manualshive.com logo in svg

Panasonic U-16GE3E5, Main Parts Replacement, Page: 1 / 91

Share
Download
Panasonic U-16GE3E5 Main Parts Replacement Download Page 1

Gas Heat Pump 

Air Conditioner

Applicable Models

2WAY MULTI/W MULTI

 U-16GE3E5

 U-20GE3E5

 U-25GE3E5

 U-30GE3E5

3WAY MULTI

U-16GF3E5

U-20GF3E5

U-25GF3E5

Reference No. GMP-1703-01A

Main Parts Replacement

March 2017

Order No. SBPAC1612011CE

Summary of Contents for U-16GE3E5

Page 1: ...ir Conditioner Applicable Models 2WAY MULTI W MULTI U 16GE3E5 U 20GE3E5 U 25GE3E5 U 30GE3E5 3WAY MULTI U 16GF3E5 U 20GF3E5 U 25GF3E5 Reference No GMP 1703 01A Main Parts Replacement March 2017 Order No SBPAC1612011CE ...

Page 2: ... lead wires 8 5 Disconnect all hoses 9 6 Remove exhaust gas heat exchanger 11 7 Remove intake manifold and exhaust manifold 12 8 Remove rocker cover 12 9 Remove ignition coils 12 10 Remove ignition coil bracket 13 11 Remove spark plugs 13 12 Remove cylinder head assembly 14 13 Strip and clean gasket Figure18 15 14 Attach cylinder head 16 15 Valve clearance adjustment procedure 17 16 Install the ro...

Page 3: ...art test operation and set engine rotational speed 28 4 Ignition timing check 29 5 Correction for distorted amount 30 6 Cancel settings 33 7 Stop test run 34 8 Final check 34 Front Oil Seal Replacement Procedure 1 Required parts and tools used 35 2 Preparation for work 35 3 Remove compressor drive belt 35 4 Remove the crank pulley 35 5 Remove front cover oil seal Figure 2 35 6 Install the front co...

Page 4: ...rocedure 1 Required parts and tools used 44 2 Prepare to remove the expansion valve liquid valve bypass valve and waste heat recovery valve 44 3 Preparation for work 44 4 Prepare to remove the expansion valve liquid valve bypass valve and waste heat recovery valve 45 5 Install the expansion valve liquid valve bypass valve and waste heat recovery valve 46 6 Preparation for operation 46 7 Final chec...

Page 5: ...g 1 Select the pump down mode 71 2 Stop operation for all indoor units 71 3 Remove refrigerant shutoff valve cap 71 4 Attach the gauge manifold 71 5 Operating the refrigerant shutoff valve 3WAY MULTI only 73 6 Start the test run Carry out a test run on the outdoor unit 74 7 Configure the forced close setting of the bypass valve 75 8 Set engine rotational speed 76 9 Fully shut off the refrigerant l...

Page 6: ...carrying out the backup operation close the closing valves of all outdoor units for which the stop operation has been performed 2 Models other than W MULTI Safety Precautions Stopping only the indoor unit is extremely dangerous because the engine may suddenly start if the customer operates the remote controller on the indoor unit side Before carrying out work on the inside of the outdoor unit make...

Page 7: ...s performed for all outdoor units an outdoor unit cannot be started even with a command of the indoor unit After 3 minutes has elapsed since the display of the indication in the seven segment LED display of Figure 2 the indication in the seven segment LED display of Figure 3 is displayed Turn off the power supply circuit breaker for the outdoor unit Models other than W MULTI Turn off the power sup...

Page 8: ...re To perform backup operation the outdoor unit for maintenance work hereafter referred to as target outdoor unit must be cut off from the system using the following procedure Review content of the maintenance work and then select the most suitable method Also after the maintenance work is finished always refer to System recovery procedure and then return the system to its normal state Backup oper...

Page 9: ...W MULTI outdoor unit 2 indicated in the left diagram perform Step 1 to Step 3 in Backup operation procedure in that order Then perform maintenance work on W MULTI outdoor unit 2 b When Step 3 is finished W MULTI outdoor unit 1 is reset It ll stop even if it is operating c After approximately five minutes if there is operation input indoor remote controller is Run or test run setting on outdoor mai...

Page 10: ...pper Do not try to rotate it any further The valve is fully closed when the slit of the tab is at right angles to the pipe and fully open when the slit of the tab is parallel to the tube Fully closed Refrigerant gas tube Refrigerant liquid tube Refrigerant gas tube Refrigerant liquid tube Fully opened Note 1 If the unit is operated while the closing valves are still closed the discharge pressure o...

Page 11: ... valve is fully open when the tab has been rotated 90 degrees when it contacts the stopper Do not try to rotate it any further The valve is fully closed when the slit of the tab is at right angles to the pipe and fully open when the slit of the tab is parallel to the pipe Fully closed Fully opened Refrigerant suction tube Refrigerant Liquid tube Refrigerant discharge tube Refrigerant suction tube ...

Page 12: ... 45 6N m 23 6N m 34 4N m 48 2N m Engine oil Small amount of Panasonic genuine AP GHP D 125 Small amount of Panasonic genuine GHP Oil 10TH Small amount of Panasonic genuine GHP Oil 10W30C2 Socket wrench set 1 set Extension bar Approx 75 150 mm long Stem seal insertion tool 1 set General tools 1 set 2 Preparation for work 1 If coolant temperature is high lower it See Coolant Check Replenishment and ...

Page 13: ...he coolant temperature sensor connector green 2P Figure 2 3 Remove the stepping motor connector white 6P and the fuel adjustment valve connector red 6P 4 Move the lead wires to the right so that they do not interfere with subsequent work Figure 1 Ignition coil connectors Figure 2 Coolant temperature sensor connector Figure 3 Fuel gas adjustment valve Stepping motor ...

Page 14: ...ure 4 4 Coolant hose from coolant pump to exhaust gas heat exchanger Figure 5 5 Coolant hose from exhaust gas heat exchanger to engine Figure 5 6 Exhaust hose from exhaust gas heat exchanger to muffler Figure 5 7 Coolant hose engine inlet side Figure 6 Figure 4 Blow by hose Equalizer hose Coolant hose Engine outlet Figure 5 Figure 6 Coolant hose engine inlet side Coolant hose from exhaust gas heat...

Page 15: ...as hose Figure 7 Hose Clamp width across flat 7 mm 9 Intake hose mixer side Figure 7 Hose Clamp width across flat 7 mm 10 Intake hose air cleaner side Figure 8 Hose Clamp width across flat 7 mm Figure 7 Fuel gas hose Air intake hose Intake hose air cleaner side Figure 8 ...

Page 16: ...45 0 56 0 71 0 kW Type Nuts Nuts Figure 9 2 85 0 kW Type 2 Remove the 6 nuts bolts and hexagon socket head bolts indicated by arrows in Figure 10 1 and 10 2 and remove the exhaust gas heat exchanger Bolt width across flat 17 mm Nut width across flat 12 mm Figure 10 1 45 0 56 0 71 0 kW Type except 3WAY 71 0 kW Type Nuts Bolts Hexagon socket head bolt Figure 10 2 85 0 kW Type 3WAY 71 0 kW Type Bolts...

Page 17: ... cover Remove the cap nuts at the 2 locations indicated by arrows in Figure 12 remove rocker cover Nut width across flat 22 mm Caution Do not lose the seal washer under the cap nut 9 Remove ignition coils Remove the bolts securing the ignition coils and remove the ignition coils indicated by arrows in Figure 13 Bolt width across flat 10 mm Caution Handle the ignition coils carefully Keep them free...

Page 18: ...bracket 1 Remove 2 securing bolts indicated by Figure 14 remove ignition coil bracket Bolt securing the bracket width across flat 12 mm 11 Remove spark plugs Using a spark plug wrench remove all 4 sparkplugs Figure 15 Figure 14 Bolts securing the bracket Ignition coil bracket Figure 15 ...

Page 19: ... compress the coil springs and tie the rocker arms with wire as shown in Figure 16 before loosening the bolts reassembly will become easier Remove the cylinder head bolts Remove the cylinder head gasket Caution To prevent distortion of the cylinder head when loosening the cylinder head bolts loosen them gradually in the order shown in Figure 17 Bolt width across flat 14 mm Figure 16 Valve rocker b...

Page 20: ... remove carbon and sludge adhering inside circulation channels 5 Clean each circulation hole in the cylinder head by blowing with compressed air 6 Strip gasket material from and clean both the attachment areas for the intake manifold exhaust manifold and the exhaust gas heat exchanger using the same procedure as described for the cylinder head above Caution 1 Make absolutely sure no foreign matter...

Page 21: ...ctor Do not judge the angle by eye 3 Install pushrods and rocker shaft assemblies Install the pushrods for each of the cylinders and each of the intake and exhaust in the positions where they were before disassembly Figure 21 The pushrods must be correctly seated in the depression for them on the valve lifter Assemble the rocker shaft assembly Bolt width across flat 12 mm Tightening torque 21 6 2 ...

Page 22: ... compression top dead centre and when cylinder no 4 is at the compression top dead centre Figure 24 Cylinder No 4 3 2 1 Status Valve Ex In In Ex Ex In In Ex Cylinder no 1 at compression TDC Cylinder no 4 at compression TDC Caution Adjust the valve clearance while the engine is warm Valve clearance adjustment Adjustment value when warm Intake valve 0 45 mm Exhaust valve 0 45 mm 3 Adjustment Figure ...

Page 23: ... too lean Investigate these possibilities 4 Check for damage to the washer and cracking on the insulator 5 If the tip of the centre electrode is rounded as shown in of Figure 28 replace the plug with a new one 6 If the ground electrode is worn as shown in of Figure 28 replace the plug with a new one 7 Check the electrode gap of the sparkplug Reference value 0 4 0 5 mm Caution Do not adjust the gap...

Page 24: ...7 0 0 6 N m Caution Handle the ignition coils carefully Keep them free from shock 20 Install intake manifold and exhaust manifold Install the intake manifold and exhaust manifold by tightening the 10 bolts and nuts indicated by the arrows in Figure 32 use a new gasket Bolt nut width across flat 14 mm Bolt 2 tightening torque 35 3 2 9 N m Flange nut 4 tightening torque 44 7 3 5 N m Nut flangeless 4...

Page 25: ...anger and those for the engine 3 Full tightening to be performed in the following order Fully tighten the rhombic flange of the exhaust gas heat exchanger to the engine Figure 33 1 Tighten the bolts in the order a b c d with emphasis on diagonal relation Fully tighten the bolts of the fittings on the connection joints to the engine The one joint shown in Figure 33 1 and the two joints shown in Fig...

Page 26: ...34 1 to 34 4 Nut width across flat 17 mm Tightening torque 41 5 3 5 N m 22 Reconnect all hoses Securely connect all hoses and parts and install and tighten hose bands so that no leakage occurs 23 Connect all lead wires Check the pins of the connecting parts to make sure none of them are loose or missing 24 Install other parts Install all other parts in the reverse of the sequence by which they wer...

Page 27: ... procedure see Coolant Check Replenishment and Replacement Procedure in this manual 27 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no coolant or oil leaks Make sure that none of the attached parts are loose 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have b...

Page 28: ...ing the starter Remove the starter Bolt width across flat 14 mm 4 Install starter The starter installation procedure is the reverse of the removal procedure 1 Install the starter by tightening the bolts in Figure 2 that secure the starter Tightening torque 35 3 2 9 N m 2 Reconnect the wires for the B and S terminal connectors on the starter as shown in Figure 1 Tightening torque 10 8 1 0 N m 5 Pre...

Page 29: ...onnectors Remove the ignition coils 2 Points to keep in mind during installation Handle the ignition coils carefully Keep them free from shock Bolt width across flat 10 mm Tightening torque 7 0 0 6 N m 4 Crank angle sensor Figure 2 1 Crank angle sensor removal and installation Remove the harness connector Remove the crank angle sensor 2 Points to keep in mind during installation Coat the O ring wi...

Page 30: ...16 mm 3 If the tip of the plug is completely black with dry carbon the mixture may be too rich the ignition timing may be retarded or oil may be going up and down within the cylinder Investigate these possibilities 4 If the tip of the plug is black and moist the air cleaner element may be clogged Investigate this possibility 5 If the insulator at the tip of the plug is burned completely white and ...

Page 31: ...ug to the specified torque Socket width across flat 16 mm Tightening torque 24 5 4 5 N m 14 Install ignition coils Install the ignition coils by tightening the bolts that secure them indicated by arrows in Figure 8 Bolt width across flat 10 mm Tightening torque 6 9 0 5 N m Caution Handle the ignition coils carefully Keep them free from shock 7 Preparation for operation 1 Turn on the power supply c...

Page 32: ...for one second or more Menu item number Figure 1 will be displayed 2 Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item in the Figure 2 The display Figure 3 will appear 3 Press the SET key SW007 Figure 4 will bedisplayed The LEVEL LED LED053 will be illuminated 4 Press the UP SW005 or DOWN SW006 key to display Figure 5 Press the SET key SW007 for one second or m...

Page 33: ...he display Figure 8 will appear 3 Press the SET key SW007 Figure 9 will be displayed The LEVEL LED LED053 will be illuminated Press the SET key SW007 for one second or more The TEST WARNING LED LED052 will be illuminated and the test run will start Set the engine rotational speed to 800 min 1 4 Press the HOME key SW004 for one second or more Menu item number Figure 10 will be displayed 5 Press the...

Page 34: ...rned by the engine in units of 100 revolutions 4 Ignition timing check When the operation conditions stabilize select operation data display and display engine ignition timing Check that this value is the value shown in table 1 1 Press the HOME SW004 key for one second or more Menu item number Figure 13 will be displayed The TEST WARNING LED LED052 will be illuminated After that as in the example ...

Page 35: ...004 for one second or more Menu item number Figure 15 will be displayed 2 Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item in the Figure 16 The display Figure 17 will appear 3 In this state press the SET key SW007 The display will change to Figure 18 and the LEVEL LED LED053 will be illuminated 4 Next press the UP SW005 or DOWN SW006 key to display ignition ti...

Page 36: ... be illuminated and LEVEL LED LED053 will flash 3 Press the UP SW005 or DOWN SW006 key to set a correction of 2 in relation to the current value checked in 1 The display will show Figure 20 Caution The display example at right is an example for when the current value checked in 1 is zero 0 If the current value is 1 and a 2 correction is set in relation to that value the value will become 3 after t...

Page 37: ...ated and LEVEL LED LED053 will flash 3 Press the UP SW005 or DOWN SW006 key to set a correction of 3 in relation to the current value checked in 1 The display will show Figure 23 Caution The display example at right is an example for when the current value checked in 1 is zero 0 If the current value is 2 and a 3 correction is set in relation to that value the value will become 1 after the setting ...

Page 38: ...e forced set speed will be displayed at one second intervals as shown below Display Item 10 1400 Forced engine rotational speed example 1400 min 1 11 1400 Engine rotational speed example 1400 min 1 12 0 56 Compressor inlet pressure Example 0 56MPa 13 2 70 Compressor outlet pressure Example 2 70MPa 15 85 0 Compressor outlet temperature Example 85 0 C 4 Press the SET key SW007 for one second or more...

Page 39: ... number Figure 33 will be displayed 2 Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item in the Figure 34 The display Figure 35 will appear 3 Press the SET key SW007 Figure 36 will be displayed The LEVEL LED LED053 and TEST WARNING LED LED052 will be illuminated 4 Press the SET key SW007 for one second or more The TEST WARNING LED LED052 will go out and the test...

Page 40: ...mpressor Replacement Procedure in this manual for instructions on removing the compressor drive belt 4 Remove the crank pulley Remove the 8 bolts indicated by arrows in Figure 1 and remove the crank pulley Bolt width across flat 12 mm 5 Remove front cover oil seal Figure 2 1 Use a flat blade screw driver or the like to make a groove in the front cover oil seal 2 Insert needle nose pliers or the li...

Page 41: ... of the crank pulley is aligned with the timing pin on the front cover Bolt width across flat 12 mm Tightening torque 19 6 N m Caution The pitch is different only for the hole marked with a Reference Use a ratchet or the like in the crank pulley hole Figure 4 to turn the crank pulley Do not use any other part to forcibly turn the pulley 8 Install the compressor drive belt For details on the proced...

Page 42: ...ccurs Make sure there are no oil leaks Make sure that none of the attached parts are loose 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgotten within the unit Use rags to wipe up any water or oil that has accumulated in the bottom of the unit ...

Page 43: ... socket wrench with a hand Figure 2 Bolt width across flat 19 mm Caution To prevent the flywheel from falling out when removing the flywheel bolts leave two of the bolts in a state in which two or three turns is still required to remove them 3 Insert flat blade screwdrivers to the right and left of the flywheel and remove the flywheel from the crankshaft housing while twisting it 4 Remove the flyw...

Page 44: ...at 19 mm Tightening torque 137 3 N m Caution Do not forget to remove the flywheel stopper 6 Preparation for operation 1 Turn on the power supply circuit breaker for the outdoor unit 2 Open the main gas valve starting the fuel supply 3 Set the STOP SW SW001 from STOP to NORM Figure 6 7 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no ...

Page 45: ...nect the fuel gas pipe Remove the hose band from the fuel gas hose and disconnect the hose Remove bolt B 1 and hexagon socket head bolts C 2 places and remove the fuel gas solenoid valve and zero governor integral part Figure 2 Bolt B width across flat 10 mm Hexagon socket head bolt C width across flat 4 mm Hose band width across flat 7 mm Figure 2 Zero governor Hose clamp Fuel gas solenoid valve ...

Page 46: ...er for the outdoor unit 2 Open the main gas valve starting the fuel supply 3 Set the STOP SW SW001 from STOP to NORM Figure 3 8 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no gas leaks Make sure that none of the attached parts are loose 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around...

Page 47: ...Remove the hose clamp from the three way valve and separate the hose from the valve 3 Remove the securing bolts and remove the three way valve and its securing bracket 4 Remove the securing bracket from the three way valve 5 Install the three way valve 1 Installation procedure is the reverse of the removal procedure Caution After you connect the wires secure the wires together in position with the...

Page 48: ...ibration occurs Make sure there are no coolant leaks Make sure there is no looseness in any parts attachment area 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgotten within the unit Use rags to wipe up the water or oil that has accumulated at the bottom inside the unit ...

Page 49: ...Clamp As needed General tools 1 set 2 Prepare to remove the expansion valve liquid valve bypass valve and waste heat recovery valve 1 Perform the pump down procedure to recover the refrigerant from within the compressor and unit and move it to the indoor unit For details on the pump down procedure see Pump Down Procedure Common for Cooling and Heating in this manual Recover any refrigerant that ca...

Page 50: ...sulation in order to prevent burning inside the unit 4 Use a welder flame to heat the welded joints of the pipes at the locations indicated by the arrows in Figures 1 to 3 and then remove the expansion valve liquid valve bypass valve and waste heat recovery valve When soldering be sure to replace with nitrogen gas Liquid valve Expansion valve Bypass valve Waste heat recovery valve Liquid valve Exp...

Page 51: ...Purge the refrigeration circuit Degree of vacuum 0 133 kPa abs 1 0 mmHg Set to valve open and carry out evacuation from the low pressure outlet After evacuation is finished cancel the valve open setting 6 Preparation for operation 1 Cancel pump down Set each of the closing valves from the fully closed position to the fully open position Figures 2 3 Outdoor unit Refrigerant liquid tube Refrigerant ...

Page 52: ...the STOP side to the NORM side Figure 4 7 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no refrigerant leaks Make sure that none of the attached parts are loose 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgotten within the unit Wipe up any water ...

Page 53: ... setting Press the HOME key SW004 for one second or more Menu item number Figure 1 will be displayed Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item in the Figure 2 The display Figure 3 will appear In this state press the SET key SW007 The display will change to Figure 4 and the LEVEL LED LED053 will light Press the UP SW005 key or DOWN SW006 key to display i...

Page 54: ...sening the flare portions Figure 6 3 Install pressure sensor 1 Install a new pressure sensor Always use 2 wrenches when tightening the flare portions Tightening torque 17 5 2 5 N m Caution Make sure the connector on the sensor is facing the rear of the unit when installing 2 Other installation procedures are the reverse of the removal procedures 3 Perform an air tightness test with nitrogen from t...

Page 55: ...7 Open Closed Refrigerant liquid tube Refrigerant gas tube Refrigerant liquid tube Refrigerant gas tube Note For details on 3WAY MULTI valves refer to 5 Basic Operation for Shutoff Valves of 3WAY MULTI under Basic Operations in this manual 6 Remove the gauge manifold 7 Turn on the power supply circuit breaker for the outdoor unit Figure 8 Shutoff valve open close Fully open Fully closed Status ...

Page 56: ...ess the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item in the Figure 10 The display Figure 11 will appear In this state press the SET key SW007 The display will change to Figure 12 and the LEVEL LED LED053 will light Press the UP SW005 key or DOWN SW006 key to display ignore pressure sensor The TEST WARNING LED LED052 lights In this status press the SET SW007 key for ...

Page 57: ...ition check Make sure that no abnormal noise or vibration occurs Make sure there are no refrigerant leaks Make sure there is no looseness in any parts attachment area 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgotten within the unit Use rags to wipe up the water or oil that has accumulated at the bottom insid...

Page 58: ...Check Replenishment and Replacement Procedure in this manual 4 Remove the coolant pump 1 Unplug the connector for the coolant pump from the power board in Figure 1 Caution Remove the connector after verifying that the power breaker has been turned off Removing the connector with the power supply still on may lead to damage to the unit Power board Connector for coolant pump 2 Remove the wires from ...

Page 59: ...or unit 2 Open the main gas valve starting the fuel supply 3 Set the STOP SW SW001 from STOP to NORM Figure 3 7 Fill up with coolant For details of the coolant filling procedure see Coolant Check Replenishment and Replacement Procedure in this manual 8 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no coolant leaks Make sure that none...

Page 60: ...eration in this manual 3 Check and replenish coolant 1 Check and replenish coolant Check the coolant level inside the reserve tank from the cutout of the side panel on the filler neck side of the unit Figure 1 Suitable Levels Between the L and H levels If the level within the reserve tank is low replenish the coolant with the specified concentration of genuine Panasonic coolant 50 5 up until the H...

Page 61: ... the end of the hose in a plastic container in order to collect the coolant 4 Open the coolant replenishment port cover and filler neck cap on the top panel to allow air to enter Figure 4 Figure 4 Filler neck cap Coolant Coolant refill hole cover 5 Discharge from the heat exchanger Figure 5 Turn the manual stopcock on the coolant discharge port to Fully opened Figure 5 Coolant discharge port Fully...

Page 62: ... Amount of Coolant Coolant GHP model Amount when mixed with water litre Concentrate solution amount litre 45 0 or 56 0 kW Type 21 0 10 5 71 0 or 85 0 kW Type 27 0 13 5 4 Remove the coolant replacement port cover from the top panel 5 Use pinch pliers or the like to pinch the hose from the filler neck to the reserve tank place indicated by the arrow in Figure 7 Protect the hose with a rag or the lik...

Page 63: ... mode Turn off the remote controllers for all indoor units and stop the operation of the outdoor unit 1 Operation procedures Press the HOME key SW004 for one second or more Menu item number Figure 10 will be displayed Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item Figure 11 The display will appear Figure 12 In this state press the SET key SW007 The display w...

Page 64: ... perform any manual operations Replenish the coolant in the coolant replenishment container before it runs out Be careful because if the coolant replenishment container runs out of water air will become mixed with the coolant and the air will be unable to be sufficiently purged Furthermore check the air discharge state with the air purge hose transparent during the automatic airpurge operation The...

Page 65: ...ach the coolant replenishment port cover Figure 4 7 Wipe up any spilt coolant with a rag and reattach the front panel and rear panel to complete the work procedure 5 Coolant pump operation and stopping procedures Turn off the remote controllers for all indoor units and stop the operation of the outdoor unit 1 Operation procedures Press the HOME key SW004 for one second or more Menu item number Fig...

Page 66: ...er Figure 22 will be displayed Press the UP SW005 or DOWN SW006 key displaying the menu item numbers Select menu item Figure 23 The display will appear Figure 24 In this state press the SET key SW007 The display will change to and the LEVEL LED LED053 will be illuminated Figure 25 Press the UP SW005 DOWN SW006 key and select menu item Figure 26 In this status press the SET SW007 key for one second...

Page 67: ...9 6 to 92 0 N m General tools 1 set Clamp As needed Socket wrench 1 set 2 Prepare to remove the compressors 1 Perform a pump down and recover all refrigerant from within the compressor and unit and move it to the indoor unit For details about the pump down procedure see Pump Down Procedure Common to Cooling and Heating in this manual Recover any refrigerant that cannot be pumped down 3 Preparation...

Page 68: ...bracket Figure 4 Bolt width across flat 19 mm Rotate the tension adjustment bolt until the compressor drive belt can be removed then remove the belt 2 Unplug the crankcase heater sensor and clutch connectors 3 Cut the oil tube clamps 4 Remove the bolts indicated by arrows in Figure 5 and remove the discharge and suction pipe flanges Bolt width across flat 10 mm Figure 5 Figure 4 ...

Page 69: ...e unit s base leave hoses in place Put a block of wood or the like against the edge of the engine s oil pan and jack it up until there is no load on the rubber vibration damper on the compressor Then remove the mounting bracket from under the rubber vibration damper and remove the damper from the engine mount Adjust the height with the jack so no significant load is on the rubber vibration damper ...

Page 70: ...ne 4 Tighten each of the bolts nuts in the order of unit base and mounting bracket mounting bracket and vibration damper vibration damper and engine mount Once the unit base and mounting bracket bolts are tightened gently rock the engine itself a number of times and make sure there is no significant strain on the vibration damper before fastening the vibration damper to the mounting bracket Unit b...

Page 71: ...all provisionally adjust it rotate the centre of the pulley about one turn with a socket wrench and then adjust the tension again Repeat this operation until the tension is adjusted Figure 9 Tighten the tension adjustment bolt so that the tension of the compressor drive belt measured with a noncontact sonic belt tension meter reaches the specified value Belt tension 1695 25N initially 1205 25N aft...

Page 72: ...starting the fuel supply 4 Set the STOP SW SW001 from STOP to NORM Figure 11 7 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there are no refrigerant leaks Make sure that none of the attached parts are loose 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgott...

Page 73: ...autions and 2 Preparation for work of Basic Operation in this manual 3 Remove the fan motor 1 Remove the fan guard 2 Use a flat blade screwdriver to remove the hub cover of the fan 3 Loosen the bolts indicated by circles in Figure 1 and remove the fan 4 Disconnect the connectors for the fan motor from the circuit board indicated by circles in Figure 2 Caution Remove the connecter after verifying t...

Page 74: ...or the cooling fan motor to the board in Figure 2 and secure the wires in place 3 Coat the fan securing bolts indicated by circles in Figure 4 with Loctite 272 align the fan with the shaft of the fan motor chamfered on both sides and install the fan Tightening torque 7 5 0 5 N m 4 Use a plastic hammer to attach the hub cover of the fan Important Align the protruding portions of the hub cover with ...

Page 75: ...e NORM side Figure 5 6 Final check 1 Running condition check Make sure that no abnormal noise or vibration occurs Make sure there is no looseness in any parts attachment area 2 Cleanliness check of the surroundings Make sure no unneeded items or trash is scattered around Make sure no tools etc have been forgotten within the unit Use rags to wipe up the water or oil that has accumulated at the bott...

Page 76: ...wing explanation is for both the cooling mode and heating mode 2 Stop operation for all indoor units Turn off remote controllers for all indoor units The test run settings cannot be configured from the outdoor main board while the indoor unit is being operated remote controller is on Cooling is not possible during the pump down work and until recovery is complete after the work is finished so make...

Page 77: ...arge tube and refrigerant suction tube Figure 3 Heating pump down Connect the gauge manifold to the service port of the refrigerant discharge tube and refrigerant suction tube Close the valve on the manifold gauge Figure 4 Figure 3 Cooling Gauge manifold Refrigerant discharge shutoff valve Refrigerant suction shutoff valve Refrigerant liquid shutoff valve Gauge manifold Refrigerant discharge shuto...

Page 78: ...ake tube Refrigerant liquid tube Refrigerant discharge tube Closed Open Open Close up view Shutoff valve open close Fully open Fully closed Status Figure 5 2 Heating pump down Fully close the suction shutoff valve Figures 7 and 8 Refrigerant intake tube Refrigerant discharge tube Refrigerant liquid tube Closed Open Open Close up view Shutoff valve open close Fully open Fully closed Status Figure 8...

Page 79: ...mber will be displayed 2 Press the UP SW005 DOWN SW006 key and select menu item number Figure 9 The display Figure 10 will appear 3 Press the SET SW007 key Figure 11 will be displayed The LEVEL LED LED053 will be illuminated 4 Press the UP SW005 key or DOWN SW006 key to select the test run mode Cooling mode Figure 11 Heating mode Figure 12 5 Press the SET SW007 key for 1 second or more The TEST WA...

Page 80: ... menu item Figure 13 4 Press the SET SW007 key for 1 second or more The TEST WARNING LED LED052 will be illuminated and the bypass valve will be set to fully closed Caution This setting results in not just the bypass valve but also the liquid valve outdoor fan and the like performing the operation required for the pump down Be sure to configure this setting because a pump down may not be possible ...

Page 81: ...he TEST WARNING LED LED052 will be illuminated 5 In this state use the UP SW005 key or DOWN SW006 key to change the forced engine rotational speed Refer to the following for the number of rotations to set Set RPM 800 to 1 000 min 1 Display Item Forced engine rotational speed example 1 400 min 1 Engine rotational speed example 1 400 min 1 Compressor input pressure example 0 56 MPa Compressor output...

Page 82: ... pressure drops the micro computer automatically stops the engine and the pump down is complete If the engine is stopped in this way Figure 19 is displayed on the outdoor main board However if 15 minutes have elapsed since the bypass valve forced close setting explained in item 7 was set the engine stops automatically regardless of the refrigerant pressure In such a case is displayed Caution Even ...

Page 83: ...d off because of conditions on site perform the process to Cancel Each Setting in the next item Caution To protect the equipment carry out the work to stop the outdoor unit after 3 minutes have elapsed since the engine was stopped The process to cool the engine is performed by the coolant water pump outdoor fan and the like immediately after the engine has stopped 13 Cancel setting This procedure ...

Page 84: ...ot spray carburetor cleaner directly on the mixer because it can cause the deterioration of resin and rubber parts 4 Preparation for operation 1 Turn on the power supply circuit breaker for the outdoor unit 2 Open the main gas valve starting the fuel supply 3 Set the STOP SW SW001 from STOP to NORM Figure 1 5 Final check 1 Running condition check Make sure that no abnormal noise or vibration occur...

Page 85: ...80 Reference Document W MULTI Refrigerant Coolant Fuel Air Supply and Exhaust and Engine Oil Filling System ...

Page 86: ...81 Reference Document ...

Page 87: ...82 Reference Document ...

Page 88: ...83 Reference Document Refrigerant Coolant Fuel Air Supply and Exhaust and Engine Oil Filling System 3WAY MULTI ...

Page 89: ...84 Reference Document ...

Page 90: ... 7 06 1 47 10 3 5 M6 50 90 120 25 4 90 8 83 11 77 2 45 11 M7 90 160 220 45 8 83 15 69 21 57 4 41 13 12 4 6 M8 120 220 290 60 11 77 21 57 28 44 5 88 17 14 5 8 M10 240 430 580 120 23 54 42 17 56 88 11 77 19 17 22 6 10 M12 420 760 1 000 210 41 19 74 53 98 07 20 59 22 19 6 12 M14 690 1 240 1 650 350 67 67 121 60 161 81 34 32 24 22 27 8 14 M16 1 080 2 000 2 600 540 105 91 196 13 254 97 52 96 27 24 8 14...

Page 91: ......

Reviews:

No comments