teknisk manual - Polar Kulde AS
Contents
1. V skeoppvarming 3 11 Varmekolber for bereder tank R 1 r rgjenger Utf relse Effekt Syrefaste r relementer AISI 316 L Type kW R 1 messinghode Flatstifttilkobling 2 ulike elementer for trinnre gulering Flatebelastning ca 9W Spenning 230V 1 50 hz IU 23 2 0 0 75 1 25 450 2520398003 42 Termostat and safety devices for tapwater heating tank The thermostat and wireing for single element water heaters are shown below see figures 2 The combination 59T SPST and 66T DPST is used in residential 240VAC applications as well as in commercial electric water heater applications where each element may be independently controlled Safety device termostate For reseting the termostate press in the safety bottom 103 66 5 66T JG Limit 204 59T SPST Control 80 1 67 42 4 Heating Element 2 00 50 8 2 50 63 5 Temperature set point termostat The termostate safety device is set to 92 c Reset the safet devicey when no heating occurs Termostat temperature are set to 65 c Location off additional heating device se page 44 43 LOCATION OF ADDITIONAL HEATING DEVICE Heating and safety device for tapwater heating tank Heating and safety device for floor heating2. 100 OPERE RD ED ERE tc Far 60 40 LL ER SRI E PERS I S ER AR E 20 H 7 H PIH HH 4H ELS r i el a A 0 10 20 30 40 50 60 70 80 90 V Temperature C Outdoor air temp sensor e Outdoor heat exchanger sensor e Narrow tube sensor e Wide tube sensor sss NITTTT ENE NL LLL IL s LLL DRLIL LLL LLL 2 ss 20 15 10 5 0 15 20 gt cee C gt Resistance 2 DIMENSIONAL DATA Outdoor Unit Polarcomfort 8 6 AIR INTAKE O FR Hm EH _ ny 13 AIR DISCHARGE 13 sl 940 AIR INTAKE Narrow tube service valve 6 35 1 4 Wide tube service valve 09 52 3 8 Unit mm 3 REFRIGERANT FLOW DIAGRAM Outdoor Unit Polarcomfort 8 6 When pumpdown When heating When defrosting our way valve 2 SES NE Solenoid valve N for hot gas bypass gt 3 Outdoor heat exchanger Main accumulator HH 7 Sub Compressor accumulator Electric expansion valve Modulator Strainer s Insulation of Refrigerant Tubing IMPORTANT Because capillary tubing is used in the outdoor unit both the wide and narrow tubes of this air conditioner become cold To prevent heat loss and wet floors due to dripping of condensation both tubes must be well insulated with a proper insulation material The thickness of the insulat
3. for hot gas bypass or OM J OFF Outdoor fan OFF Defrost or clean defrost lamp Defrost start NOTE The dashed line for the defrost or clean defrost lamp indicates lamp illumination at clean defrost only e The maximum length of defrost operation is 12 minutes Defrost can also be ended based on the below conditions for the outdoor heat exchanger sensor Less than 2 minutes gt Not ended 2 minutes or more 10 or higher However the condition is 7 C or higher when the outdoor air temperature is below 0 7 6 Unit Problems and Inspection Points K5DHV ATI card Outdoor unit Problems Inspection points Operation lamp does not illuminate The outdoor air temperature is high however defrost operation occurs 4 way valve does not operate increase Self Diagnostics check CD Indoor controller control unit 3 water temperature sensor 4 Narrow tube temperature sensor 5 Inter unit cable a 6 Switch circuit board 7 Outdoor control circuit board Diode module Electrolytic capacitor comes 13 protective thermistor Outdoor fan motor a 15 4 way valve Coil thermistor a 17 Electric expansion valve Branch tubing temperature sensor Breaker Refrigerant gas pressure For details about the inspection points refer to Inspection points for each part 7 6 1 Outdoor control circuit
4. dW3L HOSS3HdllOO HOLSIWH3H L H3ONVHOX3 LVSH YOLSINYSHL YOLSISNVYL JAVA AVM YOLOVAY JATVA TYDINVHOSN 3NT1VA Q31vH3dO YOLOW NIV MNIS LV3H YOLOW 3400 d 1iHH3d ANIWA LSOYsAAG THA NHO YOLOW YOSSIHdNOD YOLOW YOSSIHdNOD ISVYOMNVYD NOILdIHIS3A L 00 81 69cS8 c v9S8 LY SGAHOSY MOd eued 0JJUOY OIH M OIH odd THA N89 60ND SIND cOOW LOON x18 LHM LHM HM LHM HM ZNO 80NO IZNO 62NO 0020 S v z 1 e TaVNd9 orm 0 PN PA N INVd Add L LHM LHM LHM 08200 21 0000 god dalla TawNu9 48 15 4 JYNINHIL I LHM NVYDVIG Ol LO4d 13 AOvZ Adee de Hsvag TyMINYaL Hlava ueijs sninuu YUE J9 eM WOJ JOSUSS AWA lamps on the PCB are off before starting work Electric shock Before replacing PCBs turn off the power and check that all will occur if work is performed while the lamps lit AUTI Electric Shock 4 ELECTRICAL DATA 4 2 Elec
5. Do not reuse the recovered refrigerant since it will contain impurities 2 Replacing Compressor Soon after removing seals of both discharge and suction tubes of the new compressor replace it quickly 3 Checking for sealing Use nitrogen gas for the pressurized gas and never use a refrigerant other than R410A Also do not use oxygen or any flammable gas 4 Evacuation Use a solenoid valve installed vacuum pump so that even if power is cut off in the middle of evacuation of air due to a power interruption the valve will prevent the pump oil from flowing back The equipment may be damaged if moisture remains in the tubing thus carry out the evacuation thoroughly When using a vacuum pump with exhaust air volume more than 25L min and ultimate vacuum pressure rate of 0 05Torr Standard time for evacuation 1 Recover refrigerant OK 2 Replace compressor OK 3 Check for sealing OK 4 Evacuation OK 5 Recharge Length of tubing Less than 10 meters More than 10 meters More than 120 minutes More than 140 minutes 27 5 Recharging Configuration and characteristics of cylinders Be sure to charge the specified amount of lt Valve refrigerant in liquid state using the service port of the wide tube service valve The proper amount is listed on the unit s nameplate When the entire amount cannot be charged all at once charge gradually while operating the unit in Cooli
6. m Section 22 Section G KWL NN 22 VENTIL SVA SIKKERHETSVENTIL m AV TAPPING LLL LL gt Va Sd p EE 7 7 SSS 2 66167 722227 SS ud 222 2 2 7 7 AI EEE y eee 2 ma 22 UTGAVENR B DATO 2005 GODKJ SOLE ART NR 3388 TEGN NR SME 20001158 40 Tapwater mixing valve SETE FOR UX MANUELL PES 30 GF SIR T ZZ 17 E yen e KLEMRING 22mm Cz 132 CuZn36Pb2As 4 x DD EG PLUGG f UP Cz 132 CuZn36Pb2As gt x x GEO gen m KLEMRING 15mm N D NN 2308 HUS f UP 15 med H IAX logo 2248 O RING 925x178 EPDM 70 2757 SPINDEL f UP PES 30 GF 2754 STEMPEL UP O 2460 72314 KLEMMUTTER 22mm 6 KT SZ lt L G ES 15 MANUELL YY IS Oy iy No SMT gt wy y Section B B 2 2 311 SSN SS x ag n s NM NN gt Alae m MANUELL BLANDING TEGN NR SOLE 20051777 U M 15 DATO 2005 GODK J SOLE 41
7. Net weight Peids net Netto Gewicht 6303 KGS 902942 117460 760 00 mm CHEMICAL ANALYSIS ANALYSE CHIMIQUE CHEMISCHE ZUSAMMENSETZUNG ____ w afn ls ele 1 80 0 800 0 030 Required Exig Anforderung maxi Cast Analysis Analyse coul s Analyse Schmelze en SR SS S Tests 10 verify batch and qualily have been carried test results am Satisfactory 92 Tests da de lu eonfennil de nuance fournie OR Les essais de pliage sont salisiaisants Verwechslungprustung wurde durchgefuehrt OR cod Braebnisse des Biggavarsuchs antsptechea don Vorschrifis eh MECHANICAL PROPERTIES PROPRIETES MECANIQUES MECHANISCHE WERTE giten 1 Room temperature Temp rature ambiante Raumtemperatur Test temperature i C03 pirecti Yield strength Tensile strongth Elongation after fracture Hardness Yleld strength Tensile str Elongation Direction Z iy inite d elasticit R sistance la traction Allongementspr s rupture Duret Limite d dlasticite R sst MpajAllongemcnt Required Streckgrenze Mnal Zugfestigkeit Mpal Brchdehnung vl Haate Streckgrenze Mpal Zugfestigkeit Brachdehnung ig Anforderung Re 02 PT maxi 840 30 EE Obtained 944 1 Ohtenu cul 2 Cis ci Impaet stren
8. Special Precautions WARNING When Wiring ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ONLY A QUALIFIED EXPERIENCED ELECTRICIAN SHOULD ATTEMPT TO WIRE THIS SYSTEM Do not supply power to the unit until all wiring and tubing are completed or reconnected and checked Highly dangerous electrical voltages are used in this system Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inadequate grounding can cause accidental injury or death Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause overheating at connection points and a possible fire hazard When Transporting Be careful when picking up and moving watertank and outdoor units Get a partner to help and bend your knees when lifting to reduce strain on your back Sharp edges or thin aluminum fins on the air conditioner can cut your fingers When Installing In a Ceiling or Wall Make sure the ceiling wall is strong enough to hold the unit s weight It may be necessary to construct a strong wood or metal frame to provide added support In a Room Properly insulate any tubing run inside a room to prevent sweating that can cause dripping and water damage to walls and floors In Moist or Uneven Locations Use a raised concrete pad or concrete blocks to provide a solid level foundation for the outdoor unit This prevents water damage and abnormal
9. us gt sl 5 u va I ma E P BS 1 MG FL i L Qu 0 5 st g il B LE cel 5 IL FIN EN Eu 3 i 4 E t t C03 CM Dm CS te 15 Me M E ass T Pb i3 OG jou fF Br ai INT I gy 1 3 Bl HEATER e zi T bl li AT ME 2 m _ PL 17 7 5 Checking the Outdoor System 7 5 1 Checking the outdoor unit em men Apply 220 V AC between terminals 1 and 2 on the The LED red on the control circuit board must outdoor unit 3P terminal block illuminate Of the connector T RUN TEST terminals short circuit The compressor fan motor 4 way valve and solenoid the T RUN terminal to the COM terminal valve for the hot gas bypass must turn ON They turn ON a few seconds after the power is turned ON NOTE Ifthe above check items are okay but the outdoor unit does not operate there may be a faulty connection between the indoor unit and the outdoor unit 7 5 2 Using forced defrost procedure Connect a dummy resistor of 39 to the outdoor coil B Non stop defrost temperature sensor connector 30 sec Indoor fan Setting Stop LL Stop LL Stop Setting 100 Hz ON Solenoid valve 4 5 sec EUR Agere
10. y panel Ground wire on Base not provided Fastened with anchor quie or similar bolts not provided M10 4 locations Unit mm Fig 5 Tubing panel 10 5 4 Recommended Wire Length and Diameter Regulations on wiring diameter differ from locality to locality For field wiring requirements please refer to your local electrical codes Carefully observe these regulations when carrying out the installation Max Power line length 2 0 215 meter Fuse or circuit capacity 20A 2 5 M2 20 meter 3 5 2 26 meter To avoid the risk of electric WARNING WARNING shock heatpump unit must be grounded Each wire must be firmly connected No wire should be allowed to touch refrigerant tubing the compressor or any moving part Be sure to connect power wires correctly matching up numbers on terminals of the outdoor unit 5 5 Wiring System Diagram Polarcomfort 8 6 and watertank Polarcomfort multisystem Watertank Outdoor Unit Water temp Sensor Terminal plate 8P I 1 xps Terminal plate Grounding line Power supply Single phase B 220 240 11 6 FUNCTIONS 6 1 Defrost Detection and End Non stop defrosting Defrost sequence HEAT operation Frost detection Non stop defrost operation Defrost end 4 way valve ON Defrost detection occurs in either of the following cases The temperature of the heat exchanger remains at or below
11. The compressor and fan motor must turn ON to the T RUN terminal If there are no problems with the above then check the indoor unit Using the TEST T RUN terminals TEST T RUN terminals T RUN Testrun compressor and fan motor turn ON TEST MV Compresses time to 1 60th accelerates operation by 60 times faster than normal Fully opens the electric expansion valve TEST MV T RUN Checking the serial communications Control 1 Control 2 Initial self Short circuit terminals 2 and 3on Short circuit terminals 2 and 3 on Probable Ineatonof malf nction diagnostics the indoor unit 3P terminal block indoor unit 3P terminal block Nocane 0000000 Nocane 0000000 control card circuit board failure 1 illuminat Change 1 and 3 illuminate NEN 1 and 3 illuminate 1 illuminate and 2 flashes 2nd meses Outdoor unit circuit board failure Change 1 and 3 illuminate Failure open circuit contact failure etc and 3 flashes l un in the inter unit cable Turn the power OFF before performing short circuiting work During the self diagnostics check the check results are the first indication when the operation switch is moved to OFF while the indicators are flashing afterpower ON DEMO 5 seconds ON So thatthe check can be made quickly indicators flash at first communication after power ON Before performing the above checks perform DEMO operation and check that AC 220 V is
12. board Refer to 9 3 1 Checking the outdoor unit NOTE Do notremove or insert the outdoor control circuit board connector when power is being supplied to it The controller will be damaged 7 6 2 HIC HIC measurement points nM 220 4 V Below Below 1kQ 1kQ Perform the continuity tests shown in the table above Locations which are not as shown in the table have suffered HIC failures Tester polarity Continuity 5 NOTE Ordinarily the red lead of the tester has negative polarity However the reverse may be true particularly with digital testers Use caution 7 6 3 Fuse Check the continuity visually or with a tester 7 6 4 Compressor Check for an open circuit in the compressor coil winding 7 6 5 Compressor protective sensor compressor discharge temperature thermistor Check that the sensor is securely contained in the thermostat holder 7 6 6 Outdoor fan motor Turn the fan slowly by hand If the fan rotates easily a Replace the running capacitor on the outdoor control circuit board b Check for an open circuit in the fan motor coil winding Use the tester AC range to check whether voltage is reaching the connector on the outdoor fan motor circuit board If the needle moves the result is normal f the fan does not rotate easily a Check whether something is obstructing the fan or if the fan itself is coming into contact with the oute
13. down procedure 1 Stop heatpumB Fully close the spindle at the valves on the narrow tube side of tubes B Refer to Fig 22 2 Connect the manifold gauge to the charging port at the valve on the wide tube side of tube A Purge the air from the Wide tube side charging hose Refer to Fig 23 3 Perform heating operation and turn on pumpdown switch Y2 terminal base 8p When the pressure atthe low pressure side is 0 15 0 2 MPa 0 5 1 kg cm G fully close the spindle at the valve on the wide tube side A and immediately stop operation Refer to Fig 23 4 Disconnect the manifold gauge and the inter unit tubes and attach the caps and flare nuts Atthis point pump down is completed If the caps and flare nuts are not 8 E 4 reattached there is the danger of gas leakage Cap Nro attach the flare nuts Refer to Fig 24 with flare bonnets If pump down is not possible Fig 24 If the heatpump cannot be operated because of a malfunction or other cause use a refrigerant recovery device to recover the refrigerant 34 11 Wiring Instructions General Precautions on Wiring 1 Before wiring confirm the rated voltage of the unit as shown on its nameplate then carry out the wiring closely following the wiring diagram 2 Provide a power outlet to be used exclusively for each unit with a power supply disconnect and circuit break er for overcurrent protection provided in the exclusive line 3 To
14. ex Thickness Min min 8 mm 8 mm Apply putty here Tubing Fig 19 31 4 Air Purging Air and moisture remaining in the refrigerant system have undesirable effects as indicated below Therefore they must be purged completely e pressure in the system rises e operating current rises e cooling efficiency drops e moisture in the air may freeze and block capillary tubing e water may lead to corrosion of parts in the refrigerant system Manifold gauge eirigerant syste 59 special for R410A H z Service T B Air Purging with a Vacuum Pump 2 a ere pressure High pressure valve valve Vacuum pump for Test Run wide abe EL PG side 92 Leave the 410 for preventing e In order to protect the earth s environment be sure to CP valve open reverse flow SET for R410A use a vacuum pump to perform the air purge Never perform an air purge by using the refrigerant gas cylinder or other external gas or by using the gas inside the outdoor unit Hex wrench nominal size 4mm Charging hose i E not provided special for R410A Perform the air purge for tubes A Fig 20 In order to prevent charging errors with that uses R410A the screw diameter at the service valve charging port has been changed When recharging or per forming other servicing use the special charging hose and manifold gauge 1 Check that each tube both narrow and wide Stopper tube
15. in the Technical amp Service Manual Insulation of Refrigerant Tubing prevent heat loss and wet floors due to dripping of con densation both tubes must be well insulated with a proper insulation material The thickness of the insulation should be a minimum 8 mm Fig 17 Taping the Tubes After a tube has Been insulated never try to bend it into a narrow curve as this may cause the tube to break or crack 1 Atthis time the 2 refrigerant tubes and electrical wire if local codes permit should be taped together with armoring tape The drain hose may also be included and taped together as 1 bundle with the tubing 2 Wrap the armoring tape from the bottom of the outdoor unit to the top of the tubing where it enters the wall As you wrap the tubing overlap half of each previous tape turn Fig 18 3 Clamp the tubing bundle to wall using 1 clamp approx every 120 cm Do not wind the armoring tape too tightly since this will decrease the heat insulation effect Also be sure the con densation drain hose splits away from the bundle and drips clear of the unit and the tubing Finishing the Installation After finishing insulating and taping over the tubing use sealing putty to seal off the hole in the wall to prevent rain and draft from entering Fig 19 Torque wrench Spanner Indoor unit Outdoor unit Fig 15 Insulation Fig 16 Insulation
16. moved from the ON or TEST position to the OFF Self diagnostics position the indicator lamps on the indoor unit will flash or remain ON for 5 seconds and then turn OFF for 2 seconds buzzer sounds once to indicate the presence of a sensor failure or the activation of a protective function Self diagnostics is completed when the buzzer sounds 3 beeps If there is no trouble the lamps do not flash illuminate Also note that the corresponding parts listed below may not be present in some models Indication on indicator lamps X OFF IR Flashing T ON AE Water temperature sensor failure 1 Sensor open circuit or short circuit 2 Contact failure at connector or open circuit at terminal crimping location short circuit Narrow tube heat sensor failure detection only for the humidity sensor 8 KBDHV A1 card outdoor circuit board failure iK gt gt Compressor temperature sensor failure 504 SH sensor failure 1 T 1 Sensor open circuit or short circuit x S05 Outdoor heat exchanger sensor failure 2 Contact failure at connector or open circuit at terminal crimping location Outdoor narrow tubing sensor failure 3 Outdoor circuit board failure 3 iK X S06 Outdoor air temperature sensor failure Outdoor wide tubing sensor failure HIC circuit failure Power Tr circuit failure MT O I Outdoor electrical current sensor failure Outdoor circuit board failure g
17. operation NN NN N NN NO 2 Exhaust fan Hot air 7 13 Heat source Outdoor unit Fig 3 Obstacle above Z LAP GO SS 2 AOI M 2m Air intake Min 20 cm A amp 2m 1 9 1 15 V ac A lt Min Air discharge M 5 10 9 Jc o 50 cm f 5 Z Z Ground Min 20 cm Air intake Anchor bolts 4 pcs Air intake Me T Concrete x or equal a EN 4 S Cushion rubber Fig 4b 5 3 Diagram of Outdoor Unit Installation The dimensions indicated by amp in the figure below are spaces that are required in order to maintain performance Install in a location where the dimensions indicated by amp are ensured and QS o where 2 or more faces of the unit are One unobstructed In principle the top direction should 5 To polarcomfort multisystem tank Power breaker Inspection panel Service space Cable fastener Using the tubing panel and covers 1 Place covers over positions that tubes do not pass through as necessary according to the number of indoor units 2 Adjust the tube positions and attach the tubing panel IIIIIII 150 of space if a drain hose is to be used x Gr
18. or tubing which is less than 0 8mm in thickness since air conditioners with R410A are subject to higher pressure than those using R22 and R407C No addition of compressor oil for R410A No additional charge of compressor oil is permitted No use of refrigerant other than R410A Never use a refrigerant other than R410A If refrigerant R410A is exposed to fire Through welding etc toxic gas may be released when R410A refrigerant is exposed to fire Therefore be sure to provide ample ventilation during installation work Caution in case of R410A leak Check for possible leak points with the special leak detector for R410A If a leak occurs inside the room immediately provide thorough ventilation 25 8 3 Tools Specifically for 410 9 For servicing use the following tools for R410A Gauge manifold Charging hose Gas leak detector Refrigerant cylinder Charging cylinder Refrigerant recovery unit Tools specifically for R410A Vacuum pump with anti reverse flow 1 Solenoid valve installed type which prevents oil from flowing back into the unit when the power is off is recommended Vacuum pump 2 can be used if the following adapter is attached Vacuum pump adapter reverse flow prevention adapter 3 Solenoid valve installed adapter attached to conventional vacuum pump Electronic scale for charging refrigerant Flare tool Bender Tools which can be Torque wrench commonly used for R22 Cutter ream
19. output to terminals 1 and 2 If itis not output there is a failure related to the control card unit power 16 7 4 Outdoor Unit Trouble Diagnostics If a protective device has activated or there is a sensor failure in the outdoor unit the 6 error monitor lamps on the outdoor control circuit board will indicate the nature of the trouble Branch tubing D sensor narrow tubing Outdoor air temperature sensor Branch tubing A sensor wide tubing Branch tubing B sensor wide tubing Branch tubing C sensor wide tubing Branch tubing D sensor wide tubing CT current sensor O O x xx x xPx x x x xx e x x x xx x xix x x xx Outdoor control circuit board mes 02 s _ s pa _ I IE p r L i n HH tm 88 S 5 1 E v Ww LI xm Dm Qo 9900 s4b t 9 D w f x O x x OO x x O x x xx O x OO O x HIC protective device current temperature i rj d i r LU i l Y f 1 p e Jp a JF i Q ON X OFF 5 x gt Compressor discharge temperature high Zero cross failure 97 DC compressor rotation failure Compressor internal thermostat activated High pressure switch activated Miswiring incorrect tubing connections e Freeze prevention a
20. peak cut trip Point B Hz reduction PointA Hz increase prohibit 6 6 Current control The operating frequency upper limits shown in the figure below are established for frequency reduction and increase prohibit Current A Example of operation during defrosting Trip Hz reduction Ls Hz reduction Hz increase 22 2 Hz increase prohibit prohibit 13 7 TROUBLESHOOTING 7 1 Precautions before performing inspection or repair After checking the self diagnostics monitor turn the power OFF before starting inspection or repair High capacity electrolytic capacitors are used inside the outdoor unit controller inverter They retain an electrical charge charging voltage DC 280 V even after the power is turned OFF and some time is required for the charge to dissipate Be careful notto touch any electrified parts before the controller LED red turns OFF If the outdoor controller is normal approximately 30 seconds will be required for the charge to dissipate However allow at least 5 minutes for the charge to dissipate if there is thought to be any trouble with the outdoor controller After inspection or repair is completed be sure to move the operation switch to the DEMO position turn the power ON and erase the diagnostics contents E Method of self diagnostics on control card KBDVH A1 If the unit operation lamp is flashing every 0 5 seconds follow the procedure below to perform detailed trouble
21. vibration In an Area with High Winds Securely anchor the outdoor unit down with bolts and a metal frame Provide a suitable air baffle In a Snowy Area for Heat Pump type Systems Install the outdoor unit on a raised platform that is higher than drifting snow Provide snow vents When Connecting Refrigerant Tubing Use the flare method for connecting tubing Apply refrigerant lubricant to the matching surfaces of the flare and union tubes before connecting them then tighten the nut with a torque wrench for a leak free connection e Check carefully for leaks before starting the test run When Servicing Turn the power off at the main power box mains before opening the unit to check or repair electrical parts and wiring Keep your fingers and clothing away from any moving parts Clean up the site after you finish remembering to check that no metal scraps or bits of wiring have been left inside the unit being serviced Others Nissen Ventilate any enclosed areas when installing or testing the refrigeration system Escaped refrigerant gas on contact with fire or heat can produce dangerously toxic gas Confirm upon completing installation that no refrigerant gas is l
22. 2 Refrigerant Gas Pressure 21 7 7 Explanations of function 22 23 8 REFRIGERANT R410A SPECIAL PRECAUTIONS WHEN SERVICING 8 1 Characteristics of New Refrigerant R410A 24 8 2 Checklist Before Servicing 24 25 8 3 Tools Specifically For R410A 26 8 4 Tubing Installation Procedures 26 8 5 In Case of Compressor Malfunction 27 28 8 6 Charging Additional Refrigerant 29 8 7 Retro Fitting Existing Systems 29 9 INSTALLATION PROCESS 30 34 10 PUMP DOWN 34 11 WIRING INSTRUCTION 35 36 12 INSTALLATION CHECK SHEET 37 13 INSTALLATION MANUAL POLAR COMFORT MULTISYSTEM 38 14 TECHNICAL DATA SHEET MULTISYSTEM TANK AND 39 47 SAFETY DEVICES 1 1 Unit specification Outdoor Unit Polarcomfort 8 6 Voltage rating 230V 220V Performance Heating Heating Capacity kW 7 2 17 86 7 2 1 7 8 6 BTU h 29 300 29 300 Air circulation High m3 h 2 400 2 400 Running amperes Af 107 15 5 107 Max 15 5 Power input 2500 j 250 Power factor 93 93 C O P Starting amperes Controls Microprocessor Fan speeds Auto Hi Lo Compressor Twin Rotary DC inverter Fefrigerant Amount charged at shipment R410A 3 0 Refrigerant control Electric Expansion Valve sound pressure level Hi dB Refrigerant tubing connections Flare type Max allowable tubing length m 0 Refrigerant Narrow tube in 6 35 1 4 tube diameter Wide tube in 9 52 3 8 Dimensions amp Weight Outdoor Unit dimensions Watertank dimen
23. 60L Temp reg Temp reg clamp 1 2 to Heotpump clamp 1 2 Heating El RGI 230V 1 fos Qe Safetyvalve 9 5kar 11001 Zh iia Floorheat turn P 4 Hydroterm X Reg volve bypos El Element p Floorheat return Tittelfelt System drawing Safetyvalve 2 5bar Adjustable feets when all Air water heat pump Leverand r Tegnet dato 30 11 06 Polar Kulde LB 38 14 W B B G1 innv G1 innv V D 15mm 3 8 flare 1 4 flare G1 2 innv G2 muffe G3 4 innv for element G3 4 innv Dato Konstr Tegnet PEU M T M lestokk 21 04 2005 Lars Hansen NS ISO 2768 rn Polar K Ide AS Kontroll Kontrollert Godkjent ok u Opstadveien 7 4332 Polarcomfort multitank IU Rev 160L 200L 1114 03 Henvisning Filenavn Arkiv nr Plot dato Polaraxmfort multiggtem 9 oafety valve ART NR BENEVNING 2240 MEMBRANPAKNING EPDM 80 IRHD Per vulc 29220 MEMBRANSKIVE 2253 O RING 14x1 8 EPDM PER 2315 SOLE KLEMMUTTER mm Cz 121 2719 FJ RHUS 2116 AVLASTNINGSRATT 6 6 30 GF CuZn39Pb3 23171 VENTILHUS SOLE SV DRAIN Oz 132 CuZn36Pb2As 2457 FJER for SV 12 Cr Ni 1 7 DIN 1 224 1 4310 PA 6 6 30 GF 1 9 BAR 5kW PA 6 6 30 GF Cz 132 CuZn36Pb2As 1 9mm KONPLUGG f T MMING SOLE KLEMRING 15mm SPINDEL for SV2 SV95 Cz 121 wass Cz 132 CuZn36Pb2As CuZn39Pb3 FH M
24. Polar Comfort DC INVERTER air water heat pump Developed by Polar Kulde AS OUTDOOR UNIT 8 6 kW IMPORTANT These alr condit TECHNICAL amp SERVICE MANUAL www polarkulde com Important Please Read Before Starting This air water heatpump system meets strict safety and operating standards As the installer or service person itis an important part of your job to install or service the system so it operates safely and efficiently For safe installation and trouble free operation you must Carefully read this instruction booklet before beginning Follow each installation or repair step exactly as shown Observe all local state and national electrical codes Pay close attention to all warning and caution notices given in this manual This symbol refers to a hazard or WARNING unsafe practice which can result in severe personal injury or death This symbol refers to hazard or unsafe practice which can result in personal injury or product or property damage If Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for special problem contact our sales service outlet or your certified dealer for additional instructions In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service including failure to follow the instructions in this document
25. Twist wire ends Fig 29 Screw lt D Screw special washer 1 Ring connector 36 12 Installation Check Sheet The strength of the installation location is sufficient to support the heatpump weight The watertank and outdoor units are installed level The power and voltage are as specified Inter unit cables are securely fastened to the terminal board Inter unit cables are securely fixed The power cord and inter unit cables are not connected anywhere along their paths The ground wire is securely connected An air purge of the refrigerant circuit has been conducted A leak test of the tubing connections has been performed Thermal insulation has been applied to the tubing connections Putty has been used to close the hole in the wall service valves are fully open 37 Installation manual Polar Comfort Multisystem T9 Polar Comfort Multisystem 1 HP have delay on 10 minutes with startup and powerfailure 2 Bypasvalve must be installed after waterpump Heatpump VP1x 3 8 2 Tw 1 Clamp 1 2 signalcable for tempreg VP2 clamp 1 2 G 2 5me cable water Innlet Min Waterflow 1100 L h Min waterflow bypass 800 L h Floorheat are shut down Temperated water ni Temp water 65 degr celsius r C p Mix valve Polar Comfort Multisystem 1
26. and fuses will not be tripped To protect the compressor coil from overheating the Operation can continue during this period with operating frequency is controlled based on the compressor somewhat reduced heating or cooling capacity discharge temperature Operation at normal capacity is restored when the cause of the current rise is eliminated C Description of function f 124 Example of operation for heating 5Hz every 30 sec reduction 225A Power Point C 9 E 140A Point B EE 130A Point A 2 2Hz every 30 sec reduction Target frequericy RE ee ei j 100 gt Increase Ss prohibit range iy No control Stops operation Hz reduction Approx 3 minutes Operates atthe target frequency at Point A and below i Stops increases to the frequency between Points A and B 12 2 Reduces the frequency by 1 Hz per 0 5 seconds when Point B is exceeded Within the increase prohibit range the range changes Stops operation and restarts it approximately 3 minutes later if Point C is to the Hz reduction range 2 Hz every 30 seconds if oe the compressor temperature rises by 2 C May operate when sudden voltage fluctuations occur Indicates trouble 6 5 Automatic frequency control The operating frequency is reduced automatically or operation is stopped in order to control the operating current so that itis at or below the values shown in the table below Point C
27. ce life Fig 4a install cushion rubber under unit s feet to reduce vibration and noise Fig 4b use lug bolts or equal to bolt down unit reducing vibration and noise select a location where the operating noise and air blowing from the outdoor unit will not disturb neighbors select a location where the clearance indicated by in the installation diagram is ensured for the front rear left and right of the main unit 9 install so that the unit is level 9 select a location that can fully support the weight of the outdoor unit and that will not magnify operating noise or vibration Fasten in place with the anchor bolts M10 provide a base using concrete or similar material and ensure proper drainage select a location where there is no danger of flammable gas leakage in snowy or rainy regions be sure to construct a roof to keep off the snow and rain and inhibit freezing and condensation select a location that is at least 3 meters away from any antennas used for television radio transceiver or other equipment for purposes of future service and repair select a location where the inspection panel can be removed select a location where the drain port will not be obstructed Install the inter unit cable more than 1 meter away from any antenna or power lines or connecting wires used for television radio telephone security system or intercom Electrical noise from any of these sources may affect
28. ctivated Reset count exceeded O x x x x x x x o x o OO Error monitor lamps OUS BLE COTL GATKI ML HL n Lm DUO amp UMS D TH vg ES i E 1 br Ty 772 35 It k n 2 m a 5 B je T 5j DE T 85 1992 s FR EN 09 39 g 2L FEET m i m Bergen Span yp 99 BB J n amp nz LS ERROR SE ic N r m i i CIOE MONITOR Z lU 1 PASSE ee UX US px slg 37 when e gt CN E CL 3 Bul Wo c B va Li pt Ko Y HL EG AG a R GE lt d de 4 ir 1 T 6 m a ya Hb GE M 8 LAL w dr Il I 3 L am z Jes 1 o o Sus a v L LI a i ws T MY m Ru 107 1 S Pan d z i l Y 1 2 Ce o am JG RM LE 9 D r rf sl 54 RTOS 2 kyi 3 Mt I me a 4 ge 58 az TENTER c4 5 71 L Bl 7 L 5 CE
29. diagnostics 1 If the operation lamp flashes every 0 5 seconds immediately when the power is turned ON there is an external ROM OTP data failure on the control panel circuit board or ROM socket insertion problem or the ROM has not been installed Operation selector Ordinarily this switch should 2 The failure mode is stored in memory even when the power is not ON Follow the procedure be in the OFF position below to perform diagnostics The OFF TEST and DEMO positions are used for inspection Remow the auto start rele yl Turn the power switch ON Move the operation selector on the main unit to OFF self diagnostics If there is a sensor failure or a protective function has activated self diagnostics lamps 1 2 and 3 will illuminate in the following pattern 5 seconds flashing illuminated 2 seconds OFF Buzzer sounds once while lamps are OFF Note If there is no trouble then self diagnostics lamps 1 2 and 3 do not illuminate and the buzzer does not sound Diagnostics is completed when the buzzer sounds 3 beeps After inspection or repair is completed be sure to move the operation selector to the DEMO position turn the power ON and erase the diagnostics contents Then move the selector to the OFF position and check that the diagnostics contents have been erased before using the unit Replays the auto start rele y1 14 7 2 Details of Self Diagnostics When the operation selector on the indoor unit is
30. eaking If escaped gas comes in contact with a stove gas water heater electric room heater or other heat source it can produce dangerously toxic gas TABLE CONTENTS SPECIFICATIONS 2 1 Unit Specifications 2 2 Major Components Specifications 2 3 Other Components Specifications DIMENSIONAL DATA REFRIGERANT FLOW DIAGRAM ELECTRICAL DATA 4 1 Electrical Wiring Diagrams 4 2 Electrical Wiring Diagrams INSTALLATIONS INSTRUCTIONS 5 1 Indoor Unit 5 2 Outdoor Unit 5 3 Diagram of Outdoor Unit Installation 5 4 Recommended Wire Length and Diameter 5 5 Wiring System Diagram FUNCTIONS 6 1 Defrost Detection and End 6 2 Current Control 6 3 Low Start Current 6 4 Compressor Temperature Control 6 5 Automatic Frequency Control 6 6 Current control TROUBLESHOOTING 7 1 Self diagnostics 2 Details of Self diagnostics 7 3 Self diagnostics failure 4 Unit Problems and Inspection Points 5 Checking the Outdoor System 7 5 1 Checking the Outdoor Unit 5 2 Using Forced Defrost Procedure 6 Unit Problems and Inspection Points 6 1 Outdoor Control Circuit Board 7 6 2 Hic 6 3 Fuse 6 4 Compressor 6 5 Compr Protective Sensor 6 6 Outdoor Fan Motor Page N 10 11 12 13 13 13 13 13 14 15 16 17 18 18 19 20 20 20 20 20 20 7 6 7 4 Way Valve 20 7 6 8 Coil Thermistor 20 6 9 Electric Expansion Valve 21 6 10 Branch Tubing Temperature Sensor 21 6 11 Breaker 21 7 6 1
31. er R407C and R410A Welding machine nitrogen gas cylinder Doing so will cause malfunction of the unit Ne 9 The above tools specifically for R410A must not be used for R22 and R407C 9 For the above vacuum pump 1 2 and vacuum pump adapter 3 those for R22 type units can be used for R407C type However they must be used exclusively for R410A and never alternately with R22 and R407C 9 To prevent other refrigerants R22 407 from being mistakenly charged to this unit sizes of the service ports and flare nuts of the narrow tube service valve and wide tube service valve have been altered 8 4 Tubing Installation Procedures When the tubes are connected always apply HAB oil on the flare portions to improve the sealing of tubing The following is the HAB oil generally used Esso ZERICE S32 For details on tubing installation procedures refer to the installation manuals attached to the indoor unit and outdoor unit 26 8 5 In Case of Compressor Malfunction CAUTION 9 Should the compressor malfunction be sure to make the switch to a replacement compressor as quickly as possible 9 Use only the tools indicated exclusively for R410A gt See 10 3 Tools Specifically for R410A Procedure for replacing compressor 1 Recovering refrigerant Any remaining refrigerant inside the unit should not be released to the atmosphere but recovered using the refrigerant recovery unit for R410A
32. f the current peak cut off function is activated The maximum length of a single defrost operation is 12 minutes For the outdoor heat exchanger temperature conditions for ending defrost refer to Table 1 below Outdoor heat End temperature exchanger temperature Defrost f operation time Less than 2 minutes 2 minutes or more Outdoor air temperature Coil temperature 1 10 or higher for ending defrost 1 The temperature for ending defrost is 7 C or higher when the outdoor air temperature is less than 0 C Fig 1 Table 1 23 8 REFRIGERANT R410A SPECIAL PRECAUTIONS WHEN SERVICING UNIT 8 1 Characteristics of New Refrigerant R410A What is New Refrigerant R410A R410A is a new refrigerant that contains two types of pseudo non azeotropic refrigerant mixture which do not adversely affect the earth s ozone layer Its refrigeration capacity and energy efficiency are about the same level as the conventional refrigerant R22 Components mixing proportions HFC32 50 HFC125 50 Characteristics Less toxic more chemically stable refrigerant The composition of refrigerant R410A changes whether it is in a gaseous phase or liquid phase Thus when there is a refrigerant leak the basic performance of the air conditioner may be degraded because of a change in composition of the remaining refrigerant Therefore do not add new refrigerant Instead recover the remaining refrigerant
33. failure 2 Contact failure at connector 3 Outdoor circuit board failure Outdoor system communications failure m Outdoor high voltage SW OLR operation Miswiring 2 Blown fuse 8 Power relay failure 4 Open phase Outdoor power supply open phase 5 Outdoor circuit board failure 6 Compressor failure outdoor coil freezing E13 Freeze prevention operation 1 Water pump system failure 2 No refrigerant 3 Low temperature operation Other Timer lamp flashes 3 second intervals 1020 2020 NOTE Ifthe operation lamp continues to flash orange even when the KBDHV A1 card operation selector has been moved to the OFF position an indoor unit external ROM failure has occurred E14 After inspection or repair is completed be sure to move the operation selector to the DEMO position turn the power ON and erase the diagnostics contents 19 7 3 E ifthe self diagnostics function fails to operate No indicators illuminate Check the control card e Check the power voltage Blown Is the fuse blown Normal Replace the circuit Replace the controller board or the fuse If there are no problems with the above then check the outdoor unit Checking the outdoor unit NNNM Check items unit operation Apply the rated voltage between outdoor control panel LED red must illuminate unit terminals 1 and 2 S hort circuit the outdoor unit COM terminal
34. fference is large the valve is closed Then rotate 5 revolutions counterclockwise to open the valve Operation is normal if the temperature difference between the 2 tubes drops NOTE amp Cool the main unit with a damp cloth or other means while welding When applying vacuum use the special service magnet No temperature change and rotate at least 5 revolutions counterclockwise to fully open the electric Replace the electric expansion valve expansion valve f you have manually checked the electric expansion valve be sure to reapply the outdoor 220 V after you have replaced the wiring The position of the electric expansion valve will be changed Open and close the electric expansion valve by hand to check it Temperature changes This part is normal Check elsewhere 7 6 10 Branch tubing temperature sensor Check that the sensor is securely contained in the thermostat holder 7 6 11 Breaker Check whether or not the breaker has been tripped amp Check that the breakers and fuses used are of the specified capacity Check that the breaker and its line are exclusive for use 7 6 12 Refrigerant gas pressure Starta COOL testrun and measure the temperatures of the A C intake air and discharge air Compare the values with the performance charts If the values are higher than the performance charts Check for refrigerant shortage or blockage of the refrigerant circuit A
35. gth test Corroston test Essai de r silieace Test de corrosion Kesbsohlagzaehigkeitstesl Korrosionstest psi Internal oleanliness temperature CAS a l de 5 _ en Location of the sample 1 The delivery Is in accordance with the order Organisation inspection Emplacement de l chantillon La fourniture est conforme aux exigences de la commande Organisme et ou service contr lo Lage des Probenabschnittes Die Lieferung entspricht den Bestellbedingungen vot Ueberwachungsabieilung nas Frent D but Anfang reique Vin Bada Service Metallurgiq Milieu Mitte col Le 02 10 2006 JG EVON Direction of the test pleces 2 Marking inspection and measurement without objection 2 Orientation des prouvettes Contrbie de marquage d aspect et de dimensions satisfaisants The inspector t Probenrichtung Pruefung der Stempelung des Oberflaechenaspekts nnd Le responsable Peng Laengs T Abmessungen ohne Beanstandung _ oo Der Werssachverst endige Ta 5 1740 XV TG ty yi 90007530781
36. he pres sure is 101 kPa 76 cmHg The operation time for the vacuum pump varies with tubing length and the capacity of the pump The following table shows the amount of time required for evacuation Table 5 Required time for evacuation when capacity of 100 liter h vacuum pump is used 120 min or more The required time in the above table is calculated based on the assumption that the ideal or target vac uum condition is around 10 mmHg abs 5 With the vacuum pump still running close the Lo knob of the manifold valve Then stop the vacuum pump Fully close the low pressure valve and stop the vacuum pump Wait 1 2 minutes and check that the manifold gauge pointer does not return If it does return find and repair the leak then apply the vacuum again 6 With a hex wrench turn the valve stem on the nar row tube service valve counter clockwise by 90 degrees 1 4 turn for 10 seconds and then turn the stem clockwise to close it again N cAUTION Besure to completely insert the hex wrench before attempting to turn the valve 7 With a standard screwdriver turn the wide tube service valve stem counterclockwise to fully open the valve 8 Turn the narrow tube service valve stem counter clockwise to fully open the valve 9 Loosen the vacuum hose connected to the wide tube service port slightly to release the pressure Then remove the hose 10 Leak test all joints at the tubing water
37. ion should be a min 8 mm After a tube has been insulated never try to bend it into a narrow curve because it can cause the tube to break or crack Service valve on wide tube side DAI N 9 52 Watertank Electric expansion Service valve valve on narrow tube mL 35 Insulation Thickness ud Thickness Min 8 mm Min 8 mm Narrow tube Wide tube ELECTRICAL DATA 4 1 Electric Wiring Diagrams 4 for outdoor unit Polarcomfort 8 6 iagram D iring Electric W ZHLOHL SHLYHL Hl GHLIHL CA 5 uMopduung Ws B FEN ED HLY dINOO MIV9 100 430 GINO ELNO g 1718 LHM SONO 90NO 13 LHM LHM LHM 20 2 8139 0 GOIH LOIH 21 21 ele 1 Q3H3Q lOS e eTt 3SV8 IVNIIAH3 L dOd IOH LNOO INVd 12 Add 0829 0IH AHE SYIM NI GYVOd 60 9 cONO LONO JYNINYIL HOLO3NNOO LHM LHM LHM OIH 3dld 3dIM 8 WOOH HOLSIINH3H L 3dld MOHHVN 8 WOOHJHOLSINHIHL dOd 3dld MOHHVN V NOOH JHOLSINHIHL 3dld IAIM V INOOH HOLSIINH3H L
38. lient Werksauftagsnummer Besteller und oder Empfaenger Kundenbestellnummer 48 6UA607320 02 55633 1 HOIAX A S 4414 Product Produit Erzeugnis Customer number COLD ROLLED COIL d article client BOBINE LAMINEE FROID F LM E KSTAD Artikelnummer des Kunden 00 KALTGEWALZTES BAND ADS Steel designatian Steelmaking process ET Product delivery conditlon D signation de l acier Pr sentation Mode d laboration de l acier Stahlherstellungsverfahren Frat de livraison du produit Stshibezcichnung hrungiProd praces Elactric re fumace VOD AOD Continusus casting Lieferzustand Proc fabrle Four arc VOD AOD Coul s continue Annealed FarigungsablauhEiektro Gfen VOD AOD Sfrangguesaniaga Reenit 820 880 Any supplementary requirements Gegiuht Prescriptions suppl mentaims Zus tzliche Amforderungeu Alt Air forc Gebdlacss Lytt p EN 10088 2 05 1 4521 em 2H VRSSEL ABERREIL PRESSION RPO t 340 MBA A 20 C 6 309 HRA 100 RM 480 204 Idontifleation of tho product Ba Dimensions Number of picces BOG 4 Ideatitication du prodvit Identifizierung des Erzeugnisses LL Dimensions Abmessungen _ jNombie de pisces Stueckzahl Coil n Heat n Thickness Po Width _ Bie Length P1 N de bobine Band Nr N decoul s Schmelz Nr Epaisseur gt Dicke Largeur Breite Longueur Laenge
39. ng Operation CAUTION Never charge a large amount of liquid refrigerant at once to the unit This may cause damage to the compressor Single valve Charge liquid refrigerant with amp When charging with a refrigerant cylinder use an electronic scale for charging refrigerant In Fig 1 this case if the volume of refrigerant in the cylinder becomes less than 20 of the fully m Valve charged amount the composition of the refrigerant starts to change Thus do not use the refrigerant if the amount in the charging cylinder is less than 20 Also charge the minimum necessary amount to q the charging cylinder before using it to charge the air conditioning unit Example In case of charging refrigerant to a unit requiring 0 6Kg using a capacity of a 10Kg cylinder the Single valve with siphon tube minimum necessary amount for the cylinder is Charge with cylinder in normal position 0 76 10 x 0 20 2 76Kg Fig 2 For the remaining refrigerant refer to the instructions of the refrigerant manufacturer f using charging cylinder transfer the specified amount of liquid refrigerant from the refrigerant cylinder to the charging cylinder Charging Prepare an evacuated charging cylinder cylinder beforehand CAUTION To prevent the composition of R410A from changing never bleed the refrigerant gas into the atmosphere while transferring the 4 Refrigerant cylinder refrige
40. p the insulation to expose the wire about 5 mm See the label Fig 26 near the terminal plate 2 Using a screwdriver loosen the terminal screw on the terminal plate 3 Insert the wire and tighten the terminal screw com pletely using a screwdriver b For Outdoor Unit For solid core wiring or F cable 1 Cutthe wire end with a cutting pliers then strip the insulation to expose the solid wire about 25 mm Fig 27 2 Using a screwdriver remove the terminal screw s on the terminal plate 3 Using the pliers bend the solid wire to form a loop suitable for the terminal screw 4 Shape the loop wire properly place it on the termi nal plate and fix it securely with the removed termi nal screw using a screwdriver For stranded wiring 1 Cutthe wire end with a cutting pliers then strip the insulation to expose the stranded wiring about 10 mm and tightly twist the wire ends Figs 28 and 29 2 Using a screwdriver remove the terminal screw s on the terminal plate 3 Using a ring connector fastener or pliers securely clamp each stripped wire end with a ring connector Fig 28 4 Place the ring connector wire and replace and tighten the removed terminal screw using a screw driver Fig 30 Special washer b 5mm ACTUAL STRIP SD Fig 26 Insulation 25 mm Fig 27 Stranded wire O Ring S 9 connector 10 mm a Fig 28
41. pered sides are of uniform length Caution Before Connecting Tubes Tightly a Besure to apply a sealing cap or water proof tape to prevent dust or water from getting into the tubes before they are used b Besure to apply refrigerant lubricant to the matching surfaces of the flare and union before connecting them together This is effective for reducing gas leaks Fig 12 Forproper connection align the union tube and flare tube straight with each other then screw in the flare nut lightly at first to obtain a smooth match Fig 13 Tubing Connections a Temporary connection Screw in 3 5 rotations by hand Fig 14 b To fasten the flare nuts apply specified torque as Table 4 Tube Dia Tightening Torque 6 35 mm 14 18 N m 140 180 kgf Copper tubing Fig 9 If the previous flare tool clutch type is used Adjust so that the amount of tube protrusion is as shown in the figure Fig 10 Flare tool Fig 11 If the special R410A flare tool is used p Copper tubing 74 Apply refrigerant lubricant here and here Fig 12 Union Flare nut Fig 13 Service valve on Service valve on wide tube side narrow tube side H g gt gt 1 por gt 2 lt gt Fig 14 30 CAUTION Be sure to match refrigerant tubing and electric wiring between indoor and outdoor units For more details refer to Tubing Check Control
42. prevent possible hazard due to insulation failure the unit must be grounded 4 Each wiring connection must be done tightly and in accordance with the wiring system diagram Wrong wiring may cause the unit to misoperate or become damaged 5 Do not allow wiring to touch the refrigerant tubing compressor or any moving parts of the fan 6 Unauthorized changes in the internal wiring can be very dangerous The manufacturer will accept no responsibility for any damage or misoperation that occurs as a result of such unauthorized changes Recommended Wire Length and Diameter Regulations on wiring diameter differ from locality to locality For field wiring requirements please refer to your local elec trical codes Carefully observe these regulations when car rying out the installation Table 5 4 page 11 shows maximum wire lengths for control line and power line and fuse or circuit capacity How to Connect Wiring to the Terminal NES Loose wiring may cause the terminal to overheat or result in unit malfunction A fire hazard may also exist There fore be sure all wiring is tightly connected When connecting each power wire to the corresponding terminal follow the instructions How to connect wiring to the terminal and fasten the wire securely tight with the fixing screw of the terminal plate How to connect wiring to the terminal a For termostat Watertank 1 Cutthe wire end with a cutting pliers then stri
43. r case preventing it from rotating Correct if necessary b Otherwise the fan motor bearings have seized Replace the bearings 7 6 7 4 way valve Of the outdoor control circuit board connector T RUN TEST terminals short circuit the T RUN terminal to the COM terminal Perform a test run of the unit alone and check whether the 4 way valve inside the outdoor unit produces a click sound 7 6 8 Coil thermistor Check that the sensor is securely contained in the thermostat holder 20 7 6 9 Electric expansion valve When replacing the electric expansion valve and coil be sure to attach the connectors in the correct positions Labels applied to the valve body and coil corresponding to the connector colors to identify them Use a tester to measure the voltage 12 V amp When the power is turned ON the needle will move from MMV white MVA black gt MVB red MVC blue in sequence in approximately 10 20 seconds for each point No voltage on circuit board Voltage varies Check the illumination Check the coil resistance PE ET of the red LED gray lead wire and the other wires Resistance is OK if it is 46 40 at 20 C Replace the controller 00 Approx 46 40 Replace the coil Use the special service magnet and rotate 5 revolutions clockwise to fully close the valve Then start the unit and measure the temperatures at the inlet and outlet tubes of the electric expansion valve If the temperature di
44. rant Fig 3 Do not use the refrigerant if the amount in Fig 3 the charging cylinder is less than 20 8 6 Charging Additional Refrigerant When Tubes are Extended 9 Observe the proper amount of refrigerant as stated in this service manual or the installation manual that came with the indoor unit Charge additional refrigerant in liquid state only N CAUTION Never charge additional refrigerant if refrigerant is leaking from the unit Follow instructions given in 10 6 In Case Refrigerant is Leaking and completely carry out repairs Only then should you recharge the refrigerant 8 7 Retro Fitting Existing Systems Use of Existing Units 9 Never use new refrigerant R410A for existing units which use R22 This will cause the air conditioner to operate improperly and may result in a hazardous condition Use of Existing Tubing 9 f replacing an older unit that used refrigerant R22 with a R410A unit do not use its existing tubing Instead completely new tubing must be used 29 9 When reaming hold the tube end downward and be sure that no copper scraps fall into the tube Fig 9 1 Remove the flare nut from the unit and be sure to mount it on the copper tube 2 Make a flare atthe end of copper tube with a flare tool Figs 10 and 11 Use RIGID or equivalent good flare should have the following characteristics e inside surface is glossy and smooth e edge is smooth e ta
45. s between the watertank and outdoor units have been properly connected Note that narrow and wide tube service valve on the outdoor unit are kept closed at this stage Using an adjustable wrench or box wrench remove the valve caps from the service valve on narrow and wide tube Connect a vacuum pump and a manifold valve with pressure gauges to the service port on the wide tube service valve Fig 20 Before using the vacuum pump CAUTION adapter read the vacuum pump adapter manual and use the adapter correctly CAUTION Be sure to use a manifold valve for air purging If it is not available use a stop valve for this purpose The Hi knob of the manifold valve must always be kept closed Cap tightening torque 20 25 Nem 200 250 kgf cm Tighten by hand then use a wrench to turn 5 pindle S crew diameter 1 2 UNF 20 threads Valve ex Cap nut tightening torque 7 11 Nm 70 110 kgf cm Tighten by hand then use a wrench to turn approximately 30 lt Structure of service valve on wide tube side gt Fig 21 When using a hex wrench to open the spindle an extremely small amount of refrigerant may leak This does not indicate a problem Use hex wrench of a type to which force can be easily applied 32 4 With the Lo knob of the manifold valve open high pressure valve Hi closed completely run the vacuum pump Run the pump until t
46. sions Heat pump Watertank DATA SUBJECT TO CHANGE WITHOUT NOTICE Operating range outdoor unit 18 c 30 c Floorheating 25 c 45 c Tapwater 65 95 1 Rating conditions are Heating Water temperature 35 30 C Outdoor air temperature 7 C 6 W B 1 2 Major Component Specifications Outdoor Unit Polarcomfort 8 6 DC Twin Rotary Hermetic C TRVN153HOW 80851080 VC6BS 650 CC Coil resistance Ambienttemp 25 C 0 S 0 788 T 0 788 R 0 788 Cn 5 Safety devices CT Peak current cut off control Compressor discharge temp control Operation cut off control in abnomal ambient temp Run capacitor 18W 240V ropeller 0460 g lt lt rn m DIA c mm FC6S 61CAP C 1 200 Q Coil resistance Ambient temp 20 WHT BRN 82 02 WHT YEL 41 94 YEL PNK 18 97 Safety devices Type Thermal protector Operating temp Open C 130 x8 Close 19 15 Run capactitor pF WAC 440 Alumiminum plate fin Copper tube 2 Face area m 0 630 External Finish Acrylic baked on enamel finish Control PCB POW K5DHV5 A1 Control circuit fuse 2 50V 3 15A 1 3 Other Component Specifications Outdoor Unit e Compressor temp sensor EE qs ek s Esa E EE 14 4 180 Port EE Ca ER RE LL _ 160 g 140 17 S 120 p EXE ont de diese led
47. ssessment of refrigerant shortage a The low pressure pressure value is 5 MPa or more below the value in the performance charts b There is little condensation on the indoor heat exchanger which overall appears dry Distinguishing between refrigerant shortage and refrigerant circuit blockage If the low pressure pressure does not change when the circuit is charged 2 3 times with refrigerant gas 200 g each time or if the change is small then the problem may not be refrigerant shortage The problem may be a blockage of the refrigerant circuit a Check that there is no internal leakage inside the 4 way valve Atthe low pressure side tubing check that there is no temperature difference between the intake and discharge of the 4 way valve b Check that the electric expansion valve is not blocked Check as described on the preceding page 21 7 7 Explanation of Functions Control conditions Unit operation Explanation and outdoor temperature at the time operation MN Operation lamp illuminates The unit is forced to stop for 10 minutes after the power is turned ON or 3 minutes after the compressor stops in order to protect the compressor The frequency is increased at the rate of 1 Hz every 0 5 seconds Heat begins depending on the water temperature Heating Breaker on Outdoor unit begins operating the compressor starts the outdoor fan starts When the frequency reaches a Hz freq
48. t gt 5 K5DHV A1 outdoor communications failut t Miswiring 2 AC power failure 9 Blown fuse 4 Power relay failure serial communications 5 K5DHV A1 or outdoor circuit board failure 1 HIC or power Tr failure 2 Outdoor fan does not turn 3 Instantaneous power outage x x 02 4 Service valve notopened 5 Outdoor fan blocked 6 Continuous overload operation 7 Compressor failure 8 Outdoor circuit board failure 3 I Outdoor unit external ROM failure 1 External ROM data failure 2 Outdoor circuit board failure 1 Instantaneous power outage 2 HIC or power Tr failure m 8 Outdoor circuit board failure PAM circuit fail 1 05 Active 1 Outdoor circuit board failure 2 Outdoor power supply voltage failure le 6 Compressor discharge overheat 1 Electric expansion valve failure 2 Capillaries blocked 3 No gas 4 Continuous prevention overload operation 8 Outdoor fan does nottum 6 Outdoor circuit board failure 07 indoor fan operating failure 1 Fan motor failure 2 Contact failure at connector 3 K5DHV A1 circuit board failure 4 way valve switching failure we iK rit E 08 Indoor Zero cross failure 1 4 Way valve failure 2 Outdoor circuit board failure 09 No refrigerant protection 1 Service valve not opened 2 No refrigerant 10 DC compressor drive circuit failure 1 Open phase 2 Outdoor circuit board failure 11 Outdoor AC fan operating failure 1 Fan motor
49. tank Mixing valve tapwater Safetyvalve for tapwater 9 5 BAR for element Safety valve for floorheat 2 5 BAR 44 Electrical sheet tapwater tank 230V 1 50hz Elektroskjema Polarcomfort tapwatertank 230 V L1 Lo 230V PE 2 F Arbeidsomr de 60 95 C Drifts termost 2 eller 3 element Spenning 230V 45 Electrical sheet Floorheat Polar Kulde AS Kombi KEK Innstikkslengde kolbe inkl gjenger mm 465 Termostathus Bredde mm 94 H yde mm 200 Dybde inkl ratt for arbeidstermostat mm 165 og messing mutter Termostathuset er av aluminum med lokk i karbonplast Huset er vridbart slik at riktig stilling p kabelinntaket lett kan innjusteres Termostathuset leveres med 2 polig arbeidstermostat 30 90 C og polig sikkerhetstermostat 102 C Koblings alternativer IU 39R 6 Kw 3 230V 6 Kw 3 400V 4 kW 1 230V 2 kW 1 230V 46 MYLL CERTIFICATE BS EN 10204 3 1 06 6 85406 01 01 03 UGINE amp ALZ P Groupe Arcelor CERTIFICAT DE RECEPTION NF EN 10204 3 1 ui ABNAHMEPRUEFZEUGNIS B DIN EN 10204 3 1 Ugine amp ALZ Franca 5 Gueugnon 7730 Gueugnon FRANCE A SO TS 16949V2002 80 14001 V1996 Manufacturer s works order number Purchaser and or consignee Purchascr s order number N de l commande usine productrice Client et ou destinataire N de commande c
50. tank and outdoors with liquid soap Bubbles indicate a leak Be sure to wipe off the soap with a clean cloth N ese If a CFC gas detector is used use a special detector for HFC refrigerant such as R410A and R 134a 33 10 11 Replace the flare nut on the wide tube service port and fasten the flare nut securely with an adjustable wrench or box wrench Next mount the valve cap and tighten it with a torque wrench the cap needs to be tightened with the torque of 20 N m 200 kgf cm This process is very important to prevent gas from leaking from the system 12 While the heatpump is running apply liquid soap to check for any gas leaks around the service valves or caps 13 If there is no leakage stop the heatpump 14 Wipe off the soap on the tubing This completes air purging with a vacuum pump and the heatpump is ready for actual operation Pump Down In order to protect the earth s environment be sure to perform pump down to recover refrigerant gas without releasing it into the atmosphere e When relocating or disposing of the heat pump requestthis service from the dealer where the unit was purchased or from an appropriate agent Perform pump down as described below Charging por Whatis pump down e Pump down refers to recovering the refrigerant gas from the Narrow tube side A Close refrigerant cycle at the outdoor unit This work must be RK performed during heating operation Ke Fig 22 Pump
51. the L1 line for 35 minutes after the start of HEAT operation The temperature of the heat exchanger remains at or below the L2 line for 120 minutes after the start of HEAT operation Outdoor heat exchanger temperature Outdoor air e Compressor 100 Hz operation 4 way valve ON Outdoor fan OFF Solenoid valve ON for hot gas bypass Indoor fan 3 OFF Temperature of the outdoor heat exchanger is at or above the temperature shown in the table below Defrost operation has continued for 12 minutes max length End temperature Defrost operation time Less than 2 minutes 2 minutes or more Coil temperature for ending defrost Not ended 1 10 C or higher 1 The temperature for ending defrost is 7 C or higher when the outdoor air temperature is less than 0 C 12 6 2 Current Control 6 3 Low Start Current The operating current may rise as a result of causes O peration starts at 10 Hz and the start current is less than including increasing heating or cooling loads or the normal operating current This prevents the flickering of decreases in power voltage In these cases the fluorescent lights or television screens that occurs when operating frequency is automatically reduced or ordinary A C units start operation is stopped in order to control the operating current so that it is 20 A or less Asa resut 6 4 Compressor Temperature Control Power breakers
52. trical Characteristics sure to disconnect power before Control panel POW K5DHV5 A1 h To avoid electrical shock hazard be checking servicing and or cleaning any electrical parts Yl BK BK O UTO Star Sa E R po W Inter unit cables Y BL R 4 1 Terminal board COM SI Termostat ter outle ali HBK water temperature ROOM COIL BK sensor 215 BK M91 RE BK Narrow tube temperature sensor Fan motor BK Black White Red GRN Green Yellow BL Blue GY Gray 5 INSTALLATION INSTRUCTIONS Installation Site Selection Indoor Unit To prevent abnormal heat generation and the possibility of fire do not place obstacles enclosures and grilles in front of or surrounding the heatpump in a way that may block air flow Max allowable tubing length L1 20 m Limit of elevation difference H1 10 m Tubing length L1 Elevation difference H1 Fig 1 5 2 Outdoor Unit AVOID heat sources exhaust fans etc Fig 3 damp humid or uneven locations DO choose a place as cool as possible choose a place that is well ventilated allow enough room around the unit for air intake exhaust and possible maintenance Fig 4a provide a solid base level concrete pad concrete block 15 x 40 cm beams or equal a minimum of 15 cm above ground level to reduce humidity and protect the unit against possible water damage and decreased servi
53. uency This is in order to stabilize the return of oil to increases are stopped for a period of B seconds the compressor Refer to Table 2 on page 35 The frequency then increases If the water and outdoor temperatures are high the current peak cut off activates stopping any increases in frequency The water temperature The water temperature and the termostat Operating frequency is stabilized in order to has reached the desired controller temperature setting are maintain water temperature temperature approximately equal Control conditions Unit operation Explanation HEAT When defrost operation Non stop defrost Defrost operation begins based on outdoor begins frost has formed temperature conditions on the outdoor unit when the ambient air Non stop defrost Refer to Fig 1 below temperature is low Outdoor fan Stopped D After HEAT operation begins the Compressor 120 Hz temperature of the outdoor heat exchanger is at or below the L1 line for 35 minutes Solenoid valve gas bypass Aner HEAT operation Begin 4 way valve Remains ON temperature of the outdoor heat exchanger is at Defrost lamp Remains OFF Lamp is ON or below the L2 line for 120 minutes for clean defrost The 4 way valve remains ON during defrost The outdoor fan stops and the solenoid valve turns ON allowing the refrigerant to bypass the indoor unit The operating frequency during defrost is 120 Hz Frequency is lowered i
54. with the refrigerant recovery unit Then after evacuation totally recharge the specified amount of refrigerant with the new refrigerant at its normal mixed composition state in liquid phase 9 When refrigerant R410A is used the composition will differ depending on whether it is in gaseous or liquid phase and the basic performance of the air conditioner will be degraded if it is charged while the refrigerant is in gaseous state Thus always charge the refrigerant while it is in liquid phase Ne Ether type oil is used for compressor oil for R410A type units which is different from the mineral oil used for R22 Thus more attention to moisture prevention and faster replacement work compared with conventional models are required 8 2 Checklist Before Servicing Use clutch type flare tool for R410A or the conventional flare tool Note that sizes of the resultant flares differ between these two tools Where conventional flare tool is used make sure to observe Specification amount of extrusion by using the flare spacer Specification Diameter of tube D Flare tool for R410A Conventional flare tool for R22 O Size of flare Flare tool for R410A Conventional flare tool R22 24 9 Tubing precautions Refrigerant R410A is more easily affected by dust or moisture compared with R22 thus be sure to temporarily cover the ends of the tubing with caps or tape prior to installation Never use 0 7mm thick copper tubing
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