.0 – 10.10

7.05

24,060

After installation

1 PHASE, 50 Hz, 220 – 240V

850

650

298

Summary of Contents for Summit RAC-60YH5

Page 1: ...CITY DIMENSIONS mm NET WEIGHT SPECIFICATIONS 1 030 295 191 12 RAS 60YH5 CONTENTS SPECIFICATIONS 4 HOW TO USE 6 CONSTRUCTION AND DIMENSIONAL DIAGRAM 28 MAIN PARTS COMPONENT 30 WIRING DIAGRAM 33 CIRCUIT DIAGRAM 35 PRINTED WIRING BOARD LOCATION DIAGRAM 41 BLOCK DIAGRAM 43 BASIC MODE 45 REFRIGERATING CYCLE DIAGRAM 59 AUTO SWING FUNCTION 60 DESCRIPTION OF MAIN CIRCUIT OPERATION 61 SERVICE CALL Q A 92 T...

Page 2: ...e accurately calibrated in advance 7 In installing the unit having been repaired be careful to prevent the occurence of any accident such as electrical shock leak of current or bodily injury due to the drop of any part 8 To check the insulation of the unit measure the insulation resistance between the power cord plug and grounding terminal of the unit The insulation resistance should be 1M or more...

Page 3: ... parts Even rejected goods should be handled in the same way Fig 1 Conductive Container 2 When any part is handled uncovered in counting packing and the like the handling person must always use himself as a body earth Make yourself a body earth by passing one M ohm earth resistance through a ring or bracelet 3 Be careful not to touch the parts with your clothing when you hold a part even if a body...

Page 4: ...he screwed part using a rag plate Soldering iron Grounding wire Fig 4 Grounding a soldering iron Use a high insulation mode 100V 10M or higher when ordinary iron is to be used 7 In checking circuits for maintenance inspection or some others be careful not to have the test probes of the measuring instrument shortcircuit a load circuit or the like Metal plate of aluminium stainless steel etc Staple ...

Page 5: ...nd re start in a moment there is occasion that the cooling and heating operation does not start for 3 minutes it is not abnormal and this is the result of the operation of IC delay circuit This IC delay circuit ensures that there is no danger of blowing fuse or damaging parts even if operation is restarted accidentally 5 This room air conditioner should not be used at the cooling operation when th...

Page 6: ...MER VARISTOR NOISE SUPPRESSOR THERMOSTAT REMOTE CONTROL SWITCH LIQUID CRYSTAL RAS 60YH5 PWM DC35V NO NO NO NO NO NO NO NO YES NO NO NO NO YES IC YES 40 W NO NO NO YES INTERNAL YES 3 0A G4A NO NO YES NO 450NR YES YES IC NO 1420g WITHOUT REFRIGERANT BECAUSE COUPLING IS FLARE TYPE UNIT PIPES MAX 30m REFRIGERANT CHARGING VOLUME Refrigerant R410A RAC 60YH5 JU1013D5 4 Chargeless upto 20m above 20m upto ...

Page 7: ...g pipe no matter big or small should all be insulated with insulation pipe and then wrapped with vinyl tape The insulator will deteriorate if it is not wrapped with tape The connection of insulated drain hose Please use insulated drain hose for the indoor piping commercial product The indoor piping should be insulated with the enclosed insulation pipe If the insulator is insufficient please use co...

Page 8: ...of electric shock exists Do not install the unit near a location where there is flammable gas The outdoor unit may catch fire if flammable gas leaks around it Please ensure smooth flow of water when installing the drain hose CAUTION PRECAUTIONS DURING SHIFTING OR MAINTENANCE Should abnormal situation arises like burning smell please stop operating the unit and turn off the circuit breaker Contact ...

Page 9: ...er will condense on the air deflector and drips down occasionally This will wet your furniture Therefore do not operate under such condition for a long time If the amount of heat in the room is above the cooling or heating capability of the unit for example more people entering the room using heating equipments and etc the preset room temperature cannot be achieved This appliance is not intended f...

Page 10: ...er Send out operation signal to the indoor unit So as to operate the whole unit Refer page 10 Drain pipe Condensed water drain to outside Connecting cord and insulation pipe for piping Air inlet Back and Left side Air outlet WIDTH mm 1030 850 MODEL RAS 60YH5 RAC 60YH5 HEIGHT mm 295 650 DEPTH mm 191 298 MODEL NAME AND DIMENSIONS OUTDOOR UNIT CAUTION When heating operation drain or defrosted water f...

Page 11: ... 200 hours the FILTER lamp lights to indicate that it is time to clean the filter The lamp goes out when the AUTO SWING button is pressed while the device is on STANDBY MODE OPERATION LAMP This lamp lights during operation The OPERATION LAMP flashes in the following cases during heating 1 During preheating For about 2 3 minutes after starting up 2 During defrosting Defrosting will be performed abo...

Page 12: ...PERATURE buttons Use these buttons to raise or lower the temperature setting Keep pressed and the value will change more quickly TIME button Use this button to set and check the time and date RESET buttons FUNCTION selector Use this button to select the operating mode Every time you press it the mode will change from AUTO to HEAT to DEHUMIDIFY to COOL and to FAN cyclically FAN SPEED selector This ...

Page 13: ...sary by maximum of 3 C Press the temperature button and the temperature setting will change by 1 C each time The preset temperature and the actual room temperature may vary somewhat depending on conditions The display does not indicate the preset temperature in the AUTO mode If you change the setting the indoor unit will produce a beep 1 C RESET Press the FAN SPEED button AUTO and LOW is available...

Page 14: ...t first and varies to MED or LOW automatically when the preset temperature has been reached HI Economical as the room will become warm quickly But you may feel a chill at the beginning MED Fan speed slow LOW Fan speed slower Set the desired room temperature with the TEMPERATURE buttons the display indicates the setting The temperature setting and the actual room temperature may vary somewhat depen...

Page 15: ...temperature setting The function will stop the indoor unit will stop emitting air as soon as the room temperature becomes lower than the setting temperature Set the desired room temperature with the TEMPERATURE button the display indicates the setting The range of 20 26 C is recommended as the room temperature for dehumidifying Press the START STOP button Dehumidifying operation starts with a beep...

Page 16: ...ED Fan speed slow LOW Fan speed slower Set the desired room temperature with the TEMPERATURE button the display indicates the setting The temperature setting and the actual room temperature may vary some how depending on conditions Press the START STOP button Cooling operation starts with a beep Press the button again to stop operation The cooling function does not start if the temperature setting...

Page 17: ... setting temperature is large fan starts to run at HI speed After room temperature reaches the preset temperature the cooling operation which changes the fan speed and room temperature to obtain optimum conditions for natural healthful cooling will be performed For the cooling operation FAN OPERATION You can use the device simply as an air circulator Use this function to dry the interior of the in...

Page 18: ...EL button The RESERVED sign goes out with a beep and the TIMER lamp turns off on the indoor unit 1 Set the current month and day with the TIMER control button 1 Press the OFF TIMER button The OFF mark blinks on the display 1 Press the ON TIMER button the ON mark blinks on the display 2 Set the turn off time with the TIMER control button Press the RESERVE button 3 Press the ON TIMER button so that ...

Page 19: ...ith the TIMER control button The setting of turn off time is now complete Example The device will turn off at 11 00p m Example The device will turn on at 7 00 a m The setting of the turn on time is now complete 4Set the turn on time with the TIMER control button 5 Point the signal window of the remote controller toward the indoor unit and press the RESERVE button The ON mark starts lighting instea...

Page 20: ... 2 Press the SLEEP button and set the sleep timer The device will be turned off by the sleep timer and turned on by on timer How to Cancel Reservation Point the signal window of the remote controller toward the indoor unit and press the CANCEL button The RESERVED sign goes out with a beep and the TIMER lamp turns off on the indoor unit For heating In this case the device will turn off in 2 hours a...

Page 21: ...ir deflector within the adjusting range shown on the right When the operation is stopped the horizontal air deflector moves and stops at the position where the air outlet closes When cooling dehumidifying When heating CAUTION In Cooling operation do not keep the horizontal air deflector swinging for a long time Some dew may form on the horizontal air deflector and dew may drop RESET Adjustment of ...

Page 22: ...e old batteries 2 Install the new batteries The direction of the batteries should match the marks in the case 1 Do not use new and old batteries or different kinds of batteries together 2 Take out the batteries when you do not use the remote controller for 2 or 3 months CAUTION Push and pull to the direction of arrow ...

Page 23: ...with your wake up time in the morning This will enable you to enjoy a comfortable room temperature Please use the timer effectively Dusty air filter will reduce the air volume and the cooling efficiency To prevent from wasting electric energy please clean the filter every 2 weeks Please pay attention to the room temperature and air flow direction when operating the unit for baby children and old f...

Page 24: ...e used for a long period of time please switch off the power from the mains If the power from mains remains ON the indoor unit still consumes about 8W in the operation control circuit even if it is in OFF mode Warning To protect the whole unit during lightning please stop operating the unit and remove the plug from the socket OFF Interference From Electrical Products Caution To avoid noise interfe...

Page 25: ... written FRONT is facing front After attaching the filters push the front panel at three arrow portion as shown in figure and close it Do not bend the air cleansing and deodorizing filter as it may cause damage to the structure In case of removing the air cleansing and deodorizing filters please follow the above procedures The cooling capacity is slightly weakened and the cooling speed becomes slo...

Page 26: ...gently brush it with soft bristle brush Allow filters to dry in shade Re insert the air cleansing and deodorizing filter to the filter frame Set the filter with FRONT mark facing front and slot them into the original state After attaching the filters push the front panel at three arrow portions as shown in figure and close it Do not wash with hot water at more than 40 C The filter may shrink When ...

Page 27: ... front panel with both hands to detach and attach it CAUTION Do not splash or direct water to the body of the unit when cleaning it as this may cause short circuit Never use hot water above 40 C benzine gasoline acid thinner or a brush because they will damage the plastic surface and the coating Removing the Front Panel Arm When the front panel is fully opened with both hands push the right arm to...

Page 28: ...QUALIFIED SERVICE PERSONAL EITHER EVERY HALF YEARLY OR YEARLY CONTACT YOUR SALES AGENT OR SERVICE SHOP Is the earth line disconnected or broken Is the mounting frame seriously affected by rust and is the outdoor unit tilted or unstable Is the plug of power line firmly plugged into the socket Please ensure no loose contact between them Air Blow Cleaning and maintenance must be carried out only by q...

Page 29: ...ks to it So the air filter and the evaporator regularly must be cleaned to reduce the odor Please contact your sales agent immediately if the air conditioner still fails to operate normally after the above inspections Inform your agent of the model of your unit production number date of installation Please also inform him regarding the fault Power supply shall be connected at the rated voltage oth...

Page 30: ...17 450 Drain outlet Connecting cable Power cord Hole on the wall for 65mm pipe Drain cap connection port Narrow pipe Wide pipe Drain Drain hose View from back Pipe lead out When piping is drawn horizontally exchange the drain hose for the drain cap 191 6 5 60 47 6 5 60 Front cover 47 295 Vertical deflector P Horizontal deflector Discharge grille ...

Page 31: ...uction grille 104 64 26 850 955 79 650 96 169 5 638 10 10 10 320 340 Air outlet 340 20 22 298 201 Handle Holes for anchor bolt 2 ø12 Fixing hole 507 198 57 12 37 Notch for anchor bolt 2 ø12 Notchs More than More than More than 100 More than 700 100 100 Service space ...

Page 32: ...HEAT ON 15 6 60 1 20 0 68 0 OFF 15 3 59 5 20 7 69 3 ON 23 6 74 5 28 0 82 4 OFF 23 3 73 9 28 7 83 7 ON 31 6 88 9 36 0 96 8 OFF 31 3 88 3 36 7 98 1 M RED BLK WHT YEL BLU 35V 5V 0V 0 5V FG MODEL RAS 60YH5 POWER SOURCE DC 0 35V DC360V OUTPUT 23W 40W Control circuit built in BLU BLUE YEL YELLOW BRN BROWN WHT WHITE GRY GRAY ORN ORANGE GRN GREEN RED RED BLK BLACK PNK PINK VIO VIOLET RED 360V BLK 0V WHT 1...

Page 33: ... 20 C 68 F 75 C 167 F RESISTANCE VALUE CAUTION When the refrigerating cycle has been operated for a long time with the capillary tubes clogged or crushed or with too little refrigerant check the color of the refrigerating machine oil inside the compressor If the color has been changed conspicuously replace the compressor 2M 1 05 2M 1 28 U V W M M M WHITE YELLOW RED RAC 60YH5 JU1013D5 ...

Page 34: ...N14 CN10 RED CN9 BLU CN8 WHT CN15 WHT CN13 CN11 5 5 CN12 CN12 RED GRY 2A FUSE ICP RELAY R008 R007 3A FUSE 25A FUSE C006 R001 BLK GRN WHT WHT BRN RED BLK CONNECTING CORD BRN RED BLK BLK GRN RED BLK WHT YEL BLU POWER CIRCUIT TERMINAL BOARD GRN YEL L N C D SINGLE PHASE AC220 240V 50Hz GRN YEL THERE ARE SOME LEAD WIRES WHICH HAVE SPIRAL STRIPES WITH WHITE IN ADDITION TO THE ORIGINAL COLOR CN2 RED MAIN...

Page 35: ...EG2 SEG1 SEG0 SEG43 SEG42 SEG41 SEG40 P40 P41 P42 P43 P00 P01 P02 P03 P10 P11 P12 P13 D0 D1 D2 D3 D4 D5 D6 D7 D8 D9 BEEP P20 P30 P31 NCVL C1 VL C2 VL C3 XC IN XC OUT VDD X OUT X IN RESET CARR P23 P22 P21 VSS IC 1 M3455OM6A 504FP LCD 1 C8 50v 1u K 1 D3 RB425D 1 2 K2K3 K4 K5 P10 P11 P12 K6 K7 K8 K9 K10 K11K12 K18 K17 K15 K16 K13 K14 D0 D1 D2 D3 R1 100k SW1 R2 P 100k R3 100k R4 100k R5 Q1 2SC3443 or ...

Page 36: ...CIRCUIT DIAGRAM 37 ...

Page 37: ...CIRCUIT DIAGRAM MODEL RAC 60YH5 39 ...

Page 38: ...ON DIAGRAM MAIN P W B Marking on P W B RECEIVING P W B Marking on P W B COMPONENT SIDE SOLDERING SIDE R621 LIGHT RECEIVING UNIT 2RZK81395A 7 CN11 1 C621 C622 SW2 SW1 TEMPORARY OPERATION TEMPORARY SWITCH NORMAL FILTER RESET SWITCH 11 ...

Page 39: ... thermistor Room temperature thermistor Reset circuit Initial setting circuit Temporary switch Electric Expansion valve drive circuit Electric Expansion valve Outdoor microcomputer HIC AX 8T Trip signal synthesis circuit L N SPM2 Power source 1 50Hz 220 240V Outdoor unit Terminal board Indoor microcomputer AX 7R11 ...

Page 40: ...n the ultra Lo mode other than during preseating cooling is recovered at 18 33 C Set to ultra Lo Lo or stop depending on the room temperature and time Set to stop if the room temperature is 18 C in the ultra Lo mode other than during preseating cooling is recovered at 18 33 C The fan speed is controlled by the heat exchanger temperature the overload control is executed as in the following diagram ...

Page 41: ...min 1 CMAX 6300 min 1 CMAX2 6300 min 1 CSTD 5850 min 1 CKYMAX 4550 min 1 CJKMAX 3700 min 1 CBEMAX 3000 min 1 WMIN 1200 min 1 CMIN 1500 min 1 STARTMC 60 Seconds DWNRATEW 80 DWNRATEC 80 SHIFTW 3 33 C SHIFTC 0 33 C CLMXTP 30 00 C YNEOF 28 00 C TEION 2 00 C TEIOF 9 00 C SFTDSW 1 00 C DFTIM1 45 Minutes DFTIM2 60 Minutes ...

Page 42: ...ressor maximum rpm CMAX will maintain for 60 minutes if indoor temperature is lower than CLMXTP No time constrain if indoor temperature is higher than CLMXTP 6 When fan is set to Hi compressor rpm will be limited to CKYMAX 7 When fan is set to Med compressor rpm will be limited to CJKMAX 8 When fan is set to Lo compressor rpm will be limited to CBEMAX 9 During Cool Dashed when room temperature rea...

Page 43: ...switching is made 7 The indoor fan speed does not change even when the fan speed mode is changed 8 When operation is stopped during sleep operation the set temperature when stopped as well as the time continue to be counted 9 If the set lime is changed during sleep operation all data including set temperature time etc is cleared and restarted 10 If sleep operation is canceled by the cancel key or ...

Page 44: ...he time 2 C 2 The indoor fan is operated in the Lo mode During thermo OFF indoor fan will be OFF for 5 minutes and ON for 1 minute 3 When the operation is started by the themostat turning ON the start of the indoor fan is delayed 32 seconds after the start of compressor operation 4 The compressor is operated forcedly for 3 minutes after operation is started 5 The minimum ON time and OFF time of th...

Page 45: ...ntinue in Fuzzy control mode 4 Compressor minimum ON time and OFF time is 3 minutes 5 During normal heating mode compressor maximum rpm WMAX will maintain for 120 minutes if indoor temperature is higher than 18 C No time limit constrain if indoor temperature is lower than 18 C and outdoor temperature is lower than 2 C 6 During Hotkeep or Defrost mode indoor operation lamp will blink at interval of...

Page 46: ...operation the changed operation mode is set and sleep control starts 6 The indoor fan speed does not change even when the fan speed mode is changed Lo 7 When defrosting is to be set during sleep operation defrosting is engaged and sleep operation is restored after defrosting 8 When operation is stopped during sleep operation the set temperature when stopped as well as the time continue to be count...

Page 47: ...CE VALVE 1 2 INDOOR UNIT SINGLE ENDED UNION 1 2 COMPRESSOR SINGLE ENDED UNION 1 4 SERVICE VALVE 1 4 ELECTRIC EXPANSION VALVE STRAINER STRAINER HEATING OUTDOOR UNIT REVERSING VALVE SUCTION TANK SERVICE VALVE 1 2 INDOOR UNIT SINGLE ENDED UNION 1 2 COMPRESSOR SINGLE ENDED UNION 1 4 SERVICE VALVE 1 4 ELECTRIC EXPANSION VALVE STRAINER STRAINER ...

Page 48: ...ACH MODE ONE SWING CLOSING AIR DEFLECTOR 1 DOWNWARD 2 UPWARD INITIALIZE 1 DOWNWARD INITIALIZE 1 DOWNWARD 2 UPWARD STOP AT THE MOMENT START SWINGING 1 DOWNWARD 2 UPWARD 3 DOWNWARD STOP AT THE MOMENT START SWINGING 1 DOWNWARD 2 UPWARD 3 DOWNWARD STOP AT THE MOMENT ONE SWING CLOSING AIR DEFLECTOR 1 DOWNWARD 2 UPWARD INITIALIZE AT NEXT OPERATION INITIALIZE AT NEXT OPERATION STOP DURING ONE SWING STOP ...

Page 49: ...t this time the microcomputer starts operation When power OFF voltage drops and reaches 4 2V pin 1 of IC521 is set to Low This will RESET the microcomputer DESCRIPTION OF MAIN CIRCUIT OPERATION 1 Reset Circuit Fig 1 1 Fig 1 2 2 1 5 3 7 NORMAL HI RESET LO RES Microcomputer C524 R521 C522 C521 R522 5V 0V IC521 Voltage 5 0V Reset enter at 4 2V Reset release at 4 4V voltage 5 0V Voltage at pin 7 of mi...

Page 50: ... 3 2 Buzzer Operation Microcomputer Buzzer output BZ1 12V 0V R219 Q722 30 BZ When the buzzer sounds an approx 3 9kHz square signal is output from buzzer output pin of the microcomputer After the amplitude of this signal has been set to 12Vp p by a transistor it is applied to the buzzer The piezoelectric element in the buzzer oscillates to generate the buzzer s sound 12V R201 R1 0V 0V 13 RECEIVER I...

Page 51: ...he rotor Table 4 1 shows the rotation angle of horizontal air deflectors Table 4 1 Auto sweep Motor Rotation Rotation angle per step Time per step ms 0 0882 10 Horizontal air deflectors Microcomputer pins Step width Horizontal air deflectors 10ms Horizontal air deflectors 15 16 17 18 1 2 3 4 5 6 7 8 Fig 4 2 Microcomputer Output Signals 10 11 8 9 12 0V 7 6 5 4 18 17 16 Microcomputer IC711 C711 12V ...

Page 52: ...erature input R302 A 5 4 3 2 1 0 0 10 10 Heat exchanger temperature C Fig 6 2 20 30 40 Voltage at V A 6 Heat exchanger temperature thermistor circuit The voltage at depends on the room temperature as shown in Fig 5 2 The circuit detects the indoor heat exchanger temperature and controls the following 1 Preheating 2 Low temperature defrosting during cooling and dehumidifying operation 3 Detection o...

Page 53: ...eheating activation value and the rating and maximum speed of the compressor etc to their initial values Data of self diagnosis mode is stored in IC401 or IC402 data will not be erased even when power is turned off Fig 7 1 Microcomputer External ROM SCL SDA 0V 0V 0V 5V 5V 5V C401 IC401 or IC402 E2 PROM R404 R403 27 26 1 2 3 4 8 7 6 5 ...

Page 54: ...te In case of active module faulty or defective connection Although the compressor continues to operate normally the power factor will decrease the operation current will increase and the overcurrent breaker of the household power board will probably activate Reference If diode stack 1 is faulty the compressor may stop due to lp anbormally low speed etc immediately after it starts or it may not op...

Page 55: ...ering from power line to protect electronic parts 6 Surge absorber Varistor 1 2 3 absorbs external power surge 7 Inrush protective resistor R007 R008 This works to protect from overcurrent when power is turned on Reference When inrush protective resistor is defective diode stack may malfunction As a result DC voltage is not generated and no operation can be done Be careful to avoid an electric sho...

Page 56: ...ed by amp This signal is superimposed to DC 35V line via C801 and L801 To prevent erroneous reception the outdoor microcomputer is designed so that it cannot receive a signal while it is outputting a request signal The receiving circuit in the indoor unit consists of a comparator and transistor The interface signal from the outdoor unit on the DC 35V line is supplied to C821 where DC components ar...

Page 57: ...eceive input SDI MICROCOMPUTER 5V 0V 5V 5V 12V 5V 5V 5V 5V 5V 5V C802 R813 L801 R812 Q803 C803 C804 R811 Q802 Q801 R824 3 2 1 R822 R806 R807 R805 R803 R804 5 7 6 IC801 R810 50 49 IF transmit output SDO HIC IF receive input SDI MICROCOMPUTER 11 30 68 29 0V L801 L802 C801 C809 R802 Q801 5V 0V R801 R803 0V 0V 0V 0V 0V 0V 0V 0V C808 NF COIL2 C810 C802 C806 C807 C812 C811 Interface relay 35V Communicat...

Page 58: ...Indoor microcomputer 4 95ms Transmit receive switching time 33ms 1 frame Outdoor HIC 30 Pin 0V 29 Pin 5V 0V 50 Pin 5V 0V 49 Pin 5V 0V DC 35V line 35V Fig 2 2 Voltages Waveforms of indoor Outdoor Microcomputers Outdoor to Indoor Communications Fig 2 3 Voltages Waveforms of indoor Outdoor Microcomputers Indoor to Outdoor Communications ...

Page 59: ... 33 3ms x 8 4 95ms 371 35ms Outdoor message Indoor message Example When the outdoor message is all 0s and indoor message is all 1s 36 V 35 V 34 V When reset approx 10ms Transmit receive switching time 4 95ms Character No 0 33 3ms 1 33 3ms 2 33 3ms 3 33 3ms Character No 0 33 3ms 1 33 3ms 2 33 3ms 3 33 3ms Bit No 0 Bit No 0 0 7 0 7 0 7 0 7 7 0 7 0 7 7 Leader 100ms When reset approx 10ms Leader 100ms...

Page 60: ... minimum rotation speed 3 Compressor minimum rotation speed 2 Compressor minimum rotation speed 1 Compressor minimum rotation speed 0 LSB 7 0 6 0 5 0 4 0 3 0 2 0 1 1 0 0 7 1 0 6 1 0 5 1 0 4 1 0 3 2 1 0 7 6 5 4 3 2 1 0 7 6 5 4 1 0 3 1 0 2 1 0 1 0 0 1 0 Character No Bit No Data 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 Fan 7 step request Actual compressor rotation speed 5 MSB Actua...

Page 61: ... the upper arm and the three transistors on the negative d side the lower arm W U V W W V V U U A DC Compressor motor U coil V coil W coil System Power module 2 C501 C502 C503 R24 0 35 m H Power relay Coil R007 R008 Inrush current protection relay C006 R001 Noise filter coil L N Terminal board FUSE 25A Fig 3 1 Power module circuit U is ON V is ON ...

Page 62: ...proportional to duty ratio ON time ON time OFF time of this chopper signal Time T in Fig 3 2 shows the switching period and relation with rotation speed N of the compressor is shown by formula below Fig 3 2 Switching order of power module N 60 2 X 1 T Fig 3 3 shows voltage waveform at each point shown in Figs 3 1 and 3 4 First half of upper arm is chopper second half is ON and first half of lower ...

Page 63: ...f power module Lighting mode when operated with compressor leads disconnected 1 Disconnect connector of 3 pole WHT YEL RED lead wire connecting to compressor located at the lower part of electric parts box 2 Set to compressor operation state other than FAN mode and press Start stop switch of remote control 3 If normal operation continues for more than 1 minute LD303 lights power module is consider...

Page 64: ...12 R919 R925 R924 ZD904 C909 15 1 2 JW8 JW8 4 3 In the power circuit for P W B power supply for microcomputer peripheral circuits and system power module driver circuit and as well as DC 35V are produced by switching power circuit Switching power circuit performs voltage conversion effectively by switching transistor IC901 to convert DC 330V voltage to high frequency of about 20kHz to 200kHz Trans...

Page 65: ...ing to IC901 Reference If the power circuit for P W B seems to be faulty 1 Make sure that 5V and 12V on the control P W B upper arm U V and W and the lower arm power voltage are the specified values 2 When only the 5V output is low REG 1 regulator faulty 5V 0V shorted output is too high or REG 1 is abnormal 3 When 12V and 5V are abnormal The following defects can be considered 1 Fan operation powe...

Page 66: ...tester When collector voltage of Q701 is measured 3 1 16 24 I F 0V 0V Fig 5 1 D702 CN2 Q701 DC voltmeter or tester Reversing valve R701 R703 R219 Q705 FUSE RESISTOR MICROCOMPUTER PQ701 1 2 3 4 5V HIC I F 35V R702 V Operation condition Collector voltage of Q701 Cooling Heating Dehumidifying General operation of Cooling In normal heating operation MAX rotation speed instructed by indoor microcompute...

Page 67: ...ignal B reference voltage 1 2Vd Detection point W W U U U V V W V To detect U phase voltage at point C is produced by driving motor induced voltage signal voltage at point A and 1 2 voltage of Vd voltage at point B and comparing with comparator For V phase and W phase voltage at point D and voltage at point E are produced in the same way as above Voltage at point C is taken into indoor unit microc...

Page 68: ...put from microcomputer is input to IC1 and is inverted by active Lo to become 0 15V drive signal it is then drive the transistor of each phase Fig 7 1 6 5 4 3 2 1 MICROCOMPUTER A R512 R521 R511 R510 R509 R508 R507 10 9 4 3 2 1 8 7 6 5 1 13 14 15 16 17 18 1 23 11 8 7 5 4 10 6 3 9 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 19 20 21 2 3 4 5 6 7 8 9 10 12 22 B B B 45 44 4...

Page 69: ... U Drive signal at point B Drive signal at point A V U W V U V W U V W Low speed rotation mode High speed rotation mode V U W V U U V 5V 0V W V V W U U V 15V 0V W V W U W U V W Drive signal at point B Drive signal at point A Fig 7 2 Fig 7 3 ...

Page 70: ...hen set value exceeds input voltage Voltage amplifies DC current level detected by the detection resistor and inputs this to microcomputer Internal or external overload is judged in microcomputer Produces reset voltage Modulates chopper signal to drive signal and stops according to presence ab sence of lp signal or reset signal 59 17 61 48 58 62 60 Is D104 L CT1 N R005 0V 0V 0V 0V R221 C218 12V R2...

Page 71: ... 0V 0V R43 0V R41 QC R42 SPM2 SPM2 HIC Main P W B HIC IC1 CN14 IP Outdoor microcomputer F R43 9 9 8 20 9 2 39 17 B The Ip cut off circuit detects an instantaneous excessive current and stops inverter to protect parts such as SPM2 etc As shown in diagram if current exceeding 27A flows voltage at point recognized by detecting resistor is input to pin of SPM2 HIC and voltage divided by R41 and R43 is...

Page 72: ... speed internal judgement value OVL judgement with respect to externally set value A D converter A D converter Judgement OVL according to the rotation speed Selects data according to the rotation speed and DC voltage OVL start current data Rotation speed data Motor control process Microcomputer Detection resistor Fig 8 4 Overload Control System Configuration Fig 8 5 DC current Rotation speed 1 Ove...

Page 73: ...d to a voltage and supplies it to the microcomputer Receiving this the microcomputer converts it to a digital signal and compares it with the internal data to judge whether or not overload control is required During overload control The filter consisting of R245 and C217 removes high harmonic components from the voltage generated from the DC current flowing to the detection resistor and supplies i...

Page 74: ...when the supply voltage varies This control method copes with variations in the voltages as follows 1 Turns on the power module s U and V transistors so the current flows to the motor windings as shown in Fig8 9 2 Varies the turn ON time of the W transistor according to the DC voltage level and the start is controlled so the start current is approx 10A as shown in Fig 8 10 Fig 8 8 DC current G 0 0...

Page 75: ... defrosting condition command to the indoor microcomputer via the circuit interface The microcomputer always reads the outdoor temperature via a thermistor microcomputer pin 64 and transfers it to the indoor unit thus controlling the compressor rotation speed according to the value set at the EEPROM in the indoor unit and switching the operation status outdoor fan on off etc in the dry mode The fo...

Page 76: ...and 5V line voltages rise and 12V line voltage reaches 10 9V and reset voltage input to pin 48 of microcomputer is set to Hi Reset voltage will be hold Hi until the 12V line voltage drops to 9 90V even though the power shuts down Microcomputer R252 R289 0V 0V R288 0V 5V 12V HIC R284 JW10 IC5 1 2 C204 48 RESET Main P W B Fig 10 1 C215 R286 C225 C107 C226 R285 0V 1 3 2 62 8 0V 0V R292 12V line 12V l...

Page 77: ...top Motor will output FG pulse by following this motor revolution Outdoor Microprocessor will output PWM control signal from FMCHOP terminal by following the instruction from indoor Microprocessor This PWM control signal will convert to Vsp voltage by smoothing circuit Q101 RC filter Fan motor will start to rotate when Vsp was proceeding over than 1 7V and generate FG pulse by rotation speed FG pu...

Page 78: ...wing inside of outdoor unit by snowing It may make Fan Lock Stop by strong wind ex 17m sec or above against the Fan rotation In this case unit will be restart again after a while In case of Fan Lock Stop even though the DC Fan Motor is rotating correctly the possible casue is Fan Motor problem or PQ102 on board or control board problem Stop after the Fan motor runs 2 minutes Fan Motor may be broke...

Page 79: ...ut voltage 12 Power Factor Control Circuit Assuming the same current capacity 20A power can be used about 10 effective comparing with curent use power factor of 90 and maximum capacity is thereby improved I input current V input voltage Invalid power area Even if voltage is applied current does not flow Effective voltage area input voltage input current Effective voltage area ...

Page 80: ...ntil it is defrosted If the air conditioner operates in cooling mode when it is cold the evaporator may get frosted Normal sound when refrigerant flows in pipe Compressor may not operate when room temperature is 10 C or less It also stops when the humidity is preset humidity or less It occurs during defrost ing Wait for 5 10 minutes until the condenser is defrosted At the beginning of heating the ...

Page 81: ...y before stopping operation At this point fan speed is automatic This is because Nice temperature reservation function is operating This function starts operation earlier so the preset temperature is reached at the preset time Operation may start maximum 60 minutes before the preset time It does not work It works only during cooling and heating This is because Nice temperature reservation function...

Page 82: ...ling capability so noise becomes slightly louder This does not indicate a fault Noise from the outdoor unit occasionally changes The compressor rotation speed changes according to the difference between the thermostat set temperature and room temperature This does not indicate a fault There is a difference between the set temperature and room temperature There may be a difference between the set t...

Page 83: ...note that it takes about 10 minutes until the voltage fall after the power switch is turned off DANGER Across a b 0V line Across a ground Across b 0V line ground approx 260 360V approx 155 170V approx 155 170V When using an oscilloscope never ground it Don t forget that high voltages as noted above may apply to the oscilloscope DANGER Always keep your hands and metallic things away from the enclos...

Page 84: ...part of circuit in indoor unit electrical parts disconnect red gray lead wire connected from diode stack to system power module SPM2 to prevent secondary trouble Be sure to discharge smoothing capacitor Do not use a soldering iron with transformer If one is used thermal fuse inside transformer will be blown DISCHARGE PROCEDURE AND POWER SHUT OFF METHOD FOR POWER CIRCUIT WARNING As shown above appl...

Page 85: ...mal No No Timer lamp Press the service switch for 1 sec Does the compressor operate After checking be sure to press the service switch to stop the operation Check the refrigerating cycle Check the outdoor electrical parts Check the indoor electrical parts Check to see whether the F cable is connected incorrectly or disconnected See Out door unit self diagnosis lamp lighting mode See Troubleshootin...

Page 86: ...eading error When data read from IC401 or IC402 is incorrect 1 Reversing valve defective 2 Heat exchanger thermistor dis connected only in the heating mode Note The malfunction mode is entered the 3rd time this abnormal indication appears read every 3 minutes Electrical parts in the outdoor unit 1 Indoor interface circuit 2 Outdoor interface circuit Please check at the outdoor electrical led lamp ...

Page 87: ... 99 SELF DIAGNOSIS LIGHTING MODE ...

Page 88: ...g generated between terminals C and D on the terminal board Are control voltages 12V 5V being generated normally Check according to the proper method for checking the power circuit No No No No Yes Yes Do the air deflectors perform initial operation when the power supply is turned on and off Check the indication P W B connection cord and light receiving unit No No Is the microcomputer reset input p...

Page 89: ... 101 2 Outdoor unit does not operate but receives remote infrared signal ...

Page 90: ...nly indoor fan does not operate other is normal 4 Air deflector does not move others are normal 5 All systems stop from several seconds to several minutes after operation is started all indicators are also off ...

Page 91: ... 103 6 Check the main P W B power circuit ...

Page 92: ... 104 CHECKING THE REMOTE CONTROLLER ...

Page 93: ...cription on power circuit for details Is 5V being generated between Pin 4 0V and pin 3 5V at CN 18 test pin Operate the outdoor unit according to the instruction How to operate the outdoor unit independently How did the self diagnosis lamp LD301 light Is the switching power circuit OK Has the 3A fuse blown See the self diagnosis lamp lighting mode Check to see whether the connected C and D cable c...

Page 94: ...g supplied across the control side coil terminal of interface relay Is a voltage at least 10V being generated between the contact terminals of interface relay Check the interface curcuit Yes Yes No No Yes D907 and C910 may be defective There is a defective section between the 12V output of switching power supply on the main P W B and interface relay also check for contact with solder etc Repalce t...

Page 95: ...be forgetting to connect after servicing Is the continuity of thermistor normal Is the thermistor circuit normal Replace the power module Replace any defective parts Connect the thermistor Replace the thermistor Replace parts in the thermistor circuit Check continuity of pattern and lead wires according to the P W B and schematic diagrams Check continuity of pattern and lead wires according to the...

Page 96: ...rcuit No No No Check continuity of new parts Check continuity of pattern and lead wires according to the P W B and schematic diagrams Yes Yes Replace system power module or defective parts Replace the system power module Replace any defective parts Is the thermistor circuit normal Are R503 and peripheral circuits of system power module normal Replace the main P W B Is the system power module norma...

Page 97: ... 109 ...

Page 98: ...L lamp lit If the lamp is lit it does not indicate fault but the unit is overload status Recheck cord etc of the system power module If they are disconnected connect them securely If abnormality continues replace the system power module Overvoltage defect system power module faulty 15 times blinking Yes No ...

Page 99: ...n the same condition as above The compressor is defective Replace it and seal refrigerant If the compressor checker for an inverter type air conditioner is available re check using it JUDGING BETWEEN GAS LEAKAGE AND COMPRESSOR DEFECTIVE Blinking off Time until the lamp lights Approx 10 seconds Approx 10 seconds Approx 10 seconds Within Approx 30 seconds Compressor Compressor Gas leakage Possible m...

Page 100: ...e of digital tester since built in battery is set in reverse direction and terminals are reversed CAUTION If inner circuit of system power module is disconnected open the indicator of tester will not swing and this may assumed as normal In this case if indicator swings when and terminals are connected in reverse of diagram below it is normal Furthermore compare how indicator swings at U V and W ph...

Page 101: ...atus Be sure to push the service switch again to stop the forced cool operation HOW TO OPERATE THE OUTDOOR UNIT INDEPENDENTLY The operation method is the same as How to operate using the connector to servicing the outdoor unit 1 The charging amount of 300g is equivalent to the load in normal operation Charge refrigerant of 300g after vacuuming 1 Do not operate for more than 5 minutes Parts to be p...

Page 102: ...E Collector Emitter PGU PGV PGW NGU NGV NGW U V W P1 P2 U N1 L2 L1 W V Circuit diagram of the device excepting the reflux diode Circuit diagram of the module Terminals symbol mark of the module See next page for measuring value using tester ...

Page 103: ... 115 PARTS LIST AND DIAGRAM INDOOR UNIT MODEL RAS 60YH5 2 1 9 7 8 6 19 20 3 11 4 5 10 13 15 14 17 16 12 22 26 18 27 ...

Page 104: ...NHA 006 1 DRAIN PAN ASSY 11 PMRAK 60NHA 009 1 AUTO SWEEP MOTOR 12 PMRAS 18CH1 001 1 P W B LED 13 PMRAS 60YH5 001 1 FRONT COVER ASSEMBLY 14 PMRAS 60YH5 002 1 FRONT PANEL 15 PMRAS 10C7M 008 3 CAP 16 PMRAS 51CHA1 010 2 AIR FILTER 17 PMRAS 51CHA1 011 1 REMOTE CONTROL ASSEMBLY 18 PMRAS 10C3M 003 1 REMOTE CONTROL SUPPORT 19 PMRAS 40CNH2 026 1 THERMISTOR SUPPORT 20 PMRAS 07CH2 012 1 THERMISTOR 22 PMRAS S...

Page 105: ... 117 8 9 33 4 32 14 3 27 24 35 26 13 7 5 17 30 29 23 20 16 36 28 31 34 11 12 10 15 6 2 38 22 PARTS LIST AND DIAGRAM OUTDOOR UNIT MODEL RAC 60YH5 ...

Page 106: ...PMRAC 18SH4 901 1 REACTOR 17 PMRAC S24H2 1 P W B MAIN 20 PMRAC 40CNH2 901 1 SYSTEM POWER MODULE 22 PMRAC 51CHA1 903 2 TERMINAL BOARD 4P 23 PMRAC 19SH4 901 1 THERMISTOR OUTSIDE TEMPERATURE 24 PMRAC 40CNH2 917 1 PROPELLER FAN 26 PMRAC 40CNH2 918 1 SUPPORT FAN MOTOR 27 PMRAC 40CNH2 919 1 FAN MOTOR 40W 28 PMRAC 40CNH2 904 1 CABINET 29 PMRAC 40CNH2 921 1 NET 30 PMRAC 40CNH2 922 1 TOP COVER 31 PMRAC 60Y...

Page 107: ...HITACHI PM NO 0299E Printed in Malaysia RAS 60YH5 RAC 60YH5 ...

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