Mitsubishi Electric PUHY-HP120TNU-A Page 207 Service Handbook Download | Manualshive

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[8-3 Refrigerant Control Problems ]

10

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chapter 8

HWE18240_GB

8 Troubleshooting Based on Observed Symptoms

8-3

Refrigerant Control Problems

8-3-1

Units in the Cooling Mode Do Not Operate at Expected Capacity.

1. Phenomena

Although cooling operation starts with the normal remote controller display, the capacity is not enough

2. Cause, check method and remedy

Cause

Check method and remedy

1.

Compressor frequency does not rise sufficiently.

Faulty detection of pressure sensor.

Protection works and compressor frequency does

not rise due to high discharge temperature

Protection works and compressor frequency does

not rise due to high pressure

Pressure drops excessively.

(1)

Check pressure difference between the detected
pressure by the pressure sensor and the actual pres-
sure with self-diagnosis LED.

ĺ

If the accurate pressure is not detected, check the

pressure sensor.
Refer to the following page(s). [8-5-1 Comparing the
High-Pressure Sensor Measurement and Gauge
Pressure]

Note:

Lower inlet pressure by the low pressure sensor than
the actual pressure causes insufficient capacity.
SW4 setting (SW6-10: OFF)

(2)

Check temperature difference between the evaporat-
ing temperature (Te) and the target evaporating tem-
perature (Tem) with self-diagnosis LED.

Note:

Higher Te than Tem causes insufficient capacity.
SW4 setting (SW6-10: OFF)

Note:

Protection works and compressor frequency does not
rise even at higher Te than Tem due to high discharge
temperature and high pressure.
At high discharge temperature:
Refer to the following page(s). [7-3-1 Error Code
[1102]]
At high pressure:
Refer to the following page(s). [7-3-3 Error Code
[1302] (during operation)]

2.

Indoor unit LEV malfunction

Refer to the following page(s). [8-8 Troubleshooting
LEV Problems]

Insufficient refrigerant flows due to LEV malfunc-

tion (not enough opening) or protection works and
compressor frequency does not rise due to pres-
sure drop.

Refrigerant leak from LEV on the stopping unit

causes refrigerant shortage on the running unit.

High pressure sensor

Low pressure sensor

SW4

SW4

ON

1

2

3

4

5

6

7

8

9

10

ON

1

2

3

4

5

6

7

8

9

10

Evaporating temperature Te

Target evaporating temperature Tem

SW4

SW4

ON

1

2

3

4

5

6

7

8

9

10

ON

1

2

3

4

5

6

7

8

9

10

ON

1

2

3

4

5

6

7

8

9

10

The figure at left shows that the switches 1 through 5 are set to ON and 6 through 10 are set to OFF.

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Summary of Contents for PUHY-HP120TNU-A

Page 1: ......

Page 2: ...he performance of the unit or cause certain components of the unit to corrode which can result in refrigerant leakage wa ter leakage injury electric shock malfunc tions smoke or fire Do not try to defeat the safety features of the unit or make unauthorized setting changes Forcing the unit to operate the unit by de feating the safety features of the devices such as the pressure switch or the temper...

Page 3: ...g To reduce the risk of injury electric shock and malfunctions do not touch or allow ca bles to come in contact with the edges of components To reduce the risk of injury do not touch the heat exchanger fins or sharp edges of com ponents with bare hands Always wear protective gears when touch ing electrical components on the unit Sev eral minutes after the power is switched off residual voltage may...

Page 4: ... installed by the dealer or qualified personnel Only use the parts specified by Mitsubishi Electric Installation by unauthorized personnel or use of unauthorized parts or accessories may result in water leakage electric shock or fire Take appropriate safety measures against wind gusts and earthquakes to prevent the unit from toppling over and causing injury To reduce the risk of injury from units ...

Page 5: ...o condensation properly insulate the pipes Wiring Work To reduce the risk of wire breakage over heating smoke and fire keep undue force from being applied to the wires To reduce the risk of wire breakage over heating smoke or fire properly secure the cables in place and provide adequate slack in the cables so as not to stress the termi nals All electric work must be performed by a qualified electr...

Page 6: ...rter high frequency medical or wireless com munication equipment as well as power generators may cause the air conditioning system to malfunction Air conditioning system may also adversely affect the opera tion of these types of equipment by creating electrical noise To reduce the risk of damage to the unit leave the valves on the unit closed until re frigerant charging is completed Place a wet to...

Page 7: ...o not use the existing refrigerant piping A large amount of chloride that is contained in the residual refrigerant and refrigerant oil in the existing piping may cause the refriger ant oil in the new unit to deteriorate or dam age the compressor Charge refrigerant in the liquid state If re frigerant is charged in the gas phase the composition of the refrigerant in the cylin der will change comprom...

Page 8: ...f Outdoor Unit 4 3 4 Functions of the Major Components of Indoor Unit 7 Chapter 4 Electrical Components and Wiring Diagrams 4 1 Outdoor Unit Circuit Board Arrangement 1 4 2 Outdoor Unit Circuit Board Components 4 4 3 Outdoor Unit Electrical Wiring Diagrams 14 4 4 Transmission Booster Electrical Wiring Diagrams 16 Chapter 5 Control 5 1 Dipswitch Functions and Factory Settings 1 5 2 Outdoor Unit Con...

Page 9: ...utdoor Unit Fan Problems 24 8 8 Troubleshooting LEV Problems 25 8 9 Troubleshooting Inverter Problems 31 8 10 Control Circuit 44 8 11 Measures for Refrigerant Leakage 50 8 12 Parts Replacement Instructions 52 8 13 Troubleshooting Problems Using the LED Status Indicators on the Outdoor Unit 79 Chapter 9 USB Function 9 1 Service Overview 1 9 2 Operation Data Collection and Storage Functions 4 9 3 So...

Page 10: ... Oil 3 1 2 1 Piping Materials 3 1 2 2 Storage of Piping Materials 4 1 2 3 Pipe Processing 4 1 2 4 Characteristics of the New and Conventional Refrigerants 5 1 2 5 Refrigerant Oil 6 1 3 Working with Refrigerant Piping 7 1 3 1 Pipe Brazing 7 1 3 2 Air Tightness Test 8 1 3 3 Vacuum Drying 9 1 3 4 Refrigerant Charging 10 1 4 Precautions for Wiring 11 1 5 Cautionary notes on installation environment an...

Page 11: ...HWE18240_GB ...

Page 12: ...d or replaced Use refrigerant pipes made of phosphorus deoxidized copper Keep the inner and outer surfaces of the pipes clean and free of such contaminants as sulfur oxides dust dirt shaving particles oil and water These types of contaminants inside the refrigerant pipes may cause the refrigerant oil to deteriorate 6 If there is a leak of gaseous refrigerant and the remaining refrigerant is expose...

Page 13: ...ging The refrigerant type is indicated The cylinder is pink Charging Port on the Refrigerant Cylinder Refrigerant charging The charge port diameter is larger than that of the current port Flare Nut Connection of the unit with the pipes Use Type 2 Flare nuts Tools Materials Use Notes Gas Leak Detector Gas leak detection The ones for use with HFC refrigerant may be used Vacuum Pump Vacuum drying May...

Page 14: ...ss Select piping materials that meet the requirements set forth in ASTM B280 4 Thickness and refrigerant type indicated on the piping materials Ask the pipe manufacturer for the symbols indicated on the piping material for new refrigerant R410A 5 Flare processing Select piping materials that meet the requirements set forth in ASTM 6 Flare nut Select piping materials that meet the requirements set ...

Page 15: ...lbow pipes and T joints in plastic bags The new refrigerator oil is 10 times as hygroscopic as the conventional refrigerating machine oil such as Suniso and if not handled with care could easily introduce moisture into the system Keep moisture out of the pipes for it will cause the oil to deteriorate and cause a compressor failure 1 2 3 Pipe Processing Use a small amount of ester oil ether oil or ...

Page 16: ... out it may be replenished 3 Pressure characteristics The pressure in the system using R410A is 1 6 times as great as that in the system using R22 New Refrigerant HFC type Conventional Refriger ant HCFC type R410A R407C R22 R32 R125 R32 R125 R134a R22 Composition wt 50 50 23 25 52 100 Type of Refrigerant Pseudo azeotropic Refrigerant Non azeotropic Refrigerant Single Refrigerant Chloride Not inclu...

Page 17: ...Refrigerating machine oil R22 Mineral oil R407C Ester oil R410A Ester oil 1 Contaminants is defined as moisture air processing oil dust dirt wrong types of refrigerant and refrigerating machine oil Cause Symptoms Effects on the refrigerant cycle Water infiltration Frozen expansion valve and capillary tubes Clogged expansion valve and capillary tubes Poor cooling performance Compressor overheat Mot...

Page 18: ...BCuP 3 that requires no flux when brazing between copper pipes or between a copper pipe and copper coupling If installed refrigerant pipes are not immediately connected to the equipment then braze and seal both ends 2 Reasons The new refrigerating machine oil is 10 times as hygroscopic as the conventional oil and is more likely to cause unit failure if water infiltrates into the system Flux genera...

Page 19: ...ature variations into account Refrigerant R410A must be charged in its liquid state vs gaseous state 2 Reasons Oxygen if used for an air tightness test poses a risk of explosion Only use nitrogen to check air tightness Refrigerant R410A must be charged in its liquid state If gaseous refrigerant in the cylinder is drawn out first the composition of the remaining refrigerant in the cylinder will cha...

Page 20: ...section 6 Special vacuum drying 5 Procedures for stopping vacuum pump To prevent the reverse flow of vacuum pump oil open the relief valve on the vacuum pump side or draw in air by loosening the charge hose and then stop the operation The same procedures should be followed when stopping a vacuum pump with a reverse flow check valve 6 Special vacuum drying When 5Torr 650Pa or lower degree of vacuum...

Page 21: ... of the remaining refrigerant will change and be come unsuitable for use 2 Notes When using a cylinder with a siphon refrigerant is charged in the liquid state without the need for turning it upside down Check the type of the cylinder on the label before use If the refrigerant leaks out it may be replenished The entire refrigerant does not need to be replaced Charge refrigerant in the liquid state...

Page 22: ... stopped It is energized to evaporate the liquid refrigerant that has accumulated in the compressor Before connecting wiring to TB7 check that the voltage has dropped below 20 VDC When a system controller is connected to the centralized control transmission cable to which power is supplied from the out door unit power jumper on the outdoor unit is connected to CN40 be aware that power can be suppl...

Page 23: ...fter tightening the screw mark a line through the screw head washer and terminals with a permanent marker Example Poor contact caused by loose screws may result in overheating and fire Continued use of the damaged circuit board may cause overheating and fire Daisy chain Power supply terminal block indoor outdoor transmission line terminal block and centralized controller transmission line Mark a l...

Page 24: ...ze and minimize the exposure to salt water mist 2 Avoid installing a sun shade over the outdoor unit so that rain will wash away salt deposits off the unit 3 Install the unit horizontally to ensure proper water drainage from the base of the unit Accumulation of water in the base of the outdoor unit will significantly accelerate corrosion 4 Periodically wash salt deposits off the unit especially wh...

Page 25: ... 1 5 Cautionary notes on installation environment and maintenance 14 chapter 1 HWE18240_GB 1 Check Before Servicing ...

Page 26: ...2 7 1 Single Refrigerant System Automatic Indoor Outdoor Address Startup 12 2 7 2 Single Refrigerant System with Two or More LOSSNAY Units 14 2 7 3 Grouped Operation of Units in Separate Refrigerant Circuits 16 2 7 4 System with a Connection of System Controller to Centralized Control Transmission Line 18 2 7 5 System with a Connection of System Controller to Indoor Outdoor Transmission Line 20 2 ...

Page 27: ...HWE18240_GB ...

Page 28: ... exceeds the capacity of the outdoor unit the indoor units will not be able to perform at the rated capacity when they are operated simultaneously Select a combination of units so that the total capacity of the connected indoor units is at or below the capacity of the outdoor unit whenever possible Outdoor units Composing units Maximum total capacity of con nectable indoor units Maximum number of ...

Page 29: ...zed into 2 types transmission line and remote controller line Use the appropriate type of cables and observe the maximum allowable length specified for a given system If a given system has a long transmission line or if a noise source is located near the unit place the unit away from the noise source to reduce noise interference 1 M NET transmission line Cable type Facility type All facility types...

Page 30: ...utdoor units in the same refrigerant circuit are automatically designated as OC OS1 and OS2 in the order of capacity from large to small if two or more units have the same capacity in the order of address from small to large 3 Turn off the power to all the outdoor units in the same refrigerant circuit 4 When setting the switch SW4 of the control board set it with the outdoor unit power on Refer to...

Page 31: ...ntrol in terface Free Plan adapt er LOSSNAY OA processing unit Air handling kit 00 01 to 50 1 6 Assign an arbitrary but unique address to each of these units after assigning an address to all indoor units 00 ATW Water Hex Unit ME remote con troller Main remote controller 101 to 150 Add 100 to the smallest address of all the indoor units in the same group 101 Sub remote controller 151 to 200 2 Add ...

Page 32: ...t in sensor on the remote controller install the remote controller where room temperature can be detected Note Factory setting for SW1 1 on the indoor unit of the All Fresh Models is ON 2 When an optional temperature sensor is used set SW1 1 to OFF and set SW3 8 to ON When using an optional temperature sensor install it where room temperature can be detected System configu ration Connection to the...

Page 33: ...h the PLC software for general equipment via the AE 200 AG 150A GB 50ADA or G B 50A set SW1 9 and SW1 10 to ON With these settings made the power start stop function becomes disabled To use the auto recovery function after power failure while these settings are made set SW1 5 to ON 2 4 6 Miscellaneous Settings Cooling only setting for the indoor unit Cooling only model Factory setting SW3 1 OFF Wh...

Page 34: ...base heater change the setting using SW4 When using a base heater error output will not be available 2 Example of wiring connection CAUTION 1 Wiring should be covered by insulation tube with supplementary insulation 2 Use relays or switches with IEC or equivalent standard 3 The electric strength between accessible parts and control circuit should have 2750V or more Type Usage Function Terminal to ...

Page 35: ... at DC X Cooling Heating Y Validity Invalidity of X X Y Relay CN3N X Y Relay circuit Outdoor unit control board Maximum cable length is 10m 1 2 3 2 External input adapter 2 External input adapter 4 CN3D 2 Optional part PAC SC36NA E or field supply X Low noise mode X Low noise mode Y Compressor ON OFF X Y Relay Contact rating voltage DC15V Contact rating current 0 1A Minimum appicable load 1mA at D...

Page 36: ...ecessarily correspond with the actual capacity 5 Notes on using demand control in combination with the low noise mode To enable the low noise mode it is necessary to short circuit 1 2 pin of CN3D on the outdoor unit whose SW6 8 is set to OFF When SW6 8 is set to ON on all outdoor units the following operations cannot be performed Performing 4 step demand in combination with the low noise operation...

Page 37: ...Short circuit Open 100 No DEMAND 75 Short circuit 0 Compressor OFF 50 8 levels of on DEMAND No 2 CN3D 1 2P Open Short circuit No 1 CN3D 1 2P 1 3P Open Short circuit Open Short circuit Open Open 100 50 88 75 Short circuit 50 0 38 25 Short circuit Open 88 38 75 63 Short circuit 75 25 63 50 If the step listed as the wrong example above is taken thermo may go off The percentage of the demand listed in...

Page 38: ...al address setup Connection of multiple LOSS NAY units 3 Grouping of units in a system with multiple outdoor units NO Manual address setup 4 System with one out door unit With connection to transmission line for centralized control Manual address setup 5 System with one out door unit With connection to indoor outdoor transmission line Manual address setup System configuration Connection to the sys...

Page 39: ...ecting two or more LOSSNAY units to a system refer to the following page s 2 7 2 Single Refrigerant System with Two or More LOSSNAY Units 3 Maximum allowable length 1 Indoor outdoor transmission line Maximum distance 1 25mm2 AWG16 or larger L1 L2 L3 L4 200m 656ft L1 L2 L11 L12 L13 200m 656ft 2 Transmission line for centralized control No connection is required 3 MA remote controller wiring Maximum...

Page 40: ...on of indoor units that have different functions Automatic indoor outdoor ad dress setup is not available 4 LOSSNAY connection Connect terminals M1 and M2 on the terminal block TB5 on the indoor unit IC to the appropriate terminals on the terminal block TB5 on LOSSNAY LC Non po larized two wire Interlock operation setting with all the indoor units in the same system will automatically be made It i...

Page 41: ...OOK for further information about how many booster units are required for a given system 3 Maximum allowable length 1 Indoor outdoor transmission line Same as 2 7 1 2 Transmission line for centralized control No connection is required 3 MA remote controller wiring Same as 2 7 1 L2 TB3 51 52 TB7 S TB3 TB7 S IC TB5 S TB15 1 2 01 IC TB5 S TB15 1 2 02 A B MA A B MA LC TB5 S 05 IC TB5 S 1 2 TB15 IC TB5...

Page 42: ...of capacity from large to small if two or more units have the same capacity in the order of address from small to large Proce dures Unit or controller Address setting range Setting method Notes Factory setting 1 Indoor unit Main unit IC 01 to 50 Assign the smallest ad dress to the main unit in the group To perform a group opera tion of indoor units that have different functions designate the indoo...

Page 43: ... MA remote controller wiring Same as 2 7 1 4 Maximum line distance via outdoor unit 1 25mm2 AWG16 or larger L12 L11 L31 L22 L21 1000 m 3280ft 500 m 1640ft 1 1 If a given system includes one or more unit or remote controller that does not support the maximum allow able cable distance of 1 000 m 3280 ft the maximum allowable cable distance in the system will be 500 m 1640 ft Refer to the latest cata...

Page 44: ...inal and the S terminal on the terminal block TB7 on the out door unit whose power jumper connector is mated with CN40 3 MA remote controller wiring Same as 2 7 1 When 2 remote controllers are connected to the sys tem Same as 2 7 1 Group operation of indoor units Same as 2 7 1 4 LOSSNAY connection Same as 2 7 2 5 Switch setting Address setting is required as follows 5 Address setting method The ou...

Page 45: ...ransmission line Same as 2 7 3 2 Transmission line for centralized control L31 L32 L21 200m 656ft 3 MA remote controller wiring Same as 2 7 1 4 Maximum line distance via outdoor unit 1 25mm2 AWG16 or larger L32 L31 L12 L11 1000 m 3280ft 500 m 1640ft 1 L32 L22 L21 1000 m 3280ft 500 m 1640ft 1 L12 L11 L31 L22 L21 1000 m 3280ft 500 m 1640ft 1 1 If a given system includes one or more unit or remote co...

Page 46: ... 1 Group operation of indoor units Same as 2 7 1 4 LOSSNAY connection Connect terminals M1 and M2 on the terminal block TB5 on the indoor unit IC to the appropriate terminals on the terminal block for indoor outdoor transmission line TB5 on LOSSNAY LC Non polarized 2 core cable Indoor units must be interlocked with the LOSSNAY unit using the system controller Refer to the operation man ual for the...

Page 47: ...ion line Maximum distance 1 25mm2 AWG16 or larger L11 L12 200m 656ft L21 L22 200m 656ft L25 200m 656ft 2 Transmission line for centralized control L31 L21 200m 656ft 3 MA remote controller wiring Same as 2 7 1 4 Maximum line distance via outdoor unit 1 25mm2 AWG16 or larger L25 L31 L12 L11 1000 m 3280ft 500 m 1640ft 1 L12 L11 L31 L22 L21 1000 m 3280ft 500 m 1640ft 1 1 If a given system includes on...

Page 48: ...rcuit the earth terminal and the S terminal on the terminal block TB7 on the out door unit whose power jumper connector is mated with CN40 3 MA remote controller wiring Same as 2 7 1 When 2 remote controllers are connected to the sys tem Same as 2 7 1 Group operation of indoor units Same as 2 7 1 4 LOSSNAY connection Connect terminals M1 and M2 on the terminal block TB5 on the indoor units IC to t...

Page 49: ...ssion line for centralized control Same as 2 7 4 3 M NET remote controller wiring Maximum overall line length 0 3 to 1 25mm2 AWG22 to 16 m1 10m 32ft m2 m3 10m 32ft If the standard supplied cable must be extended use a cable with a diameter of 1 25mm2 AWG16 The section of the cable that exceeds 10m 32ft must be included in the maximum in door outdoor transmission line distance described in 1 When c...

Page 50: ...nit or controller Address setting range Setting method Notes Factory setting 1 Indoor unit Main unit IC 01 to 50 Assign the smallest ad dress to the main unit in the group To perform a group operation of indoor units that have differ ent functions desig nate the indoor unit in the group with the greatest number of functions as the main unit 00 Sub unit Assign sequential num bers starting with the ...

Page 51: ...or including one or more indoor units of the 72 model or above are connected Refer to the DATABOOK for further information about how many booster units are required for a given system 11 When a power supply unit is connected to the transmis sion line for centralized control leave the power jumper connector on CN41 as it is factory setting 3 Maximum allowable length 1 Indoor outdoor transmission li...

Page 52: ...atest number of functions as the main unit 00 Sub unit Assign sequential num bers starting with the ad dress of the main unit in the same group 1 Main unit address 1 main unit address 2 main unit ad dress 3 etc MA re mote con troller Main re mote con troller MA No settings required Main Sub remote controller MA Sub remote controller Settings to be made ac cording to the remote con troller function...

Page 53: ... In the figure above the pipes whose size should be increased by one size are indicated by C b and c when the piping length exceeds 40 meters at point C Height difference Between indoor and outdoor units Outdoor unit above in door unit H 50 164 or less Outdoor unit below in door unit H 40 131 or less Between indoor units h 15 49 or less 2 2 If the vertical difference between indoor units exceeds 1...

Page 54: ...m 6ft Max Outdoor unit Outdoor unit Unit m ft Operation Pipe sections Allowable length of pipes Length Between outdoor units A B C 10 32 or less Total pipe length A B C E F G I J K M a b c d e f g i 1000 3280 or less Total pipe length L from the outdoor unit to the farthest indoor unit A B C E J K M i 165 541 or less Equivalent length 190 623 or less Total pipe length from the first branch to the ...

Page 55: ...y A B C D E b1 and e1 by one size H1 exceeds 15 m H2 15 m or less C D c A B H2 H1 d e2 e1 E a b2 b1 Outdoor unit Outdoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Outdoor unit Increase the size of the pipe indicated by A a1 and a2 by one size H exceeds 15 m B H A a1 a2 b Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor unit Indoor un...

Page 56: ...2 model ø9 52 3 8 ø22 2 7 8 96 model ø9 52 3 8 1 1 Use ø12 7 1 2 pipes if the piping length to the farthest indoor unit exceeds 90 m 295 ft ø22 2 7 8 120 model ø9 52 3 8 2 2 Use ø12 7 1 2 pipes if the piping length to the farthest indoor unit exceeds 40 m 131 ft ø28 58 1 1 8 144 model ø12 7 1 2 ø28 58 1 1 8 192 model ø15 88 5 8 ø28 58 1 1 8 240 model ø15 88 5 8 ø28 58 1 1 8 model Pipe diameter mm ...

Page 57: ...econd distributor and outdoor units Total capacity of the downstream units Liquid pipe size mm inch Gas pipe size mm inch 54 ø9 52 3 8 ø15 88 5 8 P55 P72 ø9 52 3 8 ø19 05 3 4 P73 P108 ø9 52 3 8 ø22 2 7 8 P109 P144 ø12 7 1 2 ø28 58 1 1 8 P145 P240 ø15 88 5 8 ø28 58 1 1 8 P241 P308 ø19 05 3 4 ø34 93 1 3 8 P309 ø19 05 3 4 ø41 28 1 5 8 Liquid pipe size mm inch Gas pipe size mm inch ø19 05 3 4 ø34 93 1...

Page 58: ...nce and Refrigerant Circuit Components of Outdoor Unit 1 3 1 1 External Appearance of Outdoor Unit 1 3 1 2 Outdoor Unit Refrigerant Circuits 2 3 2 Outdoor Unit Refrigerant Circuit Diagrams 3 3 3 Functions of the Major Components of Outdoor Unit 4 3 4 Functions of the Major Components of Indoor Unit 7 ...

Page 59: ...HWE18240_GB ...

Page 60: ...mponents of Outdoor Unit 3 1 1 External Appearance of Outdoor Unit PUHY HP72 HP96 HP120T Y NU A Fan guard Fan guard Fan Fan Fin guard Fin guard Control box Control box Drain pan Drain pan Front panel Front panel Heat exchanger Heat exchanger Internal panel Internal panel Front panel Front panel Rear panel Rear panel Panel heater Panel heater Side panel Side panel Internal panel Internal panel Side...

Page 61: ...1 Linear expansion valve LEV1 Gas liquid separator Subcool coil Linear expansion valve LEV9 Linear expansion valve LEV2a Linear expansion valve LEV2b Solenoid valve SV10 Solenoid valve SV9 Solenoid valve SV2 Linear expansion valve LEV4 Solenoid valve SV1a Liquid side valve BV2 Gas side valve BV1 Oil separator Compressor Compressor cover Low pressure sensor 63LS High pressure sensor 63HS1 High pres...

Page 62: ...efrigerant Circuits 3 2 Outdoor Unit Refrigerant Circuit Diagrams 1 PUHY HP72 HP120T Y NU A SCC LEV1 LEV9 ACC 63H1 21S4a ST6 63HS1 63LS ST7 CJ1 CJ2 Comp O S LEV2a ST2 BV2 BV1 21S4b SV9 SV10 SV2 ST18 Cooling for BOX ST1 Motor SV1a CP1 CV1 HEX TH7 TH5 TH2 TH3 TH6 TH4 TH15 ST3 Rear Front LEV4 LEV2b FAN1 FAN2 Motor ...

Page 63: ... frequency and pro vides high pressure protec tion Low pres sure sensor 63LS 1 Detects low pressure 2 Provides low pressure pro tection 3 Defrost control during heating operation Pres sure switch 63H1 1 Detects high pressure 2 Provides high pressure pro tection 4 15MPa 601psi OFF setting Power supply trans former Transformer YNU only Decreases the power supply volt age 460V supplied to the circuit...

Page 64: ...ature 1 Controls frequency 2 LEV1 is controlled based on the subcool at heat exchange outlet that is obtained based on the HPS data and TH3 val ue TH7 Outdoor temperature 1 Detects outdoor air tempera ture 2 Controls fan operation TH5 Pipe temperature LEV2 are controlled based on the 63LS and TH5 values TH6 Pipe temperature Controls LEV1 based on TH2 TH3 and TH6 data TH15 Compres sor shell bot tom...

Page 65: ...w of refrigerant by passed from the pipe for cooling the control board when the control board temperature rises LEV4 Refrigerant flow adjust ment Controls the bypassed refrigerant flow to the compressor to sup press rises in the discharge tem perature TH4 LEV2a Refrigerant flow adjust ment Adjusts refrigerant flow during heating Cut off the refrigerant flow during continuous heating cycle DC12V Op...

Page 66: ...st with a Tester Continuity between white red and or ange Continuity between yellow brown and blue Thermis tor TH1 Suction air tem perature Indoor unit control Thermo 0 C 32 F 15 kȍ 10 C 50 F 9 7 kȍ 20 C 68 F 6 4 kȍ 25 C 77 F 5 3 kȍ 30 C 86 F 4 3 kȍ 40 C 104 F 3 1 kȍ Resistance check TH2 Pipe tempera ture 1 Indoor unit control Frost prevention Hot adjust 2 LEV control during heat ing operation sub...

Page 67: ... 3 4 Functions of the Major Components of Indoor Unit 8 chapter 3 HWE18240_GB 3 Major Components Their Functions and Refrigerant Circuits ...

Page 68: ...t Control Box 1 4 2 Outdoor Unit Circuit Board Components 4 4 2 1 Control Board 4 4 2 2 Power supply board PS Board 5 4 2 3 Inverter Board INV Board 6 4 2 4 Fan Board 8 4 2 5 Noise Filter 10 4 2 6 Capacitor Board CAP Board 12 4 3 Outdoor Unit Electrical Wiring Diagrams 14 4 4 Transmission Booster Electrical Wiring Diagrams 16 ...

Page 69: ...HWE18240_GB ...

Page 70: ...oor Unit Control Box HIGH VOLTAGE WARNING Control box houses high voltage parts When opening or closing the front panel of the control box do not let it come into contact with any of the internal components Before inspecting the inside of the control box turn off the power keep the unit off for at least 10 minutes and confirm that the voltage of the capacitor in the main circuit has dropped to 20 ...

Page 71: ...hat the voltage is 20 VDC or below 7 After servicing reconnect the relay connector RYFAN1 and RYFAN2 in the INV box as it was 8 When opening or closing the front panel of the control box do not touch any of the internal components Before inspecting inside the control box turn off the power to the unit leave it turned off for at least 10 minutes and check that the voltage across Pin 1 and Pin 5 of ...

Page 72: ...heck that the voltage is 20 VDC or below 7 After servicing reconnect the relay connector RYFAN1 and RYFAN2 in the INV box as it was 8 When opening or closing the front panel of the control box do not touch any of the internal components Before inspecting inside the control box turn off the power to the unit leave it turned off for at least 10 minutes and check that the voltage across Pin 1 and Pin...

Page 73: ... OFF CN40 Centralized control system power supply ON TP1 Indoor outdoor transmission check pin TP2 Indoor outdoor transmission check pin Sensor input F001 AC250V 3 15A T CNUSB USB memory connector Actuator drive output SW4 6 Dip switch CNRYA 72C drive signal Abbreviated name of connector color Example BU above CN601 indicates that the connector is blue CN600 9 VDC input GND 12 VDC input GND CN603 ...

Page 74: ...put CN202 Indoor outdoor transmission signal input output Centralized control system power supply output CNINT GND 5 VDC input Indoor unit system power supply ON OFF signal input CN101 Cooling fan ON OFF signal input Inverter reset signal input Locked cooling fan sensor output Locked cooling fan sensor output CNFAN1 FAN1INV power supply output 17 VDC output N CNFAN2 FAN2INV power supply output 17 ...

Page 75: ... less The capacitor may collect a charge and cause an electric shock when the outdoor unit fan rotates in windy conditions Refer to the wiring nameplate for details 5 After servicing reconnect the relay connector RYFAN1 RYFAN2 of the fan as it was 6 When the power is on the compressor or heater is energized even while the compressor is stopped Before turning on the power disconnect all power suppl...

Page 76: ...s The capacitor may collect a charge and cause an electric shock when the outdoor unit fan rotates in windy conditions Refer to the wiring nameplate for details 5 After servicing reconnect the relay connector RYFAN1 RYFAN2 of the fan as it was 6 When the power is on the compressor or heater is energized even while the compressor is stopped Before turning on the power disconnect all power supply wi...

Page 77: ...ctors check that the outdoor unit fan is not rotating and that the voltage across pins 1 and 5 of connector RYPN is 20 VDC or less The capacitor may collect a charge and cause an electric shock when the outdoor unit fan rotates in windy conditions Refer to the wiring nameplate for details 4 To connect wiring to TB7 check that the voltage is 20 VDC or below 5 After servicing reconnect the relay con...

Page 78: ...tors check that the outdoor unit fan is not rotating and that the voltage across pins 1 and 5 of connector RYPN is 20 VDC or less The capacitor may collect a charge and cause an electric shock when the outdoor unit fan rotates in windy conditions Refer to the wiring nameplate for details 4 To connect wiring to TB7 check that the voltage is 20 VDC or below 5 After servicing reconnect the relay conn...

Page 79: ...GB 4 Electrical Components and Wiring Diagrams 4 2 5 Noise Filter 1 YNU TB13 Input L3 TB12 Input L2 TB11 Input L1 Ground Ground Ground Ground TB22 Output L2 TB23 Output L3 TB21 Output L1 F1 F2 F3 F4 Fuse 250 VAC 6 3 A CN2 Surge absorber circuit Surge absorber circuit ...

Page 80: ...iring Diagrams 2 TNU TB12 Input L2 TB13 Input L3 TB11 Input L1 TB22 Output L2 TB23 Output L3 TB21 Output L1 Ground Ground Ground F1 F2 Fuse 250 VAC 6 3 A CN12 Output L1 L2 CN13 Output L2 L3 CN14 Surge absorber circuit Surge absorber circuit Open phase detection circuit Open phase detection circuit ...

Page 81: ...x houses high temperature parts Be well careful even after turning off the power source 4 Perform the service after disconnecting the relay connector RYFAN1 RYFAN2 Before plugging in or unplugging connectors check that the outdoor unit fan is not rotating and that the voltage across pins 1 and 5 of connector RYPN is 20 VDC or less The capacitor may collect a charge and cause an electric shock when...

Page 82: ...s a locking function Make sure the cable heads are securely locked in place Press the tab on the terminals to remove them 3 Control box houses high temperature parts Be well careful even after turning off the power source 4 Perform the service after disconnecting the relay connector RYFAN1 RYFAN2 Before plugging in or unplugging connectors check that the outdoor unit fan is not rotating and that t...

Page 83: ...1 1 2 CNINT 4 red CNDC CN101 blue Control Board 3 1 2 1 2 3 3 1 2 1 2 3 CN202 CN201 red 63LS 63HS1 1 2 CNPOW yellow 1 3 CN3K yellow 1 3 CN3S red 3 1 3 CN3D 1 3 CN3N blue 4 1 CN41 2 3 4 1 CN40 2 3 TP1 TP2 TB3 TB7 M1 M2 M1 M2 S Indoor Outdoor transmission cable Central control transmission cable 4 CNAC 3 1 2 2 2 ON OFF X10 X07 X09 5 5 1 1 CN506 red 21S4b Power failure detection circuit CN507 black 3...

Page 84: ...901 X903 Magnetic relay inverter main circuit Z22 24 25 Function setting connector 1 4 7 1 3 1 3 1 LED2 Normal operation Lit Error Blink LED3 SW6 10 is OFF and LED101 SW4 1 10 are OFF In operation Lit In stop Unlit SW6 10 is ON Function setting by SW4 enable Lit disable Unlit Normal operation Lit IC Error Unlit 10 Difference of appliance Model name Appliance LEV1 LEV9 8 Difference of appliance Mod...

Page 85: ...d Red Red U U White White White White White White Blue Red Red DSA White White Blue Red Red Red Red Varistor Varistor Noise filter Stabilized power supply 4 3 2 1 1 2 3 CN2 CN1 Black Black Black Black Green Yellow 1 2 3 E 4 Choke coil 1 2 CN3 1 2 1 2 CN4 CN2 1 2 CN1 Electronic control board Black White Red Red Black S B A S B A Terminal block 2 for transmission line TB3 Expanded indoor unit side T...

Page 86: ...y Control 12 5 2 7 Defrost Operation Control 13 5 2 8 Continuous heating mode control 15 5 2 9 Refrigerant Recovery Control 16 5 2 10 Outdoor Unit Fan Control 16 5 2 11 Subcool Coil Control Linear Expansion Valve LEV1 17 5 2 12 Refrigerant Flow Control Linear Expansion Valves LEV2a and LEV2b 17 5 2 13 Control of Controller Cooling Function Electronic Expansion Valve LEV9 17 5 2 14 Injection Contro...

Page 87: ...HWE18240_GB ...

Page 88: ...ype and model 4 5 6 7 8 SW6 1 2 COP priority setting at low outside temperature Heating COP pri ority mode Heating capacity priority control mode Before power on A 3 4 Model setting outdoor unit high static pressure setting Function depends on the setting combination with the SW6 5 setting Note 6 Factory setting OFF Before power on C 5 Model setting outdoor unit high static pressure setting Functi...

Page 89: ...or 30 seconds and comes to an error stop See the relevant pag es for details 8 9 8 Checking the Fan Board for Damage at No Load No load opera tion disabled No load opera tion enabled Any time after power on C 3 4 Enables or disables no load operation of the right fan inverter The unit continues no load operation for 30 seconds and comes to an error stop See the relevant pag es for details 8 9 8 Ch...

Page 90: ...sure is low Refer to the following page s 2 4 7 Var ious Control Methods Using the Signal Input Output Connector on Outdoor Unit 4 Operation noise is reduced by controlling the compressor frequencies and the rotation speed of the outdoor unit fans CN3D needs to be set Refer to the following page s 2 4 7 Various Control Methods Using the Signal Input Output Connec tor on Outdoor Unit 5 Operation no...

Page 91: ...OFFĺON D No 915 1100100111 Defrost start temperature Note 3 HP72 HP120 11 C 12 F 8 C 18 F Anytime after power on B No 916 0010100111 Defrost end temperature Note 3 HP72 HP120 7 C 45 F 5 C 41 F Anytime after power on B No 918 0110100111 Changes the defrost timer setting Note 3 50 minutes 90 minutes Anytime after power on OFFĺON B No 921 1001100111 Temperature pressure unit selection C kgf cm2 F psi...

Page 92: ...tion will be saved If this is the case manually record the settings configuration on the control box panel The new function is supported on most units that are manufactured in December of 2012 and later Depending on the model this function may be added on later date Ask your dealer for further details 8 The multiple stage low noise function controls the fan by targeting the capacities shown in the...

Page 93: ...umidifier control Self recovery after power failure Fan speed setting for Heating Thermo OFF Power source start stop Unit model selection Louver Vane Vane swing function Vane angle limit setting for cooling operation Initial vane position Heating 4 C 39 2 F up Automatic LEV value conversion function Indoor unit inlet 100h Disabled Fan output 2500h Enabled Thermo ON signal Built in sensor on the re...

Page 94: ...s Ordinarily only change the Main Sub setting of SW1 The factory settings are ON for SW1 2 and 3 and OFF for SW4 The MA remote controllers PAR 21MAAU PAR 30MAAU do not have the switches listed above Refer to the installation manual for the function setting ON 1 2 3 4 ON 1 2 3 4 5 6 7 8 9 10 The figure at left shows that the switches 1 through 5 are set to ON and 6 through 10 are set to OFF Comment...

Page 95: ... 10 s digit 1 s digit left right Remote controller unit Rotary switch Example In case of address 108 Address setting range Setting method Main remote controller 101 150 Add 100 to the smallest address of all the indoor units in the same group Sub remote controller 151 200 Add 150 to the smallest address of all the indoor units in the same group Setting of rotary switch Address No 01 99 1 101 199 w...

Page 96: ...ntrol When the power is turned on the initial processing of the microcomputer is given top priority During the initial processing control processing of the operation signal is suspended The control processing is resumed after the initial processing is completed Initial processing involves data processing in the microcomputer and initial setting of each of the LEV opening This process will take up ...

Page 97: ...conditions are met during the heating mode Compressor frequency after power on is greater than 0 The low pressure 63LS drops One or more minutes after compressor startup if the cumulative compressor operation time is one hour or less three or more minutes if the cumulative compressor operation time is one hour or more When the low pressure 63LS drops below 0 12 MPa 17 psi When the low pressure 63L...

Page 98: ...E18240_GB chapter 5 11 5 Control Operation SV10 ON OFF When Continuous heating mode Front part of heat exchanger is being de frosted Other than on the left When the rear part of heat exchanger is being defrosted 21S4b will be OFF ...

Page 99: ...t the frequency is decreased every 15 seconds The actuation pressure is when the high pressure reading on 63HS1 is 3 58MPa 519psi 2 Discharge temperature limit Discharge temperature TH4 of the compressor in operation is monitored and when it exceeds the upper limit the frequency is decreased every minute Operating temperature is 115 C 239 F 3 Periodic frequency control Frequency control other than...

Page 100: ... defrost prohibit time for the next defrost cycle is 50 minutes if the last defrost cycle took 12 minutes All units in the heating mode will simultaneously go into the defrost cycle in a system with multiple units The units that are not in operation may or may not go into the defrost cycle depending on the cumulative operation time of their compressors Condition 1 Condition 2 Condition 3 Outside t...

Page 101: ...etected during defrost operation the operation will be stopped and the defrost prohibition time based on the integrated compressor operation time will be set to 20 minutes 5 Change in the number of operating indoor units during defrost operation Even when there is a change in the number of operating indoor units during defrost operation the operation will continue and an adjustment will be made af...

Page 102: ... 2 Valve operation during Continuous heating cycle 1 HP72 120 Outside temperature TH7 2 0 C 35 6 F to 7 0 C 44 6 F Cumulative compressor operation time After 10 minutes at 2 0 C 35 6 F to 3 5 C 38 3 F has elapsed After 20 minutes at 3 6 C 38 5 F to 7 0 C 44 6 F has elapsed Evaporating temperature Te After 3 minutes at 0 C 32 F to 25 C 13 F has elapsed Front bottom HEX in defrost cycle Rear front H...

Page 103: ...ation Starting refrigerant recovery mode The refrigerant recovery mode starts when all the following conditions are met 30 minutes have passed since the completion of previous refrigerant recovery When the unit keeps running for 3 minutes in a row or more with high discharge temperature TH4 105 C 221 F or 63HS1 3 43 MPa 497 psi 35 kg cm2 G and SC0 10 C 50 F Refrigerant recovery The opening of LEV1...

Page 104: ...2100 pulses Valve opening is controlled based on the values of high pressure 63HS1 discharge temperature TH4 low pressure 63LS and piping temperature TH5 The valve moves to the predetermined position while the unit is stopped The valve opening may increase to 3000 pulses during the defrost cycle or when the units are operated in unusual operating conditions 5 2 13 Control of Controller Cooling Fun...

Page 105: ... both the OC and the OS to simultaneously stay in operation 3 The air conditioning load is high enough for both OC and OS to simultaneously stay in operation Initial startup mode complete or the discharge superheat TH4 Tc is detected within 5 minutes of startup that remains above approximately 25 degrees for one minute or if the shell bottom SH TH15 Te is 15 deg or above for continuous 5 minutes 1...

Page 106: ...rce Error codes that permit an emergency operation Error code description Compressor Fan motor Inverter 0403 Serial communication error 4220 4225 4226 Bus voltage drop 4230 4235 Heatsink overheat protection 4240 4245 Overload protection 4250 4255 4256 Overcurrent relay trip 5110 Heatsink temperature sensor failure THHS 5120 DCL temperature sensor circuit fault 5301 Current sensor circuit failure 5...

Page 107: ...efore servicing the unit When the OC is in trouble the OS temporarily takes over the OC s function and performs an emergency operation When this happens the indoor unit connection information are changed In a system that has a billing function a message indicating that the billing system information has an error may appear on the TG 2000A Even if this message appears do not change or set the refri...

Page 108: ...Twelve step demand control is possible in the system with three outdoor units For details refer to the following page s 2 4 7 Various Control Methods Using the Signal Input Output Connector on Outdoor Unit 5 2 19 Control of IH energization without the compressor in operation IH is used to heat the compressor motor on the stopped outdoor unit to make liquid refrigerant in the compressor evaporate o...

Page 109: ... 5 2 Outdoor Unit Control 22 chapter 5 HWE18240_GB 5 Control ...

Page 110: ... Refrigerant Charge 2 6 3 Evaluating and Adjusting Refrigerant Charge 2 6 3 1 Refrigerant Overcharge and undercharge 2 6 3 2 Checking the Refrigerant Charge during Operation 2 6 3 3 Maximum refrigerant charge 3 6 3 4 Refrigerant Charge Adjustment Mode 4 6 4 The Following Symptoms Are Normal 6 ...

Page 111: ...HWE18240_GB ...

Page 112: ...off for an extended period of time because of the accumulation of refrigerant in the compressor If insulation resistance is 1 Mȍ or below by turning on the main power and keeping it on for at least 12 hours the refrigerant in the compressor will evaporate and the insulation resistance will go up Do not measure the insulation resistance of the terminal block for transmission line for the unit remot...

Page 113: ...harge 6 3 1 Refrigerant Overcharge and undercharge Overcharging or undercharging of refrigerant can cause the following symptoms Before attempting to adjust the amount of refrigerant in the system thoroughly check the operating conditions of the system Then adjust the refrigerant amount by running the unit in the refrigerant amount adjust mode 6 3 2 Checking the Refrigerant Charge during Operation...

Page 114: ...NU A Total index of the outdoor units HP72 HP96 HP120 HP144 HP192 HP240 Factory charge kg 9 8 10 8 10 8 19 6 21 6 21 6 Factory charge lbs oz 21 10 23 13 23 13 43 4 47 10 47 10 Maximum additional refrigerant charge on site kg 19 9 22 5 23 9 31 3 31 1 32 0 Maximum additional refrigerant charge on site lbs oz 43 14 49 10 52 12 69 1 68 10 70 9 Maximum refrigerant charge kg 29 7 33 3 34 7 50 9 52 7 53 ...

Page 115: ...unt of refrigerant is truly adequate TH3 TH6 on the outdoor unit is 5 C 41 F or above and SH on the indoor unit is between 5 and 15 C 41 and 59 F The refrigerant amount may seem adequate at the moment but may turn out to be inadequate later on TH3 TH6 on the outdoor unit is 5 C 41 F or less and SH on the indoor unit is 5 C 41 F or less Wait until the TH3 TH6 reaches 5 C 41 F or above and the SH of...

Page 116: ...gerant from the service port on the low pressure side Keep the unit running for 5 minutes after adjusting the refrigerant amount to determine its adequacy Keep the unit running for 5 minutes after adjusting the refrigerant amount to determine its adequacy Turn off SW4 922 on the OC Turn on SW4 922 on the OC Adjustment complete Note 4 Has the initial start up mode been completed Gradually add refri...

Page 117: ...D BY The fan operates at extra low speed for 5 minutes after it is turned on or until the pipe temperature reaches 35 C 95 F then it operates at low speed for 2 minutes and finally it operates at the set speed Pre heating stand by When the main power is turned on the display shown on the right appears on the in door unit remote controller for 5 minutes HO or PLEASE WAIT icons blink on the display ...

Page 118: ...ror Code 3512 20 7 6 Error Code Definitions and Solutions Codes 4000 4999 21 7 6 1 Error Code 4102 21 7 6 2 Error Code 4106 22 7 6 3 Error Code 4109 22 7 6 4 Error Code 4114 23 7 6 5 Error Code 4116 23 7 6 6 Error Code 4121 23 7 6 7 Error Code 4124 24 7 6 8 Error Codes 4220 4225 4226 Detail Code 108 25 7 6 9 Error Codes 4220 4225 4226 Detail Code 108 26 7 6 10 Error Codes 4220 4225 4226 Detail Cod...

Page 119: ... 6202 45 7 8 3 Error Code 6600 46 7 8 4 Error Code 6601 46 7 8 5 Error Code 6602 47 7 8 6 Error Code 6603 48 7 8 7 Error Code 6606 48 7 8 8 Error Code 6607 Error Source Address Outdoor Unit OC 49 7 8 9 Error Code 6607 Error Source Address Indoor Unit IC 50 7 8 10 Error Code 6607 Error Source Address LOSSNAY LC 52 7 8 11 Error Code 6607 Error Source Address ME Remote Controller 53 7 8 12 Error Code...

Page 120: ...HWE18240_GB 7 9 7 Error Code 7111 70 7 9 8 Error Code 7113 71 7 9 9 Error Code 7117 72 7 9 10 Error Code 7130 73 ...

Page 121: ...HWE18240_GB ...

Page 122: ... 3121 Out of range outside air temperature O page 18 3511 3611 Refrigerant overcooling O page 19 3512 3612 Cooling fan locking O page 20 4102 4152 Open phase O page 21 4106 Transmission power supply fault O page 22 4109 Indoor unit fan operation error O page 22 4114 Indoor unit fan motor error O page 23 4116 RPM error Motor error O O page 23 4121 4171 í Function setting error O page 23 4124 í Elec...

Page 123: ...nk overheat protection at startup O page 37 5101 1202 Temperature sensor fault Return air temperature TH21 O page 38 OA processing unit inlet temperature TH4 O page 38 5102 1217 Temperature sensor fault Indoor unit pipe tempera ture TH22 O page 38 OA processing unit pipe temperature TH2 O page 38 HIC bypass circuit outlet temperature TH2 O page 39 5103 1205 00 Temperature sensor fault Indoor unit ...

Page 124: ...controller board fault clock IC error O page 45 6600 001 Detection of overlapped address in centralized control system O O O O page 46 002 Detection of overlapped address in indoor unit system O O O O page 46 6601 001 Detection of polarity setting error in centralized control system O page 46 002 Detection of polarity setting error in indoor unit system O page 46 6602 001 Transmission processor ha...

Page 125: ...rt bit detection error O page 64 6846 Start up time over O page 65 7100 Total capacity error O page 66 7101 Capacity code setting error O O O page 67 7102 Wrong number of connected units O page 68 7105 Address setting error O page 69 7106 Attribute setting error O page 69 7110 Connection information signal transmission reception er ror O page 70 7111 Remote controller sensor fault O O page 70 7113...

Page 126: ...r system Compressor inverter Fan inverter The last digit Inverter system 0 or 1 Compressor inverter system 5 or 6 Fan inverter system INV board Outdoor units Overload protec tion Imax Arms Current effective value error Arms Current peak val ue error Apeak Temperature protection TOL C INV42Y HP72YNU 27 33 56 95 HP96YNU HP120YNU INV38 HP72TNU 48 58 99 95 HP96TNU 51 61 104 HP120TNU INV board Outdoor ...

Page 127: ...rd 2 PS board failure Replace the PS board if the LED on the INV board Fan board or control board is not lit Using the detail codes check the status of the LEDs on the circuit boards below Detail code 1 LED on the INV board Detail code 5 LED on the right Fan board Detail code 6 LED on the left Fan board When the power supply board is normal all LEDs will be lit 3 INV board failure Fan board failur...

Page 128: ...rol related errors 2 Error definition and error detection method Indoor controller board Abnormal if data cannot be read normally from the nonvolatile memory of the indoor controller board 3 Cause check method and remedy Note Refer also to the Service Handbook for the indoor units Cause Check method and remedy Defective indoor controller board Replace indoor controller board ...

Page 129: ...e will start 5 For 30 minutes after the stop the first stop or the second stop of the outdoor unit preliminary errors will be displayed on the LED display 3 Cause check method and remedy Cause Check method and remedy 1 Gas leak gas shortage Refer to the following page s 6 3 Evaluating and Adjusting Refrigerant Charge 2 Overload operation Check operating conditions and operation status of indoor ou...

Page 130: ...e reads 0 098MPa 14psi immediately before start up the operation immediately stops 3 Cause check method and remedy Cause Check method and remedy 1 Inner pressure drop due to a leakage Refer to the following page s 8 5 3 Comparing the Low Pressure Sensor Measurement and Gauge Pressure 2 Low pressure sensor failure 3 Short circuited pressure sensor cable due to torn outer rubber 4 A pin on the male ...

Page 131: ... to check the opera tion Cooling Indoor unit LEV2 Heating Indoor unit LEV Refer to the following page s 8 8 Troubleshooting LEV Problems 2 Closed refrigerant service valve Confirm that the refrigerant service valve is fully open 3 Short cycle on the indoor unit side Check the indoor units for problems and correct them if any 4 Clogged filter on the indoor unit 5 Reduced air flow due to dirty fan o...

Page 132: ...ge of the outdoor unit the same sequence as Item 1 above first detection is followed 4 For 30 minutes after the stop of the outdoor unit preliminary errors will be displayed on the LED display 3 Cause check method and remedy Cause Check method and remedy 1 Inner pressure drop due to a leakage Refer to the following page s 8 5 1 Comparing the High Pressure Sensor Measurement and Gauge Pressure 2 Pr...

Page 133: ...ion of water leakage is also performed while the unit is stopped 4 Preliminary water leakage is cancelled when the following conditions are met One hour after the preliminary water leakage was detected it is not detected that the drain pump goes from OFF to ON The operation mode is changed to Cool Dry The liquid pipe temperature minus the inlet temperature is 10 C 18 F or less 3 Cause check method...

Page 134: ...llowing conditions are met One hour after the preliminary water leakage was detected it is not detected that the drain pump goes from OFF to ON The operation mode is changed to Cool Dry The liquid pipe temperature minus the inlet temperature is 10 C 18 F or less 3 Cause check method and remedy Reference Cause Check method and remedy 1 Drain water drainage problem Clogged drain pump Clogged drain p...

Page 135: ... came to an error stop 6 Forced stoppage of the outdoor unit Detection timing The error is detected whether the unit is in operation or stopped 7 Ending criteria for the forced stoppage of outdoor unit Power reset the indoor unit that was identified as the error source and the outdoor unit that is connected to the same refrig erant circuit Forced stoppage of the outdoor unit cannot be cancelled by...

Page 136: ...ohibited and the outdoor unit brings all the indoor units in the same refrigerant circuit that are in any mode other than Fan or Stop to an error stop 2502 appears on the monitor of the units that came to an error stop 6 Forced stoppage of the outdoor unit Detection timing The error is detected whether the unit is in operation or stopped 7 Ending criteria for the forced stoppage of outdoor unit Po...

Page 137: ...except during the defrost cycle When the liquid temperature thermistor or suction temperature thermistor or short or open circuited Drain pump is in operation One hour has elapsed since the drain sensor went off Short 90 C 194 F or above Open 20 C 4 F or below 3 Cause check method and remedy Cause Check method and remedy 1 Faulty connector CN31 insertion 1 Check for connector connection failure Re...

Page 138: ...Error code definition Water supply cutoff 2 Cause check method and remedy Cause Check method and remedy 1 The water tank of the humidifier is empty Check the amount of supply water Check for the solenoid valve and for the connection 2 The solenoid valve for humidification is OFF Check the connector 3 Disconnected float switch Check the connecting part 4 Poor operation of float switch Check for the...

Page 139: ... needs to be canceled by setting the remote controller Outdoor temperature error is canceled if the units stop during error stop The error display needs to be canceled by setting the remote controller 3 Cause check method and remedy Check the following factors if an error is detected without drop in the outdoor temperature Reference Cause Check method and remedy 1 Thermistor failure Check thermist...

Page 140: ...l come to an abnormal stop and this error will be indicated as 3511 4 If the condition THHS A 1 C remains true for continuous 6 minutes and 30 seconds is met regardless of the first or second time after 30 minutes of the first occurrence or after the condition THHS A 1 C remains true for continuous 2 minutes has been met it is considered as the first occurrence and the unit will follow the same be...

Page 141: ...ing the rotation of the cooling fan 2 Cooling fan motor trouble Disconnect the wiring from the cooling fan motor and check the insulation resistance and the coil resistance of the motor Replace the motor if problems are found Criteria for insulation failure Insulation failure if below 1 Mȍ Wire disconnection Normal if coil resistance is between 56 and 65 ȍ 3 Contact failure Check the wiring betwee...

Page 142: ...s Check for coil burnout 3 Wiring failure TNU models Check the wiring between CN13 on the noise filter and CNAC on the control board Check the wiring between CN11 on the noise filter and CN110 on the control board YNU models Confirm that the voltage at the control board connector CNAC is 190 V or above If the voltage is below 190 check the wiring between each of the following TB21 TB22 TB23 of the...

Page 143: ...ection method Transmission power reception failure 3 Cause One of the outdoor units stopped supplying power but no other outdoor units start supplying power 4 Check method and remedy Check the transmission power supply circuit on all outdoor units in a given refrigerant circuit for problems 8 10 2 Trouble shooting Problems with Outdoor Unit Transmission Power Supply Circuit 7 6 3 Error Code 4109 1...

Page 144: ...d remedy 1 Fan motor connector contact failure Check the fan motor connector CNMF for proper connection 2 Indoor unit circuit board failure Remove the fan motor connector CNMF and check the voltage at the indoor unit circuit board Testing point 1 280 VDC Between CNMF1 and CNMF4 2 15 VDC Between CNMF5 and CNMF4 Replace the indoor unit circuit board if the voltage is abnormal If the 4114 error persi...

Page 145: ...ot 0V DC between CN1X1 and ĺReplace the damper limit switch open There is not 5V DC between CN1X1 and ĺReplace the damper limit switch close 4 If damper opens or closes and voltages in 3 are normal measure the voltage between CN1X1 and and the voltage between CN1Y1 and during the damper close by pressing VANE CONTROL button There is not 5V DC between CN1X1 and ĺReplace the damper limit switch open...

Page 146: ...20 V check the following items 1 Check the coil L connections and for broken wiring 2 Check the wiring connections between noise filter board and INV board and between INV board and R1 through R5 3 Check the in rush current resistor Refer to the following page s 8 9 14 Simple Check on Inverter Circuit Components 4 If the problem persists after reboot replace the INV board 4225 4226 Check the volta...

Page 147: ...below 253 V check the following items 1 Check the coil L connections and for broken wiring 2 Check the wiring connections between noise filter board and INV board between INV board and capacitor board and between INV board and R1 3 Check the in rush current resistor Refer to the following page s 8 9 14 Simple Check on Inverter Circuit Components 4 If the problem persists after reboot replace the I...

Page 148: ...V board failure If the problem recurs replace the INV board or fan board In the case of 4220 INV board In the case of 4225 and 4226 Fan board For inverter related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems 7 6 11 Error Code 4220 Detail Code 110 1 Error code definition VDC error Detail code 110 2 Error definition and error detection method BUS voltage error When...

Page 149: ...and remedy For inverter related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 External noise Refer to the following page s 8 9 2 Checking the Inverter Board Error Detection Circuit 2 INV board failure Cause Check method and remedy 1 External noise Refer to the following page s 8 9 8 Checking the Fan Board Error Detection Circuit at ...

Page 150: ...e as detail code 108 of 4220 error For inverter related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems 7 6 16 Error Codes 4220 4225 4226 Detail Code 131 1 Error code definition Low bus voltage at startup Detail code 131 TNU 2 Error definition and error detection method When Vdc 160 V is detected just before the inverter operation TNU 3 Cause check method and remedy...

Page 151: ...or proper installation of the INV board and FAN board IGBT Check for proper installation of the IGBT heatsink 2 Check the THHS sensor reading on the LED monitor ĺIf an abnormal value appears replace the INV board 3 Outdoor unit LEV9 malfunc tion Check the operation of the unit in the Cooing or in the Heating mode LEV9 Refer to the following page s 8 8 Troubleshooting LEV Problems 4 Low pressure se...

Page 152: ...e 4 Inverter FAN board failure Refer to the following page s 8 9 Troubleshooting Inverter Problems 5 Compressor failure Check that the compressor has not overheated during operation ĺ Check the refrigerant circuit oil return section Refer to the following page s 8 9 3 Checking the Compressor for Ground Fault and Coil Resistance Problems 6 The model selection switches SW5 3 5 8 on the outdoor unit ...

Page 153: ... Checking the Inverter for Damage at No Load 8 9 5 Checking the Inverter for Damage during Compressor Operation 8 9 11 Checking the Installation Conditions Check the IGBT module resistance value of the INV board if no problems are found 8 9 15 Troubleshooting Problems with IGBT Module 2 The model selection switches SW5 3 5 8 on the outdoor unit are set incorrectly Check the setting for the model s...

Page 154: ...fer to the following page s 8 9 3 Checking the Compressor for Ground Fault and Coil Resistance Problems 2 Inverter output related Refer to the following page s 8 9 2 Checking the Inverter Board Error Detection Circuit 8 9 3 Checking the Compressor for Ground Fault and Coil Resistance Problems 8 9 4 Checking the Inverter for Damage at No Load 8 9 5 Checking the Inverter for Damage during Compressor...

Page 155: ...Cause Check method and remedy In the case of 4250 In the case of 4255 and 4256 For inverter related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 Short circuited compressor Refer to the following page s 8 9 3 Checking the Compressor for Ground Fault and Coil Resistance Problems 2 Output wiring Check for a short circuit Cause Check m...

Page 156: ...heck the IGBT module resistance value of the INV board if no problems are found 8 9 15 Troubleshooting Problems with IGBT Module 2 The model selection switches SW5 3 5 8 on the outdoor unit are set in correctly Check the setting for the model selection switch on the outdoor unit Dipswitches SW5 3 5 8 on the outdoor unit control board For switch settings refer to the following page s 7 9 2 Error Co...

Page 157: ...es refer to the following page s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 Inverter output related items Refer to the following page s 8 9 2 Checking the Inverter Board Error Detection Circuit Refer to the following page s 8 9 3 Checking the Compressor for Ground Fault and Coil Resistance Problems Refer to the following page s 8 9 4 Checking the Inverter for Damage at N...

Page 158: ...s 7 6 27 Error Code 4260 1 Error code definition Heatsink overheat protection at startup 2 Error definition and error detection method When heatsink temperature THHS remains at or above TOH for 10 minutes or longer after inverter startup 3 Cause check method and remedy Same as 4230 error models TOH INV42Y INV38 100ÛC ...

Page 159: ...ror detection method If a short or an open is detected during thermostat ON the outdoor unit turns to anti restart mode for 3 minutes When the error is not restored after 3 minutes if restored the outdoor unit runs normally the outdoor unit makes an error stop Short detectable at 90 C 194 F or higher Open detectable at 40 C 40 F or lower Sensor error at gas side cannot be detected under the follow...

Page 160: ...ort or an open of the thermistor is detected just before the restart of the outdoor unit the outdoor unit makes an error stop and the error code 5102 5103 5104 5105 5106 5107 or 5115 will appear During 3 minute antirestart mode preliminary errors will be displayed on the LED display A short or an open described above is not detected for 10 minutes after the compressor start during defrost mode or ...

Page 161: ... 3 minutes when the detected high pressure sensor is 0 098MPa 14psi or more If the high pressure sensor detects 0 098MPa 14psi or less just before the restart the outdoor unit makes an error stop and the error code 5201 will appear During 3 minute antirestart mode preliminary errors will be displayed on the LED display A error is not detected for 3 minutes after the compressor start during defrost...

Page 162: ...s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 Contact failure Check the connector CNCT2 on the INV board for proper connection 2 INV output phase loss Check the output wire for proper connection 3 ACCT sensor failure Refer to the following page s 8 9 14 Simple Check on Inverter Circuit Components 4 Compressor failure Refer to the following page s 8 9 3 Checking the Compre...

Page 163: ...related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 INV board failure Refer to the following page s 8 9 2 Checking the Inverter Board Error Detection Circuit 8 9 4 Checking the Inverter for Damage at No Load 8 9 5 Checking the Inverter for Damage during Compressor Operation 2 Compressor failure Refer to the following page s 8 9 3 ...

Page 164: ...ted 3 Cause check method and remedy For inverter related error codes refer to the following page s 8 9 Troubleshooting Inverter Problems Cause Check method and remedy 1 ACCT sensor connection error Check the ACCT for proper connection Refer to the following page s 8 9 14 Simple Check on Inverter Cir cuit Components 2 ACCT sensor failure Refer to the following page s 8 9 14 Simple Check on Inverter...

Page 165: ...ter Problems 7 7 13 Error Code 5701 1 Error code definition Loose float switch connector 2 Error definition and error detection method Detection of the disconnected float switch open phase condition during operation 3 Cause check method and remedy 1 CN4F disconnection or contact failure Check for disconnection of the connector CN4F on the indoor unit control board Cause Check method and remedy 1 O...

Page 166: ...error is detected when the data cannot be read out from the built in nonvolatile memory on the remote controller 3 Cause check method and remedy 1 Remote controller failure Replace the remote controller 7 8 2 Error Code 6202 1 Error code definition Remote controller board fault clock IC error 2 Error definition and error detection method This error is detected when the built in clock on the remote...

Page 167: ...remedy 1 Two or more of the following have the same address Outdoor units indoor units LOSSNAY units control lers such as ME remote controllers Example 6600 01 appears on the remote controller Unit 01 detected the error Two or more units in the system have 01 as their ad dress Find the unit that has the same address as that of the error source Once the unit is found correct the address Then turn o...

Page 168: ...o the noise on the transmission line 7 Voltage is not applied on the transmission line for centralized control in case of grouped indoor units connected to different outdoor units or in case of the system connected with MELANS 4 Check method and remedy NO Tightly reconnect the male power supply connector to the female power supply switch connector CN40 YES YES YES YES YES YES NO NO NO NO Is the tr...

Page 169: ...on circuit board and transmission processor or M NET processor Detail code 003 Communication error between device processor on circuit board and M NET processor The address attribute appeared on the display on the remote controller indicates the controller where an error oc curred 3 Cause check method and remedy Cause Check method and remedy 1 The transmission processor cannot be transmit ted as t...

Page 170: ...ppeared on the display on the remote controller indicates the controller which did not provide the response ACK 3 Cause check method and remedy Cause Check method and remedy 1 Incidental cause 1 Turn off the power source of the outdoor unit and turn it on again 2 Contact failure of transmission line of OC or IC 2 If the error is accidental it will run normally If not check the causes 2 5 3 Decreas...

Page 171: ...ngle refrigerant system Grouped operation of multi ple refrigerant systems Types of indoor units experiencing problems Part of the indoor units IC are experiencing problems All indoor units IC in the same system are experiencing problems All indoor units IC are experiencing problems Troubleshooting prob lems for indoor units A Troubleshooting problems for indoor units A Troubleshooting prob lems f...

Page 172: ...r is connected to the female power supply switch connector CN40 for the transmission line for centralized control 1 Check voltage of the transmission line for central ized control 20 V or more Check 1 on the left Less than 20 V Check 2 on the left 2 Disconnection or shutdown of the power source of the power supply unit for transmission line 3 System controller MELANS malfunction 2 Check the causes...

Page 173: ...K 3 Cause check method and remedy 1 Troubleshooting problems for LOSSNAY units Error display ME remote controller RC MA remote controller MA Types of refrigerant systems Single refrigerant system Grouped operation of multiple refrigerant systems Troubleshooting problems for LOSSNAY units Troubleshooting problems for LOSSNAY units Troubleshooting problems for all units A Cause Check method and reme...

Page 174: ...ms Single refrigerant system Grouped operation of mul tiple refrigerant systems Types of indoor units experiencing problems Part of the indoor units IC are experiencing problems All indoor units IC in the same system are experi encing problems All indoor units IC are experiencing problems Troubleshooting problems for ME remote controllers Troubleshooting prob lems for ME remote con trollers Troubl...

Page 175: ...oubleshooting problems for system controllers Error display ME remote controller RC MA remote controller MA Type of unit controller in error Part of the ME remote con trollers RC are experi encing problems All indoor units IC in the same system are experi encing problems All ME remote controllers RC are experiencing problems Troubleshooting problems for system controllers Troubleshooting prob lems...

Page 176: ...n the Cause col umn When no errors are present Indoor unit circuit board failure 4 The male power supply connectors on 2 or more outdoor units are connected to the female power supply switch connector CN40 for centralized control If an error occurs after the unit runs normally once the following causes may be considered Total capacity error 7100 Capacity code error 7101 Error in the number of conn...

Page 177: ...sting address which some indoor units have Use either of the following two methods for dele tion 2 Although the address of LOSSNAY has been changed af ter the interlock registration of LOSSNAY is made using ME remote controller the indoor unit is keeping the mem ory of the previous address 1 Address deletion by ME remote controller Delete unnecessary address information using the manual setting fu...

Page 178: ... 3 Decrease of transmission line voltage signal by exceeding acceptable range of transmission wiring Farthest 200m 656ft or less Remote controller wiring 12m 39ft or less 4 The transmission line voltage signal is decreased due to erroneous sizing of transmission line Wire diameter 1 25mm2 AWG16 or more 4 Check method and remedy 1 When an error occurs during commissioning turn off the power sources...

Page 179: ...nds or receives the signals from the remote controller 4 Check method and remedy 1 Check for disconnected or loose transmission lines for the indoor units or MA remote controllers 2 Confirm that the power is supplied to the main power source and the remote controller line 3 Confirm that MA remote controller s capacity limit is not exceeded 4 Check the sub main setting of the MA remote controllers ...

Page 180: ...ethod and remedy 1 Check for disconnected or loose transmission lines for the indoor units or MA remote controllers 2 Confirm that the power is supplied to the main power source and the remote controller line 3 Confirm that MA remote controller s capacity limit is not exceeded 4 Check the sub main setting of the MA remote controllers One of them must be set to MAIN 5 Diagnose the remote controller...

Page 181: ...d remedy 1 Check for disconnected or loose transmission lines for the indoor units or MA remote controllers 2 Confirm that the power is supplied to the main power source and the remote controller line 3 Confirm that MA remote controller s capacity limit is not exceeded 4 Check the sub main setting of the MA remote controllers One of them must be set to MAIN 5 Diagnose the remote controller describ...

Page 182: ... sends or receives the signals from the remote controller 4 Check method and remedy 1 Check for disconnected or loose transmission lines for the indoor units or MA remote controllers 2 Confirm that the power is supplied to the main power source and the remote controller line 3 Confirm that MA remote controller s capacity limit is not exceeded 4 Check the sub main setting of the MA remote controlle...

Page 183: ...the indoor units Cause Check method and remedy 1 Contact failure short circuit or miswiring converse wiring of in door outdoor unit connecting wire Check disconnecting or looseness of indoor outdoor unit connecting wire of indoor unit or outdoor unit Check all the units in case of twin triple quadruple indoor unit system 2 Defective transmitting receiving circuit of outdoor controller cir cuit boa...

Page 184: ...error Transmitting error Abnormal if 1 receiving is detected 30 times continuously though indoor controller board has transmitted 0 3 Cause check method and remedy Note Refer also to the Service Handbook for the indoor units Cause Check method and remedy 1 Defective transmitting receiving circuit of indoor controller board Turn the power off and on again to check If abnormality generates again rep...

Page 185: ... door outdoor unit connecting wire Check disconnecting or looseness of indoor outdoor unit connecting wire of all indoor units or outdoor units 2 Defective transmitting receiving circuit of outdoor controller cir cuit board Turn the power off and on again to check If abnormality generates again replace indoor controller board or outdoor controller circuit board Note other indoor controller board m...

Page 186: ...connecting wire of in door and outdoor units 2 Diameter or length of indoor outdoor unit connecting wire is out of specified capacity Check the following Diameter of the cables used for indoor outdoor lines maximum line distance between indoor and outdoor units max 50 m maximum line distance be tween indoor units daisy changed cables max 30 m and if flat cables such as VVF is used make sure they a...

Page 187: ...g capacity code of the connected indoor unit set by the switch SW2 on indoor unit board When the model name set by the switch is dif ferent from that of the unit connected turn off the power source of the outdoor and the indoor units and change the setting of the Qj capac ity code 2 The model selection switches SW5 3 5 8 on the outdoor unit are set incorrectly Check the setting for the model selec...

Page 188: ...of the in door unit which has the error source address set by the switch SW2 on indoor unit board When the model name set by the switch is differ ent from that of the unit connected turn off the power source of the outdoor and the indoor units and change the setting of the capacity code The capacity of the indoor unit can be con firmed by the self diagnosis function SW1 operation of the outdoor un...

Page 189: ...ssion line When 2 and 3 apply the following display will appear 3 Check whether the transmission line for the terminal block for cen tralized control TB7 is not con nected to the terminal block for the indoor outdoor transmission line TB3 ME remote controller Nothing appears on the remote controller be cause it is not powered MA remote controller HO or PLEASE WAIT blinks 4 The model selection swit...

Page 190: ...ng of OC unit address The address of outdoor unit is not being set to 51 100 Check that the address of OC unit is set to 51 100 Reset the address if it stays out of the range while shutting the power source off Error source Cause Check method and remedy A remote controller for use with indoor units such as the MA remote controller is connected to the OA processing unit whose attribute is FU To ope...

Page 191: ...t off 1 Confirm that the power to the transmission booster is not cut off by the booster being connected to the switch on the indoor unit The unit will not function properly unless the transmission booster is turned on 2 Power resetting of the transmission booster and outdoor unit ĺReset the power to the outdoor unit 3 Wiring failure between OC and OS 2 Confirm that the TB3 on the OC and OS are pr...

Page 192: ... con nection 4 Check the connector CNTYP on the INV board for proper connec tion Detail code 16 1 Check the settings of SW5 3 through SW5 6 on the control board 2 Check the connector CNTYP5 on the control board for proper con nection 3 Check the connector CNTYP2 on the control board for proper con nection 4 Check the wiring between the control board and INV board Refer to the following page s 7 2 ...

Page 193: ... CNTYP5 on the control board for proper connection 2 Check the connector CNTYP2 on the control board for proper connection 3 Check the wiring between the control board and INV board Refer to the following page s 7 2 1 Error Code 0403 4 Check the connector CNTYP on the INV board for proper connection Detail codes 56 66 1 Check the wiring between the control board and the Fan INV board Refer to the ...

Page 194: ...ted 3 Error source cause check method and remedy Error source Cause Check method and remedy Outdoor unit The connected indoor unit is for use with R22 or R407C Incorrect type of indoor units are connected The M NET connection adapter is connected to the indoor unit system in a system in which the Slim Model A control of units are con nected to the M NET Check the connected indoor unit model Check ...

Page 195: ... 7 9 Error Code Definitions and Solutions Codes 7000 7999 74 chapter 7 HWE18240_GB 7 Troubleshooting Using Error Codes ...

Page 196: ... 8 5 4 Low Pressure Sensor Configuration 63LS 21 8 6 Troubleshooting Solenoid Valve Problems 22 8 7 Troubleshooting Outdoor Unit Fan Problems 24 8 8 Troubleshooting LEV Problems 25 8 8 1 General Overview on LEV Operation 25 8 8 2 Possible Problems and Solutions 28 8 8 3 Coil Removal Instructions 29 8 9 Troubleshooting Inverter Problems 31 8 9 1 Inverter Related Problems and Solutions 31 8 9 2 Chec...

Page 197: ... Four way Valve and Check Valve Replacement Procedure 54 8 12 4 Compressor Replacement Procedure 62 8 12 5 Removal Instructions for the Control Box 64 8 12 6 Transformer box replacement instructions 66 8 12 7 Maintenance Procedure for the Drain Pan 68 8 12 8 Maintenance Procedures for the Heat Exchanger 70 8 12 9 Accumulator Replacement Procedure 77 8 13 Troubleshooting Problems Using the LED Stat...

Page 198: ...0 240 VAC power supply cable Reversed connection of the wire for the MA remote controller and the M NET transmission line on the indoor unit 3 The number of the MA remote controllers that are connected to an indoor unit exceeds the allowable range 2 units 4 The length or the diameter of the wire for the MA remote controller are out of specification 5 Short circuit of the wire for the remote displa...

Page 199: ...ale power supply connectors on the multiple outdoor units are connected to the female power supply switch connector CN40 In the system to which the power supply unit for transmission lines is connected the male power supply connector is connect ed to the female power supply switch connector CN40 on the outdoor unit 4 Disconnected M NET transmission line on the indoor unit side 5 Disconnected wire ...

Page 200: ... the indoor unit and the indoor unit board CN2M or disconnected connector 6 Incorrect wiring for the MA remote controller Short circuited wire for the MA remote controller Disconnected wire for the MA remote controller No 2 and disconnected line to the terminal block Reversed daisy chain connection between groups Incorrect wiring for the MA remote controller to the terminal block for transmission ...

Page 201: ...door unit Does an error occur when the power is reset Check that no error occurs in other indoor units Check the indoor unit on which LED2 is lit All the indoor unit power failure All the indoor unit power failure Error display Error display Thermo is OFF Is operation possible Short circuit of the remote controller After turning the power on check whether HO PLEASE WAIT is displayed on the remote ...

Page 202: ...cted line to the terminal block The indoor transmission line is connected incorrectly to the transmission terminal block for centralized controller TB7 4 Disconnected transmission line on the remote controller 5 Remote controller failure 6 Outdoor unit failure For details refer to the following page s 8 13 Troubleshooting Problems Using the LED Status Indica tors on the Outdoor Unit 3 Check method...

Page 203: ... YES NO NO NO NO NO NO YES 1 1 Check LED1 on the indoor unit control board Is it lit When it is lit When it is off or cannot be checked Check for the change of LED display by operating dip switch for self diagnosis Check voltage of the power supply terminal on the indoor unit AC220V Check the fuse on the circuit board Melted Check 200V circuit for short circuit and ground fault Check the connectio...

Page 204: ...minal block for M NET line connection TB5 of the indoor unit and the male connector CN2M 7 The male power supply connectors on 2 or more outdoor units are connected to the female power supply switch connector CN40 for the transmission line for centralized control 8 Outdoor unit control board failure 9 Indoor unit control board failure 10 Remote controller failure Interlocking control with MELANS 1...

Page 205: ... wrong address is set to the outdoor unit Wrong switch setting Change it from ON to OFF A wrong address is set to the ME remote controller A wrong address is set to the indoor unit Wrong wiring of the M NET transmission line of the indoor unit Disconnected connector CN2M Correct the error Disconnected 17 30V ME remote controller 100 Check the address of the indoor unit to be coupled Indoor unit 10...

Page 206: ...e indoor units connected to different outdoor units are grouped 6 The power of the outdoor unit to be confirmed has been cut off 5 Check the power supply of the outdoor unit which is coupled with the unit to be confirmed 7 Transmission line is disconnected from the terminal block for central control system connection TB7 on the outdoor unit 6 Check that the transmission line for centralized contro...

Page 207: ...insufficient capacity SW4 setting SW6 10 OFF 2 Check temperature difference between the evaporat ing temperature Te and the target evaporating tem perature Tem with self diagnosis LED Note Higher Te than Tem causes insufficient capacity SW4 setting SW6 10 OFF Note Protection works and compressor frequency does not rise even at higher Te than Tem due to high discharge temperature and high pressure ...

Page 208: ...eam side and downstream side When the temperature drops significantly the foreign object may clog the pipe ĺ Remove the foreign object inside the pipe 8 The indoor unit inlet temperature is excessively low Less than 15 C 59 F WB Check the inlet air temperature and for short cy cling Change the environment where the indoor unit is used 9 Compressor failure The amount of circulating refrigerant decr...

Page 209: ...ing the High Pressure Sensor Measurement and Gauge Pressure Note Higher inlet pressure by the high pressure sensor than the actual pressure causes insufficient capac ity SW4 setting SW6 10 OFF 2 Check the difference between the condensing tem perature Tc and the target condensing tempera ture Tcm with self diagnosis LED Note Higher Tc than Tcm causes insufficient capacity SW4 setting SW6 10 OFF No...

Page 210: ... of pipe during cooling operation ĺ Remove the blockage in the pipe 9 The indoor unit inlet temperature is excessively high exceeding 28 C 82 F Check the inlet air temperature and for short cy cling Change the environment where the indoor unit is used 10 Insufficient refrigerant amount Protection works and compressor frequency does not rise due to low discharge temperature Refrigerant recovery ope...

Page 211: ...or history on LED display with SW4 2 Abnormal discharge air temperature 3 Heatsink thermistor failure ĺ Refer to the reference page for each error mode Display the indoor piping temperature with SW4 to check whether the freeze proof operation runs properly and check the temperature 4 Thermistor failure 5 Pressure sensor failure Refer to the following page s 10 LED Status Indi cators on the Outdoor...

Page 212: ...ot a problem when the shield of the transmission line is grounded 2 The sectional voltage level of transmission signal should be as follows Cause Erroneous operation Error code Error code definition Noise interference on the transmission line Signal is transformed and will be misjudged as the signal of another address 6600 Address overlap Transmission wave pattern is transformed due to the noise c...

Page 213: ... no grounding is provided the noise on the transmission line can not escape leading to change of the transmission signal 6 Check the treatment meth od of the shield of the transmission line for cen tralized control The transmission cable for centralized control is less subject to noise interference if it is grounded to the outdoor unit whose power jumper cable was moved from CN41 to CN40 or to the...

Page 214: ...enerated on the transmission line and the communication between the MA remote controller and the indoor unit is interrupted for 3 minutes in a row MA transmission error 6831 will occur 2 Confirmation of transmission specifications and wave pattern A B No polarity Across terminal No 1 2 Power supply 9V to 12VDC Satisfies the formula 12 msec bit 5 Voltage among terminals must be between DC9 and 12 V...

Page 215: ...essure displayed on self diagnosis LED1 while the sen sor is running Compare them by MPa psi unit 1 When the difference between both pressures is within 0 098MPa 14psi both the high pressure sensor and the control board are normal 2 When the difference between both pressures exceeds 0 098MPa 14psi the high pressure sensor has a problem perfor mance deterioration 3 When the pressure displayed on se...

Page 216: ...t and the value of this voltage will be converted by the microcomputer The output voltage is 0 071V per 0 098MPa 14psi The pressure sensor on the body side is designed to connect to the connector The connector pin number on the body side is different from that on the control board side Body side Control board side Vcc Pin 1 Pin 3 Vout Pin 2 Pin 2 GND Pin 3 Pin 1 0 0 5 73 1 0 145 1 5 218 2 0 290 2 ...

Page 217: ...the low pressure sensor has a problem performance dete rioration 3 When the pressure displayed on the self diagnosis LED1 does not change the low pressure sensor has a problem 3 Remove the low pressure sensor from the control board to check the pressure with the self diagnosis LED1 display 1 When the pressure displayed on the self diagnosis LED1 is between 0 and 0 098MPa 14psi the low pressure sen...

Page 218: ...t and the value of this voltage will be converted by the microcomputer The output voltage is 0 173V per 0 098MPa 14psi The pressure sensor on the body side is designed to connect to the connector The connector pin number on the body side is different from that on the control board side Body side Control board side Vcc Pin 1 Pin 3 Vout Pin 2 Pin 2 GND Pin 3 Pin 1 0 0 2 29 0 4 58 0 6 87 0 8 116 1 0 ...

Page 219: ...e to check whether the valve has no faults and the electricity runs between where and where Do not touch the pipe when checking the temperature as the pipe on the oil separator side will be hot Do not give an impact from outside as the outer hull will be deformed leading to the malfunction of the inner valve 2 21S4b 4 way switching valve About this 4 way valve When not powered Conducts electricity...

Page 220: ... next to the valve Therefore temperature of the downstream piping will not be low with the valve closed 4 SV2 solenoid valve This solenoid valve is a switching valve that opens when energized Proper operation of this valve can be checked on the LED and by the switching sound 5 SV9 Solenoid valve This solenoid valve is a switching valve that opens when energized Proper operation of this valve can b...

Page 221: ...the indoor unit operation capacity is low the revolution of the fan may change If the fan does not move or it vibrates fan board problem or fan motor problem is suspected When checking the fan motor for problems by shutting down the power be sure to disconnect the motor wire from the fan board If a short circuited fan board malfunctions it will keep the fan motor from rotating smoothly For details...

Page 222: ... the number of pulses 1 Indoor unit control board and the LEV Indoor unit Linear expansion valve 2 Outdoor unit control board and the LEV Outdoor unit Linear expansion valve Note The connector numbers on the intermediate connector and the connector on the control board differ Check the color of the lead wire to judge the number Control board Drive circuit LEV M 5 5 2 2 1 1 3 3 4 4 6 6 DC12V Red In...

Page 223: ...wer on the indoor unit circuit board sends a 2200 pulse signal to the indoor unit LEV and a 3200 pulse signal to the outdoor unit LEV to determine the valve position and always brings the valve to the position as indicated by A in the diagram When the valve operates smoothly no sound from LEV or no vibration occurs however when the pulses change from E to A in the chart or the valve is locked a bi...

Page 224: ...s closed 8 7 6 5 4 3 2 1 8 1 When the LEV opening angle does not change all the output phases will be off 2 When the output is open phase or remains ON the motor cannot run smoothly and rattles and vibrates Output phase number Output state Upon power on the indoor unit circuit board sends a 520 pulse signal to the indoor unit LEV to determine the valve position and always brings the valve to the p...

Page 225: ...eplace the LEV coils Indoor Measure the resistance between coils red white red orange red yellow red blue with a tester When the resistance is in the range of 100ȍ 10 the LEV is normal Replace the LEV coils Outdoor LEV2a LEV2b Measure the resistance between coils red white red orange brown yellow brown blue with a tester When the resistance is in the range of 46ȍ 3 the LEV is normal Replace the LE...

Page 226: ...ill not move then pull out the coils toward the top If the coils are pulled out without the body gripped undue force will be applied and the pipe will be bent 3 Installing the coils Fix the body tightly at the bottom Part A in the figure so that the body will not move then insert the coils from the top and insert the coil stopper securely in the pipe on the body If the coils are pushed without the...

Page 227: ...r checking that the stopper is re moved pull up and out the coil When removing the coil hold the LEV body securely to prevent undue force from being placed on the pipe and bending the pipe 3 Installing the coil Securely hold the bottom of the LEV Part A in the figure insert the coil from above and turn the coil until the coil stopper is properly installed on the LEV body When removing the coil hol...

Page 228: ...er disconnecting the relay connectors of the outdoor unit fan RYFAN1 and RYFAN2 Before plugging in or unplugging connectors check that the outdoor unit fan is not rotating and that the voltage across Pin 1 and Pin 5 of connector RYPN is 20 VDC or less The capacitor may collect a charge and cause an electric shock when the outdoor unit fan rotates in windy conditions Refer to the wiring nameplate f...

Page 229: ...ently at all times or makes an abnormal sound Check the inverter frequency on the LED monitor If the frequency indi cates that the units are in operation refer to the following page s 8 9 7 Checking the Fan Board Error Detection Circuit at No Load 8 9 8 Checking the Fan Board for Damage at No Load 8 9 9 Checking the Fan Board for Damage with Load 9 Noise is picked up by the peripheral device 1 Che...

Page 230: ...l code No 117 Replace the INV board 4 Put the outdoor unit into operation 4 IPM open Error code 5301 Detail code No 119 Normal Items to be checked Phenomena Remedy Disconnect the compressor wir ing and check the compressor Meg and coil resistance 1 Compressor Meg failure Error if less than 1 Mȍ Check that there is no liquid refrigerant in the compressor If there is none replace the compres sor 2 C...

Page 231: ...pressor and that there is no liquid backflow ĺGo to d when the problem per sists after compressor startup was repeated several times d Check that there is a pressure dif ference between high and low pressures after compressor start up ĺCheck the high pressure with LED monitor for changes Replace the compressor if there is no pressure difference the com pressor may be locked 2 There is a voltage im...

Page 232: ...4 Operate the unit Items to be checked Phenomena Remedy 1 Stop the unit Turn off the breaker Be sure to turn off the power 1 An error other than the current sen sor error 5305 5306 Detail code 135 is detected within 30 seconds from the startup of operation Replace the fan board 2 To allow for the disconnection of output wiring from the fan motor disconnect connector RYFAN1 On a model with two fan ...

Page 233: ... fan motor 3 Operate unit 3 Sensor error during operation Check code 5305 5306 Detail code 135 136 a Check for disconnection of fan in verter output wiring and for broken wiring b If the error is not associated with any of the items above replace the fan board c Change fan motor if Fan board change doesn t resolve issue 4 Voltage overload error Check code 4225 4226 Detail code 109 a Check for gust...

Page 234: ...aker 2 Perform Meg check between the terminals on the power terminal block TB1 Zero to several ohm or Meg failure Check each part and wiring Refer to the following page s 8 9 13 Sim ple Check on Inverter Circuit Components IGBT module Rush current protection resistor Electromagnetic relay DC reactor 3 Turn on the power again and check again 1 Main power breaker trip 2 No remote control display 4 T...

Page 235: ...Replace with a regulation earth leakage breaker 2 Check the resistance at the power supply terminal block TB1 with a megger Failure resistance value Check each part and wiring Refer to the following page s 8 9 13 Sim ple Check on Inverter Circuit Components IGBT module Rush current protection resistor Electromagnetic relay DC reactor 3 Disconnect the compressor wir ings and check the resistance of...

Page 236: ... a coil Check the resistance between terminals YNU TNU DC reactor DCL Measure the resistance between terminals 1ȍ or lower almost 0 ȍ Measure the resistance between terminals and the chassis Current sensor ACCT Disconnect the wiring connector from CNCT2 and measure the inter teminal resistance 280ȍ 30ȍ Between pins 1 and 2 U phase pins 3 and 4 W phase 4 3 2 1 Coil Contact INV board X901 X902 Acros...

Page 237: ...t the resistance is not open ȍ or not shorted to 0 ȍ The values are for reference and the margin of errors is allowed The result that is more than double or half of the result that is measured at the same measurement point is not allowed Disconnect all the wiring connected the INV board and make the measurement 2 Tester restriction Use the tester whose internal electrical power source is 1 5V or g...

Page 238: ...utline drawing INV42Y Reference resistance value Black SC P CN N SC L1 SC L2 SC L3L Red SC P 5 200 ȍ 5 200 ȍ 5 200 ȍ CN N SC L1 5 200 ȍ SC L2 5 200 ȍ SC L3 5 200 ȍ Black SC P1 CN N SC U SC V SC W Red SC P1 5 200 ȍ 5 200 ȍ 5 200 ȍ CN N SC U 5 200 ȍ SC V 5 200 ȍ SC W 5 200 ȍ SC L1 SC L2 SC L3 SC U CN N SC P SC P1 SC V SC W ...

Page 239: ... Reference resistance value Black SC L1 SC L2 SC L3L SC PL SC N1 Red SC L1 5 200 ȍ SC L2 5 200 ȍ SC L3 5 200 ȍ SC PL 5 200 ȍ 5 200 ȍ 5 200 ȍ SC N1 Black SC P1L SC N2 SC D1 SC D2 SC D3 Red SC P1L 5 200 ȍ 5 200 ȍ 5 200 ȍ SC N2 SC D1 5 200 ȍ SC D2 5 200 ȍ SC D3 5 200 ȍ SC L3 SC D1 SC U SC D2 SC V SC D3 SC W SC L2 SC L1 SC N2 SC P1L SC PL SC N1 ...

Page 240: ...inside the duct To remove the duct follow the procedures 1 through 2 below Reassemble the components in the reverse order as they were removed 1 Remove the front service panel Service panel Top section of the duct Remove the two screws holding the top section of the duct 2 Remove the upper section of the duct by unscrewing the screws on the control box shown in the figure below Check inside the du...

Page 241: ...roller Indoor unit TB1 AC Power source YNU 460 VAC Power supply terminal block Outdoor unit CN40 Inverter board Rectifier Rectifier 72C DCL 5 V power supply Smoothing capacitor Inverter Microcomputer Inverter drive circuit Compressor Noise filter Fuse Surge protector Solenoid valve Four way valve Control board Fuse Microcomputer FAN board Fuse Heat exchanger fan Microcomputer 5Vpowersupply FAN boa...

Page 242: ...ire TB1 AC Power source TNU 208 230 VAC Power supply terminal block Outdoor unit CN40 Inverter board Rectifier Rectifier 72C DCL 5 V power supply Smoothing capacitor Inverter Microcomputer Inverter drive circuit Compressor Noise filter Fuse Fuse Surge protector Solenoid valve Four way valve Control board Fuse Microcomputer FAN board Fuse Heat exchanger fan Microcomputer 5Vpowersupply FAN board Fus...

Page 243: ...m TB3 Check whether the male connector is connected to the female power supply connector CN40 Connected Check voltage of terminal block for centralized control TB7 Check voltage of TB7 by removing transmission line from TB7 Check the voltage across pins 3 and 4 of CNPW on the control board Check the voltage across pins 1 and 2 of CNPW on the control board Check the voltage across pins 1 and 2 of C...

Page 244: ... Any loose screws NO Tighten loose screws Replace the noise filter Check the power supply wiring and the main power supply and correct any problems found Turn the power supply back on Check the wiring between the noise filter board and TB1 of power supply terminal block for proper connections Check the voltage across L1 and L2 of power supply terminal block TB1 Check for conductivity between TB11 ...

Page 245: ... whether the male connector is connected to the female power supply connector CN40 Connected Check voltage of terminal block for centralized control TB7 Check voltage of TB7 by removing transmission line from TB7 Check the voltage across pins 3 and 4 of CNPW on the control board Check the voltage across pins 1 and 2 of CNPW on the control board Check the voltage across pins 1 and 2 of CN600 on the...

Page 246: ... loose screws NO Tighten loose screws Replace the noise filter Check the power supply wiring and the main power supply and correct any problems found Turn the power supply back on Check the wiring between the noise filter board and TB1 of power supply terminal block for proper connections Check the voltage across L1 and L2 of power supply terminal block TB1 Check for conductivity between TB12 and ...

Page 247: ...d is ON 2 Change the setting of the remote controller for all the indoor units to the cooling mode 3 Check that all the indoor units are performing a cooling operation 2 Check the values of Tc and TH6 To display the values on the LED screen use the self diagnosis switch SW4 when SW6 10 is set to OFF on the outdoor unit control board 1 When Tc TH6 is 10 C 18 F or more See the next item 3 2 When Tc ...

Page 248: ...ing a heating operation 2 Stop all the indoor units and stop the compressor 1 To stop all the indoor units and the compressors turn SW4 769 from ON to OFF when SW3 1 on the outdoor control board is ON 2 Check that all the indoor units are stopped 3 Close the service valves BV1 and BV2 4 Collect the refrigerant that remains inside the indoor unit and optional unit Do not discharge refrigerant into ...

Page 249: ...er in place with a cable tie 6 Remove the drain pan by unscrewing the two screws See Figure 2 Be sure to remove the two rod holders holding the check joints to the drain pan Figures 2 and 3 show the cable ties to be cut 7 Remove the two cable straps holding the weak electrical wiring and the two cable straps holding the strong electrical wiring from the control box See Figure 4 8 Place the excess ...

Page 250: ... HEATER WIRE TRANSFORMER BOX WIRE YNU Fix the wires in place to leave no space between the rubber bushes and the wires Fix the wires in place to leave no space between the notches on the rubber bushes and the wires Fix the wires in place with cable straps HIGH VOLTAGE WIRE Fix the wires in place with cable straps SENSOR WIRE LEV WIRE Cable strap UNUSED LEFT VIEW TOP LEFT VIEW BOTTOM CONTROL BOX CO...

Page 251: ...he Maintenance of Refrigerant Circuit Parts 1 Remove the top compressor cover by unscrewing the three screws See Figure 1 Remove the compressor cover by unhooking the hooks on the back 2 Remove the front compressor cover by unscrewing the four screws See Figure 2 3 Cut the two cable ties holding TH4 and TH15 and remove the wiring from the rubber bush on the left compressor cover See Figure 3 4 Rem...

Page 252: ... remove the pipes Save the removed pipes for later use 6 Remove the plastic cover and the coil holding the four way valve See Figure 6 Figure 6 Four way valve coil A Four way valve coil B Notes on replacing refrigerant circuit components check valve four way valve solenoid valve and LEV Be sure to perform non oxidized brazing Before heating the pipes wrap the refrigerant circuit components with a ...

Page 253: ...ith the one included with the four way valve The replacement parts for this part is included with the replacement kit that contains four way valve 21S4a Replace the old cap with the one included with the four way valve 12A Remove the pipe below four way valve 21S4a and on the back by removing the braze at the two areas on the bottom of the pipe shown in Figure 12 Then remove the braze at the areas...

Page 254: ...equire brazing including the area indicated in 15A and the areas indicated in Figure 16 Figure 16 Front view 90 Cut the pipe here Severed pipe Pipe diameter φ19 05 ID of the pipe with an extended end φ19 05 Figure 15 Cut the pipe with an expanded end that is included with four way valve 21S4a so that the section of the pipe excluding the extended end will be the same length as the pipe that was re...

Page 255: ...re 17 18A Mount four way valve 21S4a to the pipe below four way valve 21S4a and on the front by brazing at the four areas See Figure 18 This step completes the replacement procedure for four way valve 21S4a Re place the solenoid valve and LEV assembly that were removed in step 7 and all the pipe covers that were removed during the maintenance work as they were Figure 17 Reinstall these pipes Re pl...

Page 256: ...ned below is the procedure for replacing four way valve 21S4b on the left when seen from the front of the unit Secure sufficient work space before starting maintenance work See 8 12 1 Ensuring Maintenance Space Preparation for the Maintenance of Refrigerant Circuit Parts Remove the rubber spacer Figure 19 Figure 20 Figure 21 L module Severed pipe Pipe diameter φ19 05 ID of the pipe with a narrowed...

Page 257: ... Re place the solenoid valve and LEV assembly that were removed in step 7 and all the pipe covers that were removed during the maintenance work as they were 23B Mount four way valve 21S4b to the pipe below four way valve 21S4b and in the middle A total of five areas require brazing including the area indicated in 22B and the areas indicated in Figure 22 Mount four way valve 21S4b horizontal to fou...

Page 258: ...dures below to remove check valve CV1 located in the back of the four way valve 1 Follow the steps 1 through 9A under item 1 L module under 8 12 3 Four way Valve and Check Valve Replacement Procedure to Create Access to Check Valve CV1 2 Remove the braze from two areas on check valve CV1 The above step completes the check valve CV1 replacement procedure Re place the solenoid valve LEV assemby and ...

Page 259: ...compressor cover See Figure 3 4 Remove the right and left compressor covers by unscrewing the four screws See Figure 4 5 Remove the saddle and the rubber spacers on the compressor by unscrewing the screw See Figure 5 6 Remove the cover of the compressor terminal block box mounting support metal and the mounting plate by unscrewing the two screws See Figure 6 7 Remove thermal insulation 1 and therm...

Page 260: ...n Figure 9 10 Remove the pipe covers and then remove the braze See Figure 10 Do not force the injection pipe to deform 11 Remove the compressor discharge pipe by cutting the pipe where indicated in Figure 11 or by removing the braze Figure 11 Damper and cable tie Pipe cover Cut the suction pipe here Cut the compressor discharge pipe here Figure 10 Remove the braze here Remove the two pipe covers S...

Page 261: ...ng pipes Be sure to perform non oxidized brazing Before heating the pipes wrap the refrigerant circuit components with a wet towel to keep the temperature of the components from rising above 120 C After brazing is done check that the brazing is done properly and check for leaks before vacuum drying the pipes Direct the brazing torch flame away from the wiring and sheet metals inside the unit not t...

Page 262: ...t Notes on replacing the control box when replacing the refrigerant cooling pipes Be sure to perform non oxidized brazing Before heating the pipes wrap the refrigerant circuit components with a wet towel to keep the temperature of the components from rising above 120 C After brazing is done check that the brazing is done properly and check for leaks before vacuum drying the pipes Direct the brazin...

Page 263: ...igure 2 1 Ensure there is adequate work space See 8 12 1 2 Remove the control box cover 5 screws as shown in Fig 1 3 Unstrap the cable straps holding the transformer box wiring and disconnect the wiring connectors and the grounding wire 5 cable straps 3 connectors and 1 grounding screw as shown in Fig 2 Connector Cable strap Cable strap Cable strap Cable strap Relay connector Grounding screw ...

Page 264: ... as shown in Figure 3 5 Remove the transformer box Figure 4 Transformer box Figure 3 Figure 4 4 Lift the transformer box to the position as shown in the figure move the box to the designated position and screw it down 3 screw as shown in Figure 5 Use caution not to damage the heat exchanger fins or pipes and wires in the adjacent areas when replacing the transformer box Screw down 3 locations Figu...

Page 265: ...ee Figure 2 3 Cut the cable tie unscrew the screw and pull the drain cover out to the right See Figure 3 4 Remove the two rod holders holding the check joints in place using a wrench See Figure 4 5 Remove the drain pan by unscrewing the two screws See Figure 5 6 Clean the drain pan and the drain pan cover See Figure 6 Remove dust and dirt from the drain groove Front panel Fin guard left Fin guard ...

Page 266: ...n pan See Figures 9 and 10 4 Thread a cable tie through the rectangle hole on the screwed down drain cover and hold the silicon tube and the defrost pipe together in place See Figure 11 5 Screw down the fin guards center pillar and front panel with 14 screws See Figure 12 Drain pan Silicon tube Defrost pipe Defrost pipe cable tie Check joint Rod holders Fin guard left Fin guard right Center pillar...

Page 267: ...pan cover make sure that the silicon tube is properly placed on the defrost pipe and then fix the drain pan cover in place with a cable tie 6 Remove the drain pan by unscrewing the 2 screws See Figure 3 Be sure to remove the two rod holders holding the check joints to the drain pan See Figure 4 7 Remove the cover from the control box by unscrewing the 5 screws See Figure 5 8 Remove the cable strap...

Page 268: ...ater wiring with adhesive tape or other materials 4 locations as shown in Figure 8 Before removing the protective tube After removing the protective tube Unit wiring Cable tie Protective tube Panel heater wiring sold separately Unit wiring Connector Panel heater wiring sold separately Right fin guard 2 2 2 Figure 7 Right Figure 7 Rear Figure 7 Left Figure 8 Right Figure 8 Rear Figure 8 Left Rear f...

Page 269: ...ure 12 Rear 17 Remove the TH7 wiring from the heat exchanger by cutting the cable tie See Figure 13 14 Remove the unit wiring from the left frame See Figure 11 Bundle all excess unit wirings including those that have been removed so that they do not interfere with the replacement of the heat exchanger Use the supplied spacers Use the spacers 60 D x 250 W x 60 H when replacing the heat exchangers f...

Page 270: ...emove the left front pillar by unscrewing the 9 screws on a standard model or 10 screws on a high efficiency model See Figure 15 Front and Left 21 Remove the right front pillar by unscrewing the 5 screws See Figure 15 Front and Right Use the supplied spacers Use the spacers 60 D X 250 W X 60 H when replacing the heat exchangers for the maintenance of the accumulator and the pipes Right frame Front...

Page 271: ...and check for leaks before vacuum drying the pipes Direct the brazing torch flame away from the wiring and sheet metals inside the unit not to damage them Place the wet felt sheets listed below or their equivalents around the areas to be brazed to protect the heat exchanger pipes and pipe covers from being damaged from the brazing torch flame Recommended felt sheets Spatter felt 50CF 11 5t x 1 m x...

Page 272: ... on a standard model See Figure 18 To remove the rear heat exchanger loosen the screws on the back of the right rear pillar 4 screws on a standard model See Figure 19 Remove the screw holding the pillar to the rear heat exchanger support Loosen the screws Unscrew the screws Removing the front heat exchanger Figure 18 Removing the rear heat exchanger Figure 19 24 Remove the heat exchanger by diagon...

Page 273: ...ure 22 Figure 23 Front heat exchanger Front heat exchanger support Unscrew the screws Rear heat exchanger support Center pillar Unscrew the screws 26 Re place the front and the rear heat exchangers in the reverse order as they were removed Re place the components that were removed as they were Re place each unit wiring according to the wiring color and identification label attached to the wiring p...

Page 274: ... procedure for details 4 Remove the right and inside right panels by unscrewing the eight screws Applicable only to the S module See Figures 1 and 2 5 Unscrew the four screws from the right accumulator fixing plate See Figures 3 and 5 6 Unscrew the four screws from the rear accumulator fixing plate See Figures 3 and 4 7 Remove the four screws from the accumulator fixing accumulator legs See Figure...

Page 275: ... circuit components with a wet towel to keep the temperature of the components from rising above 120 C After brazing is done check that the brazing is done properly and check for leaks before vacuum drying the pipes Direct the brazing torch flame away from the wiring and sheet metals inside the unit not to damage them Wet felt sheets listed below or its equivalent and place them around the areas t...

Page 276: ... Supply Circuit 2 If the LED error display becomes lit when the power is turned on with all the connectors on the control board except CNDC disconnected there is a problem with the wiring to those connec tors or with the connectors themselves 3 If nothing appears on the display under item 2 above AND the voltage between pins 1 and 3 of CNDC is within the range between 220 VDC and 380 VDC control b...

Page 277: ... 8 13 Troubleshooting Problems Using the LED Status Indicators on the Outdoor Unit 80 chapter 8 HWE18240_GB 8 Troubleshooting Based on Observed Symptoms ...

Page 278: ...d Storage Functions 4 9 2 1 Preparation 4 9 2 2 Storing Data on a USB Memory Stick 4 9 2 3 Collecting Operation Data 6 9 2 4 Precautions 7 9 3 Software Rewrite Function on the USB 8 9 3 1 Preparation 8 9 3 2 Rewriting Software 8 9 3 3 Precautions 9 9 4 Maintenance LED Display and Troubleshooting 10 9 4 1 Maintenance LED Display Content List 10 9 4 2 Troubleshooting 13 ...

Page 279: ...HWE18240_GB ...

Page 280: ...d andstored in the flash memory in the control board of the outdoor unit OC The data can be transferred and stored in a USB memory stick 2 Software rewrite function The software on outdoor units can be rewritten using a USB memory stick For detailed information about each function refer to Section 9 2 Operation Data Collection and Storage Functions and Sec tion 9 3 Software Rewrite Function on the...

Page 281: ...iew 2 chapter 9 HWE18240_GB 9 USB Function 9 1 2 System Structure 1 Control board on the outdoor unit CN601 SWP3 Push switch Function setting LED301 Maintenance LED CNUSB USB memory connector SW4 Dip switch SW6 10 SW7 9 ...

Page 282: ...d in FAT 32 Without a security function 2 Portable battery charger Use a portable battery charger that meets the following specifications for rewriting the software USB 2 0 compatible Voltage and amperage rating of 5 V and 2 1 A MAX A LEAD WIRE ASSY USB is required to connect the control board and the portable charger Use a cable that meets the following specifications Type A male Male XA connecto...

Page 283: ...nd files should be deleted 2 Storing data on a USB memory stick Data can be stored to a USB memory stick either with the main power to the outdoor unit turned on Method 2 or off Method 1 For safety reasons it is recommended to store the data on a USB memory stick with the main power to the outdoor unit turned off Method 1 If turning off the power is not feasible take appropriate measures to ensure...

Page 284: ...End on the LED indicates successful completion of the data storage process It takes approximately five minutes for the data storage process to be completed Ending the data storage mode When done storing data disconnect the USB memory stick from the control board Press and hold SWP3 ENTER for approximately 10 seconds until End disappears from the monitoring LED 301 Restart the indoor and outdoor un...

Page 285: ...ata collection 1 Set the switches on the control board by following the table shown above Switch setting SW6 10 ON SW4 817 2 Press SWP3 ENTER With each switch operation the setting can be alternately switched ON and OFF 3 After conducting step 1 check that the operating condition is stable Data collection start OFF Enabled Data collection end ON Disabled Setting procedure is now complete 3 Setting...

Page 286: ...er storing process nor unit operation If an error occurs refer to 9 4 2 Troubleshooting After normal startup set the operation status of the air conditioning units to the original status USB memory sticks may become unusable due to unexpected damage or memory shortage It is recommended to take extra USB memory sticks to the site If only the OS is operated due to problems with the OC collect data a...

Page 287: ...nsert the USB memory stick into the USB port CNUSB on the control board 4 Connect the portable battery charger to the XA connector CN601 for the PCB The power of the control board will turn on 5 Make sure the display Pro is shown on the maintenance LED LED301 This shows that Software Rewrite Mode has been started 2 Performing software rewriting 1 Wait for 5 seconds after Pro appeared on the LED an...

Page 288: ...ortable battery charger to the LEAD WIRE ASSY USB and then to the control board Make sure the portable battery charger is sufficiently charged Rewrite error may occur if battery charge is insufficient Take care not to forget to remove the USB memory stick in step 3 2 or forget to turn off SW7 9 in step 3 3 9 3 2 Rewriting Software If these precautions are not taken the system may not start normall...

Page 289: ...y stick is active Storage is en abled See Section 9 4 2 Troubleshooting 1 1 and 1 2 2 Storage in progress 0 to 99 is displayed Status of the data storage to the USB memory stick is shown by the progress rate 3 Storage completed END The storage process has been completed successfully 4 Error USB memory side Er01 The storage process cannot be started due to failure of the USB memory stick See Sectio...

Page 290: ...ting is neces sary Data collection will be resumed automatically See Sec tion 9 4 2 Troubleshooting 2 1 7 Collection suspended OFF Collection of operation data is suspended 8 Flash memory error F Er Collection of operation data is suspended due to failure in the flash memory used to store opera tion data It may be necessary to change the board See Section 9 4 2 Troubleshooting 2 2 9 Error Err Erro...

Page 291: ...leted END Software rewrite has been completed successfully 13 Error USB memory side Er01 Software rewrite process cannot be started due to failure of the USB memory stick See Section 9 4 2 Troubleshooting 3 4 Er02 Software rewrite was stopped due to failure of the USB memory stick during the software rewrite process See Section 9 4 2 Troubleshooting 3 5 14 Error control board side Er10 Software re...

Page 292: ...ry stick meets the specification described in Section 9 1 3 Necessary Materials 1 USB memory stick If compliance is confirmed the USB memory stick may be broken Replace it with a new one 3 Maintenance LED displays Er01 Meaning or Cause Because there was a problem regarding the USB memory before the start of data storage data storage has not been com pleted Solution Check the connection of the USB ...

Page 293: ...in the data storage mode by following either of the two methods 1 or 2 the control board may be malfunctioning 2 Collecting operation data 1 Maintenance LED displays blinking ON Meaning or Cause Despite data collection function being enabled it is not started yet There may be two causes Firstly the initialization process immediately after the system startup may have inhibited the start of data col...

Page 294: ...software rewrite process has failed Solution After turning off control board switches SW7 9 turn on the system again If the switches are in the OFF position it means the software rewrite process has failed Try rewriting the software again by following the procedure detailed in 1 1 Starting software rewrite mode under Section 9 3 2 Rewriting Software If the problem persists rewrite the software usi...

Page 295: ...B memory stick If no problems are found follow the procedure starting with the step explained in 1 Operation procedure 1 Starting software rewrite mode under 9 3 2 Rewriting Software 6 Maintenance LED displays Er10 or Er11 Meaning or Cause Because there was a problem in the control board during the software rewrite process software rewrite has not been com pleted Solution Try rewriting the softwar...

Page 296: ...pter 10 LED Status Indicators on the Outdoor Unit Circuit Board 10 1 LED Status Indicators 1 10 1 1 How to Read the LED 1 10 1 2 Initial LED Display 2 10 1 3 Clock Memory Function 3 10 2 LED Status Indicators Table 4 ...

Page 297: ...HWE18240_GB ...

Page 298: ...other types of information Pressure and temperature are examples of numerical values and operating conditions and the on off status of solenoid valve are examples of flag display In the example above 1 through 9 are set to ON and 10 is set to OFF 1 Display of numerical values Example When the pressure data sensor reads 18 8kg cm2 Item No 58 The unit of pressure is in kg cm2 Use the following conve...

Page 299: ...n the display if there is a wiring failure between the control board and the trans mission line power supply board or if the circuit board has failed How to convert HP capacity to Model name HP capacity is the capacity of outdoor unit that is shown on LED display at initial setting Please refer to the following table to covert from HP capacity to Model name No Item Display Remarks 1 Software versi...

Page 300: ...indoor unit is turned off When the power is turned off and then on again the count will resume from the time before the power was turned off Thus the time that differs the actual time will be displayed This also applies when a power failure occurs The system controller such as AG 150A adjusts the time once a day When the system controller is connected the time will be automatically updated to the ...

Page 301: ... sion line A A Bottom SV14 SV15 5 1010000000 Relay output display 4 Top Optional 200 V output A A Bottom 7 1110000000 Special control Retry operation Emergency op eration Communication error between the OC and OS Communication error 3 minute restart delay mode B B 9 1001000000 Communication demand ca pacity 0000 to 9999 B B If not demanded controlled appears on the display 10 0101000000 Contact po...

Page 302: ...nit No 4 Unit No 5 Unit No 6 Unit No 7 Unit No 8 B Lit when thermostat is on Unlit when thermostat is off Bottom Unit No 9 Unit No 10 Unit No 11 Unit No 12 Unit No 13 Unit No 14 Unit No 15 Unit No 16 25 1001100000 Top Unit No 17 Unit No 18 Unit No 19 Unit No 20 Unit No 21 Unit No 22 Unit No 23 Unit No 24 Bottom Unit No 25 Unit No 26 Unit No 27 Unit No 28 Unit No 29 Unit No 30 Unit No 31 Unit No 32...

Page 303: ...01000 AK 0000 to 9999 A A 95 1111101000 FAN1 0000 to 9999 A A Fan output 96 0000011000 Fan inverter output rpm FAN1 0000 to 9999 A A rpm 97 1000011000 FAN2 0000 to 9999 A A Fan output 98 0100011000 Fan inverter output rpm FAN2 0000 to 9999 A A rpm 103 1110011000 LEV1 0000 to 9999 A A Outdoor LEV opening Fully open 480 104 0001011000 LEV2a 0000 to 9999 A A Outdoor LEV opening Fully open 3000 105 10...

Page 304: ...nverter Error details of inverter 0001 0120 A A 184 0001110100 Error history 4 0000 to 9999 B B 185 1001110100 Error details of inverter Error details of inverter 0001 0120 A A 186 0101110100 Error history 5 0000 to 9999 B B 187 1101110100 Error details of inverter Error details of inverter 0001 0120 A A 188 0011110100 Error history 6 0000 to 9999 B B 189 1011110100 Error details of inverter Error...

Page 305: ...r units is being supplied A A Bottom SV14 SV15 214 0110101100 Relay output display 4 Top Optional 200 V output A A Bottom 216 0001101100 TH4 99 9 to 999 9 A A The unit is C 217 1001101100 TH3 99 9 to 999 9 A A 218 0101101100 TH7 99 9 to 999 9 A A 219 1101101100 TH6 99 9 to 999 9 A A 220 0011101100 TH2 99 9 to 999 9 A A 221 1011101100 TH5 99 9 to 999 9 A A 227 1100011100 THHS1 99 9 to 999 9 A A The...

Page 306: ...o 9999 A A Outdoor LEV opening Fully open 3000 284 0011100010 LEV2c 0000 to 9999 A A Outdoor LEV opening Fully open 3000 286 0111100010 LEV9 0000 to 9999 A A Outdoor LEV opening Fully open 480 288 0000010010 COMP Operation time Upper 4 digits 0000 to 9999 A A The unit is h 289 1000010010 COMP Operation time Lower 4 digits 0000 to 9999 A A 294 0110010010 COMP number of start stop events Upper 4 dig...

Page 307: ...hen SW6 10 is set to OFF Item Display Unit A B 1 Remarks 1234567890 LD1 LD2 LD3 LD4 LD5 LD6 LD7 LD8 OC OS 301 1011010010 Power supply unit OC OS 1 OS 2 ļ Address B 302 0111010010 Start up unit OC OS 1 OS 2 ļ Address B 1 A The condition of either OC or OS is displayed individually B The condition of the entire refrigerant system is displayed ...

Page 308: ...Address capacity code 0000 to 9999 0000 to 9999 370 0100111010 IC20 Address capacity code 0000 to 9999 0000 to 9999 371 1100111010 IC21 Address capacity code 0000 to 9999 0000 to 9999 372 0010111010 IC22 Address capacity code 0000 to 9999 0000 to 9999 373 1010111010 IC23 Address capacity code 0000 to 9999 0000 to 9999 374 0110111010 IC24 Address capacity code 0000 to 9999 0000 to 9999 375 11101110...

Page 309: ...temperature 99 9 to 999 9 420 0010010110 IC13 Suction temperature 99 9 to 999 9 421 1010010110 IC14 Suction temperature 99 9 to 999 9 422 0110010110 IC15 Suction temperature 99 9 to 999 9 423 1110010110 IC16 Suction temperature 99 9 to 999 9 424 0001010110 IC17 Suction temperature 99 9 to 999 9 425 1001010110 IC18 Suction temperature 99 9 to 999 9 426 0101010110 IC19 Suction temperature 99 9 to 99...

Page 310: ...7 Liquid pipe temperature 99 9 to 999 9 465 1000101110 IC8 Liquid pipe temperature 99 9 to 999 9 466 0100101110 IC9 Liquid pipe temperature 99 9 to 999 9 467 1100101110 IC10 Liquid pipe temperature 99 9 to 999 9 468 0010101110 IC11 Liquid pipe temperature 99 9 to 999 9 469 1010101110 IC12 Liquid pipe temperature 99 9 to 999 9 470 0110101110 IC13 Liquid pipe temperature 99 9 to 999 9 471 1110101110...

Page 311: ...quid pipe temperature 99 9 to 999 9 497 1000111110 IC40 Liquid pipe temperature 99 9 to 999 9 498 0100111110 IC41 Liquid pipe temperature 99 9 to 999 9 499 1100111110 IC42 Liquid pipe temperature 99 9 to 999 9 500 0010111110 IC43 Liquid pipe temperature 99 9 to 999 9 501 1010111110 IC44 Liquid pipe temperature 99 9 to 999 9 502 0110111110 IC45 Liquid pipe temperature 99 9 to 999 9 503 1110111110 I...

Page 312: ...model A A 513 1000000001 IC FU address Count up display of number of connected units B 514 0100000001 RC address Count up display of number of connected units B 516 0010000001 OS address Count up display of number of connected units B 517 1010000001 Version Capacity S W version ĺ Refrigerant type ĺ Model and capacity ĺ Communication address A A 518 0110000001 OC address OC address display B 1 A Th...

Page 313: ...o 999 9 541 1011100001 IC19 Gas pipe temperature 99 9 to 999 9 542 0111100001 IC20 Gas pipe temperature 99 9 to 999 9 543 1111100001 IC21 Gas pipe temperature 99 9 to 999 9 544 0000010001 IC22 Gas pipe temperature 99 9 to 999 9 545 1000010001 IC23 Gas pipe temperature 99 9 to 999 9 546 0100010001 IC24 Gas pipe temperature 99 9 to 999 9 547 1100010001 IC25 Gas pipe temperature 99 9 to 999 9 548 001...

Page 314: ...001 IC11SH 99 9 to 999 9 584 0001001001 IC12SH 99 9 to 999 9 585 1001001001 IC13SH 99 9 to 999 9 586 0101001001 IC14SH 99 9 to 999 9 587 1101001001 IC15SH 99 9 to 999 9 588 0011001001 IC16SH 99 9 to 999 9 589 1011001001 IC17SH 99 9 to 999 9 590 0111001001 IC18SH 99 9 to 999 9 591 1111001001 IC19SH 99 9 to 999 9 592 0000101001 IC20SH 99 9 to 999 9 593 1000101001 IC21SH 99 9 to 999 9 594 0100101001 ...

Page 315: ...001 IC6SC 99 9 to 999 9 629 1010111001 IC7SC 99 9 to 999 9 630 0110111001 IC8SC 99 9 to 999 9 631 1110111001 IC9SC 99 9 to 999 9 632 0001111001 IC10SC 99 9 to 999 9 633 1001111001 IC11SC 99 9 to 999 9 634 0101111001 IC12SC 99 9 to 999 9 635 1101111001 IC13SC 99 9 to 999 9 636 0011111001 IC14SC 99 9 to 999 9 637 1011111001 IC15SC 99 9 to 999 9 638 0111111001 IC16SC 99 9 to 999 9 639 1111111001 IC17...

Page 316: ...661 1010100101 IC39SC 99 9 to 999 9 662 0110100101 IC40SC 99 9 to 999 9 663 1110100101 IC41SC 99 9 to 999 9 664 0001100101 IC42SC 99 9 to 999 9 665 1001100101 IC43SC 99 9 to 999 9 666 0101100101 IC44SC 99 9 to 999 9 667 1101100101 IC45SC 99 9 to 999 9 668 0011100101 IC46SC 99 9 to 999 9 669 1011100101 IC47SC 99 9 to 999 9 670 0111100101 IC48SC 99 9 to 999 9 671 1111100101 IC49SC 99 9 to 999 9 672 ...

Page 317: ... to 31 Year and month and date alter nate display 698 0101110101 Time of error detection 5 00 00 to 23 59 Hour minute 699 1101110101 Time of error detection 5 2 00 00 to 99 12 1 to 31 Year and month and date alter nate display 700 0011110101 Time of error detection 6 00 00 to 23 59 Hour minute 701 1011110101 Time of error detection 6 2 00 00 to 99 12 1 to 31 Year and month and date alter nate disp...

Page 318: ...1101101 IC18 LEV opening 0000 to 9999 732 0011101101 IC19 LEV opening 0000 to 9999 733 1011101101 IC20 LEV opening 0000 to 9999 734 0111101101 IC21 LEV opening 0000 to 9999 735 1111101101 IC22 LEV opening 0000 to 9999 736 0000011101 IC23 LEV opening 0000 to 9999 737 1000011101 IC24 LEV opening 0000 to 9999 738 0100011101 IC25 LEV opening 0000 to 9999 739 1100011101 IC26 LEV opening 0000 to 9999 74...

Page 319: ...0 Operation mode 774 0110000011 IC11 Operation mode 775 1110000011 IC12 Operation mode 776 0001000011 IC13 Operation mode 777 1001000011 IC14 Operation mode 778 0101000011 IC15 Operation mode 779 1101000011 IC16 Operation mode 780 0011000011 IC17 Operation mode 781 1011000011 IC18 Operation mode 782 0111000011 IC19 Operation mode 783 1111000011 IC20 Operation mode 784 0000100011 IC21 Operation mod...

Page 320: ... 0000 to 9999 818 0100110011 IC5 filter 0000 to 9999 819 1100110011 IC6 filter 0000 to 9999 820 0010110011 IC7 filter 0000 to 9999 821 1010110011 IC8 filter 0000 to 9999 822 0110110011 IC9 filter 0000 to 9999 823 1110110011 IC10 filter 0000 to 9999 824 0001110011 IC11 filter 0000 to 9999 825 1001110011 IC12 filter 0000 to 9999 826 0101110011 IC13 filter 0000 to 9999 827 1101110011 IC14 filter 0000...

Page 321: ...999 851 1100101011 IC38 filter 0000 to 9999 852 0010101011 IC39 filter 0000 to 9999 853 1010101011 IC40 filter 0000 to 9999 854 0110101011 IC41 filter 0000 to 9999 855 1110101011 IC42 filter 0000 to 9999 856 0001101011 IC43 filter 0000 to 9999 857 1001101011 IC44 filter 0000 to 9999 858 0101101011 IC45 filter 0000 to 9999 859 1101101011 IC46 filter 0000 to 9999 860 0011101011 IC47 filter 0000 to 9...

Page 322: ...t effective val ue 1 99 9 to 999 9 A A 873 1001011011 Power factor phase angle 1 99 9 to 999 9 A A The unit is deg 880 0000111011 Control board Reset counter 0 to 254 A A The unit is time 881 1000111011 INV board Reset counter 0 to 254 A A 884 0010111011 Fan board address 5 reset counter 0 to 254 A A The unit is time 885 1010111011 Fan board address 6 reset counter 0 to 254 A A 980 0010101111 M NE...

Page 323: ... 10 2 LED Status Indicators Table 10 LED Status Indicators on the Outdoor Unit Circuit Board 26 chapter 10 HWE18240_GB ...

Page 324: ......

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