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Sanyo CHDX07263 Refrigerator User Manual

Contents

1. EE ees b Gas tube Balance tube Dry core bidirectional for R410A refrigerant BR Ball valve ee Liquid tube Fig 21 W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures 10 3 Removing and Installing Compressors When removing and installing compressors use sufficient caution to ensure that moisture or other substances do not enter the refrigerant tubing system 10 3 1 Replacing compressors For all types 90 and 140 follow the replacement procedure below A Replacing the inverter compressor Compressor 1 on remote controller alarm display E Removal 1 Connect a manifold gauge to the high and low pressure outlet ports at the outdoor unit where the compressor will be replaced Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement in the outdoor unit tubings 2 Follow the instructions in 1 Removing Panels and 2 Removing Electrical Component Box and Duct and remove the corresponding parts from the outdoor unit where the compressor will be replaced Remove the cap at the compressor terminal plate Disconnect the power terminal Remove the crankcase heater Remove the 3 bolts and remove the washers and rubber washers quantities indicated in the figure below Disconnect the tube with flare nut using two adjustable wrenches At thi
2. 7 I mo b S Pi Low pressure i outlet port High pressure f For B e vs For 5 16 7 94mm Se or 7 94mm dia connector dia connector E ES Upper valve 1 service port P For 5 16 7 94mm dia connector pen Hi T Procedure 1 Open OIL l Cid e ele bos A Loner arer gt EH B Procedure 3 Open Connect from here to refrigerant recovery unit Fig 18 To terminate the oil charging work do as follows To end the charge process first close the valve on the high pressure side of the manifold gauge Then wait several tens of seconds after the pressure display on the manifold gauge low pressure gauge stabilizes in order to equalize the pressure with the low pressure outlet port and to vaporize the refrigerant in the charge tank Then perform steps 1 and 3 in sequence and fully close the valves Finally connect the refrigerant recovery unit to the Lo gauge side shut down all indoor and outdoor units and then recover the remaining refrigerant in the oil charging tank manifold gauge valves and connecting hoses Perform these procedures quickly and securely so that no air can enter After charge the necessary amount of new refrigerant by referring to the Installation Instructions that came with the outdoor unit To determine the completion of refrigerant recovery follow the instructions that came with the refrigerant r
3. tions Demand setting Control Demand meaning Contact 1 Contact 2 X X No control Operates to maximum capacity O X Operates to the upper limit for the rated current X Q Operates to 7096 of the upper limit for the rated current O O Always in stop condition O Input present X Input not present The rated current indicates the current value that is listed in the catalog or similar material W 2WAY ECO i SYSTEM 10 Indoor Unit Control of the Electronic Control Valve Control Functions 10 1 Normal Control 1 Cooling operation Position of electronic control valve e Outdoor unit Outdoor unit operating stopped Stopped 20 20 Fan 20 20 Thermostat 20 20 Coolin SEE 9 Thermostat Performs SH control in the range of 55 480 ON pulses The SH target value is controlled so that the E3 E1 becomes between 2 F to 6 F depending on the operating conditions However a decline in the required level may cause the SH target value to increase Be aware that in this case the electronic control valve closes slightly This can be easily identified incorrectly as insufficient gas 2 Heating operation A Except Type D Position of electronic control valve i Outdoor unit Outdoor unit operating stopped Liquid refrigerant is gradually returned to the outdoor unit Stopped at pulses ranging from 55 to 80 iid F Liquid ref
4. W 2WAY ECO i SYSTEM 16 Backup Operation Control Functions Field Application Functions Backup Operation 16 1 Automatic Backup Operation This system includes a function for automatic backup operation An alarm is also displayed to inform the operator that a failure has occurred 1 Alarms that result in automatic backup operation When compressor trouble or fan motor trouble makes emergency continued operation impossible automatic backup operation mode is engaged Automatic backup mode is not engaged in cases of communications alarms automatic reset alarms and other instances when emergency operation is possible by pressing the remote controller buttons or changing other conditions The alarms that result in automatic backup mode are P16 P22 P26 P29 H11 H12 and H31 2 Start of automatic backup operation If the above alarms occur the alarm is displayed on the control device Pressing the control device button again starts automatic backup mode 3 Operation 1 When 1 outdoor unit is installed When 1 compressor has failed backup operation is possible using the other compressors only in the 09663 model 8 Ton However operation does not occur when the outdoor fan is unable to operate as a result of alarm P22 2 When multiple outdoor units are installed When automatic backup mode is engaged the outdoor unit where the above alarm occurred stops operating However if one or more of the
5. Lower duct 8 Remove the upper duct remove 3 screws Fig 7 Upper duct W 2WAY ECO i SYSTEM 3 Discharging Compressor Oil Outdoor Unit Repair Procedures Discharged oil can be used for checking the condition of the system Based on the appearance and color of the discharged oil a judgment can be made on whether the system is operating normally or not 3 1 Discharging Oil from Oil Separator Recover the refrigerant from the outdoor unit following the procedure given in 5 Recovering Refrigerant Install hoses as indicated on the equipment and feed nitrogen gas gradually to provide pressure to the system from the low pressure outlet and collect oil in a pan or container Fig 8 The low pressure outlet port is at the Lo side of the right side CAUTION A faulty outdoor unit may remain pressurized The oil outlet port employs a Schrader type push to release valve Be careful to avoid accidental oil release when using the port Packless valve or the like i Container NL Oil outlet port For 1 4 6 35mm dia connector Manifold gauge Lo Hi RAF Nitrogen gas Low pressure outlet port Fig 8 For 5 16 7 94mm dia connector 3 2 Discharging Oil in Compressor Recover the refrigerant in the outdoor unit following the procedures in 5 Recovering Refrigerant Remove the compressor and discharge the oil in it Refer to 10
6. Cooling operation 14 Even if the fan mode is 0 during cooling operation the fan mode may change to 1 at regular intervals for tem perature protection of the inverter hybrid IC 8 3 Fixed Initial Fan Mode For the first 30 seconds after operation starts the mode is fixed at the initial mode which was calculated from the relationship between the outdoor air temperature and the outdoor unit horsepower If the outdoor unit horsepower changes dramatically say for about 2 hp the initial mode may be recalculated and may be again fixed for 30 seconds 8 4 Operation after Fixed Initial Fan Mode After the fixed initial fan mode the fan mode is increased or decreased according to the operating conditions 1 When all indoor units are operating in cooling mode A Fan mode is increased when the high pressure satulation temperature sensed by the pressure sensor is high and is decreased when the pressure sensor temperature is low The fan mode is always increased when the high pressure satulation temperature sensed by the pressure sensor is 113 F or higher B The fan mode may be decreased when symptoms of insufficient refrigerant gas are detected at an indoor unit 2 When all indoor units are operating in heating mode A If the condensation temperature is low the fan mode is increased at regular intervals B If the condensation temperature is high the fan mode is decreased in order to prevent excessive loa
7. Outdoor unit model mismatch 4 way valve operation failure W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis Compressor 1 discharge temperature trouble High pressure switch activated Reverse phase or missing phase detected Compressor 2 discharge temperature trouble Fan motor trouble Inverter compressor high frequency overcurrent alarm 5 26 Inverter compressor missing phase or lock alarm 5 26 Blinking Inspection Display on the remote CHECK blinking 1 controller CHECK blinking 2 Compressor 1 INV overcurrent alarm ke kA MIS NO W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis E06 Alarm gem ege E Alarm meaning Outdoor unit failed to receive serial communication signals from indoor unit Alarm conditions Outdoor unit failed to receive serial communication signals from indoor unit Probable cause 1 The indoor unit power was cut OFF after initial communications were completed 2 An open circuit or short circuit occurred in the inter unit control wiring after initial communications were completed Check Check the power at the indoor and outdoor units and check the inter unit control wiring Correction o CE Example BE Notes This alarm is detected after initial communications are completed Therefore it does not occur in cases of disconnected serial connector no terminal unit set or other trouble that occurs before initial communications are
8. D Press and hold the button for 4 seconds or longer Test appears on the remote controller LCD display Fig 3 Start operation Press the button to return to normal remote controller display RCS TM80BG Fig 3 3 Remote Controller Servicing Functions E Sensor Temperature Display Function displayed regardless of whether unit is operating or stopped The procedure below displays the sensor temperatures from the remote controller indoor unit and outdoor unit on the remote controller Procedure D Press and hold the and 8N buttons simultaneously for 4 seconds or longer The unit No X X main unit No item code XX sensor address and servicing monitor XX sensor temperature are displayed on the remote controller LCD display See Fig 4 at right Press the temperature setting A H v R buttons and select the item code to the address of the sensor to monitor rere LILI For the relationships between the sensor addresses and sensor types refer to the table of temperature sensors and addresses on the next page If group control is in effect press the UNIT J button to select the unit to monitor Press the temperature setting buttons to select the item code to change Press the button to return to normal remote controller display W 2WAY ECO i SYSTEM Remote Controller Fu
9. 0 99999999 hrs 0 99999999 hrs Compressor 1 operating time se eee RENNES PERENNE 0 Empty 1 Insufficient 2 Sufficient 0 Empty 1 Insufficient 2 Sufficient HEEN j E I Display only Alarm code and unit No of unit ISIN where alarm occurred are displayed alternately Alarm history 5 0 CCU 1 2 Outdoor unit Alarm history 6 Alarm history 7 Alarm history 8 oldest Lu I FN Be m Du m D ad m rn 1t 1 W 2WAY ECO i SYSTEM Outdoor Unit Maintenance Remote Controller 3 Ordinary Display Controls and Functions UG Locations where D and Q9 are displayed Displays the outdoor unit sub bus address which is as shown in Fig 3 currently selected D XX Outdoor system address on main bus line 1 30 YY Outdoor unit sub bus address 1 8 1 appears when there is only 1 outdoor unit ek COPY gs ca ava e gu EH Fig 3 Sample displays Cs COPY amp J C L ri O mea i y mem Ei mE E eea 01 lt No of connected indoor units gt 02 lt Unit Nos 1 2 3 and 4 are 4 units connected connected gt Fig 4 Fig 5 W 2WAY ECO i SYSTEM Outdoor Unit Maintenance Remote Controller 3 Ordinary
10. 00 cee eee eee eee 2 3 3 Discharging Compressor OU 2 5 4 Backup Operation cise ces ss seedeerelst onde beGe Sere evens eee E ROUEN Roe us n 2 6 5 Recovering Refrigerant eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 2 9 6 Checking for Leakage After Repair 2 14 7 Evacuating System i sucus cae ce eee e heed ae ew eee ee ee eee ee ee 2 15 8 Charging Compressor Oil 2 16 9 Pumping Out Refrigerant from Outdoor Un 2 20 BONES Mm ncm 2 23 11 High and Low Pressure Sensors 2 35 12 Replacing 4 way Valve oe NNN EK kn EEN ERR ECKER ENEE eee CR RR CRONACA E 2 36 W 2WAY ECO i SYSTEM 1 Removing Panels Outdoor Unit Repair Procedures Procedures 1 9 10 11 12 1 Front panel removal Fig 1 Remove the front panel remove 11 screws ox oc onm Removing Panels Removing Electrical Component Box and Duct Discharging Compressor Oil Backup Operation Recovering Refrigerant Checking for Leakage After Repair Evacuating System Charging Compressor Oil Pumping Out Refrigerant from Outdoor Unit when repairing parts other than compressor Compressor High and Low Pressure Sensors Replacing the 4 way Valve 2 Power outlet panel amp valve cover removal Fig 2 Remove the power outlet panel remove 2 screws Remove the tubing cover remove 2 screws Power outlet panel Tubing cover Fig 2 W 2WAY ECO i SYSTEM 2 Removing Electrical Component Box and Duc
11. This setting reduces the voltage drop by preventing multiple systems from starting at the same time when opera tion is restarted after multiple operating systems were stopped due to a power outage or other cause Setting Effect 0 No delayed start setting at time of factory shipment 1 Start begins after 1 second x System address 2 Start begins after 2 seconds x System address 3 Start begins after 3 seconds x System address 17 4 Automatic Backup Outdoor EEPROM 48 set only on outdoor unit No 1 Automatic backup is set to occur at the time the unit is shipped from the factory However the automatic backup function can be disabled by changing this setting to 1 W 2WAY ECO i SYSTEM 17 Service Maintenance Functions Control Functions 17 5 Optional Solenoid Valve Control Operation Setting Outdoor EEPROM CO set at each outdoor unit Setting Operation 0 No output setting at time of factory shipment 1 Refrigerant shut off valve control for cooling when the outdoor air temperature is below standard conditions 2 External liquid valve control used in special cases when the discharge gas temperature is especially likely to rise 17 6 High Static Pressure Mode Outdoor EEPROM 8F set at each outdoor unit This product can be made compatible with high static pressure by changing the settings By changing the setting item 8F to 6 this product can be made compatible with o
12. ecm i s CE procram 8 C cov amp J C LE 7 JC owr C 4 J y 0 NN ti 88 sc E HU Refrigerant type and are displayed alternately Example shows 0000 0410 R410A List of Item Codes DN Parameter Description Outdoor unit capacity 0 Disabled 224 72 Type 280 96 Type W 2WAY ECO i SYSTEM Remote Controller Functions Contents 4 REMOTE CONTROLLER FUNCTIONS 1 Simple Settings Function iius dna sh hah RE REG RE eee ee eens Al EA wee ee RARE 4 2 2 Detailed Settings Function 0 006 000 eee eee NNN ENEE EE ENNEN E NEEN EN NEE ee 4 4 3 Remote Controller Servicing Functions 000 cece eee eee 4 15 1 Simple Settings Function This allows the filter lifetime operating mode priority change central control address and other settings to be made for an individual or group control indoor unit to which the remote controller used for simple settings is connected When simple settings mode is engaged operation stops at the individual or group control indoor unit to which the remote controller for simple settings is connected Procedure CD Press and hold the and E buttons simultaneously for 4 seconds or longer Ea unit No or ALL in the case of group control item code 7 and settings data ff XX are displayed blinking on the remote controller
13. 5 seconds is a sufficient interval between closing each of the 2 valves 3 Press the ON OFF button on the outdoor unit maintenance remote controller to stop the operation of all units f the outdoor unit maintenance remote controller is not available use the following method to stop the oper ation of all units Pull out the SCT connector 2P YEL CN231 from the outdoor unit control PCB of the unit where pump down is being performed When the SCT connector is pulled out alarm F12 sensor trouble immediately occurs and all outdoor units stop operating Be sure that you do NOT grasp the lead wire when pulling out the connector Removing any other connector may not cause the units to stop Therefore be sure to pull out only the SCT connector 4 Connect a refrigerant recovery device to the liquid tube service port Schrader type valve of all outdoor units where dry cores will be attached then recover the refrigerant from the tubing Be sure that no air enters the tubing at this time When the hose is connected internal pressure is applied by the remaining refriger AN eme ant in the inter unit tubing The connection port employs a Schrader type valve To determine when refrigerant recovery is compete follow the instructions in the instruction manual of the refrigerant recovery device b As shown in Fig 21 disconnect the tube that runs from the liquid tube valve to the ball valve on all outdoor units where dry co
14. The HIC judges the current and temperature and outputs the trouble signal In general this indicates trouble with the HIC itself Probable cause Overcurrent in HIC circuit and the resultant abnormal heating caused by HIC failure Check Check the power wiring and connector wiring If the wiring and connectors are normal use a tester to measure the resistance between the compressor HIC power HIC and ground HIC If there is a short circuit there is an HIC malfunction HIC HIC SIDON T TOUCH A ul LLL eyes vi e d mu i e e L Z ss D 7 E 7 HIC PCB If an HIC failure is found replace the PCB Turn OFF the power and check the continuity of HIC and HIC on the HIC PCB W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis L04 Alarm Outdoor system address duplication Alarm conditions Communication by inter unit control wiring was received that contained the same address as that unit 5 times or more within 3 minutes Probable cause Incorrect outdoor system address settings Check the system address settings again Correct the system address settings Notes Recovery from this alarm occurs automatically when communication that contains the same address as that unit is not received for 3 minutes after detection L10 Alarm Outdoor unit capacity not set Alarm conditions The outdoor unit capacity has not been set or the setting is not allowed by the system This alarm occurs b
15. 2 During the thermostat ON the indoor unit electronic thermostatic expansion valve is opened about 10 pulses from the current status W 2WAY ECO i SYSTEM 13 Discharge Temperature Control Functions lt Alarm Information gt 1 Discharge temperature protection alarm This device sets an upper limit discharge temperature of 222 F for all compressors When the discharge tem perature reaches 222 F that compressor is stopped and restarted If the same high discharge condition occurs 4 times then an alarm occurs After a compressor has stopped that compressor will not operate until the temperature has dropped to or below the start prohibit temperature Discharge temperature protection list Compressor No Compressor 1 Compressor 2 Type Inverter Constant speed Stop temp 222 F 222 F Start prohibit temp 158 F 158 F Alarm display P03 P17 2 Discharge sensor trouble detection control An alarm occurs if the discharge temperature remains abnormally high above 158 F when the system has been stopped for 60 minutes In this case possible causes include sensor failure and compressor overheating caused by an insufficient level of refrigerant The alarm also occurs if the sensor temperature is at or above the abnormal temperature 176 F when 20 min utes have passed after the compressor stopped In this case it is possible that the discharge temperature from a different outdoor unit is being d
16. 2 Removing Electrical Component Box and Duct 2 3 3 Discharging Compressor OU 2 5 4 Backup Operation sei eee ea pods ode he dam dees TERRE dhe Guard arae ou See ees ae 2 6 5 Recovering Refrigerant 0 ccc teens 2 9 6 Checking for Leakage After Repair nunaa cee tee 2 14 f Evacuating System sess cede v IK e eee hee e AEN eg d dE ban twee oe 2 15 8 Charging Compressor OU 2 16 9 Pumping Out Refrigerant from Outdoor Unit 0 0000 ee 2 20 el 2 23 11 High and Low Pressure Sensors 2 35 12 Replacing 4 way Valve 2 36 OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER 3 1 Iz OVEIVICW epeen cava hed bode wings 4 eee Ee bee tee ana pile Lee othe eine Pen nee 3 2 2 FUNCIONS g e eet Ae eine uae de either edie piel 4 aidan CEA EE oka 3 3 3 Ordinary Display Controls and Functions 3 4 4 Monitoring Operations a se aasan aaaea 3 9 5 Outdoor Unit Alarm History Monitor 3 11 6 Mode Settings eenia rg ua ha S rA bei a a a E xs 3 12 REMOTE CONTROLLER FUNCTIONS l l 4 1 1 Simple Settings FUNCION c asca AR Diceta and ig a EEE Ad ACH er dE E A E nee 4 2 2 Detailed Settings Function sasssa aeaaaee aaaea 4 4 3 Remote Controller Servicing Functions l i 4 15 Section 5 TROUBLE DIAGNOSIS sskssua lg ER EE EE RAR aaa 5 1 1 Contents of Remote Controller Switch Alarm Display 5 2 2 Outdoor Unit Control Panel LED Display
17. 3 minute stop Normal operation 2 Cooling cycle Control time Maximum 3 minutes Stops once before and once after control Outdoor units All outdoor units operate at maximum horsepower Electronic Thermostat Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity Expansion Valve eid RAP valve kit Valve kits at all indoor units operate in Cooling mode OFF status units Fan Fan operates at the set fan speed or stops depending on the operation mode of the indoor unit 3 Heating cycle Control time Maximum 3 minutes Stops once before and once after control Outdoor units All outdoor units operate at maximum horsepower Electronic Thermostat Valves at all indoor units operate at 480 pulse Expansion Valve Jor RAP valve kit Valve kits at all indoor units operate in Heating mode ON status Fan Fan operates at the set fan speed stops or operates at a very low speed 4 3 Defrost Control 4 3 1 Defrost Methods This system uses the following 2 defrosting systems System employs Defrost control method 1 outdoor unit in the refrigerant system Reverse cycle defrost 2 outdoor units in the refrigerant system Outdoor unit cycle defrost 4 3 2 Constraint conditions 1 Frost detection does not occur for 5 minutes after operation starts 2 Defrost does not begin again for 35 minutes of A C operation after
18. 5 4 3 Remote Controller Servicing Functions 5 5 4 W 2WAY ECO i Alarm Codes eeeeeeeeeee ee ee ee rn 5 7 5 Blinking Inspection Display on the Remote Controller 5 27 6 Inspection of Parts ANEREN SEET eem aeodemo sce douce sore ete a ee do Y Rue war AR 5 28 VB up REC RE 5 29 8 Thermister Characteristics Curve sssusa aaaea ee ee res 5 30 W 2WAY ECO i SYSTEM Contents Control Functions 1 CONTROL FUNCTIONS 1 lntroduction og Spee e ee EE E ER RE E RE EE SUE e terre RR 1 2 2 Selecting Outdoor Unit for Operation eeeeeeeeeeeeeeeeeeeeeeeeeeeeee 1 3 3 Compressor Control 2 ANN NNN NN NN cere ieee ee ened cee beet et ENNEN NN E Ed 1 4 4 Special Controls i i co visio a Erw ER KA EGRE EUR QE RR vane een RR OUR RD cad 1 9 5 Other Controls 2 p x bebe ence erie ed ee te dene deed RU ER ANE EE w 1 14 6 Operation of Solenoid Valves leeren 1 15 7 Outdoor Unit Electronic Thermostatic Expansion Valves MOV1 MOV2 amp MOV4 1 17 8 Outdoor Fan Control ek ANER EINEN E H aim mE mc CR S ck ee d RU RS S UR 1 19 9 Demand Control 2ssasu rh rur NN NENNEN EEN ECH SIN REX KO dese TS 1 20 10 Indoor Unit Control of the Electronic Control Valve 1 21 11 Rap Valve Kit Control 52252 on n ERR KEE EELER EISE AREE ER A 1 23 12 Indoor Unit Refrigerant Oil Self Recovery Control 1 24 13 Discharge Temperature 1 25 14 Current Protection iussa xg c
19. 5 7 Blinking Inspection Display on the Remote Controller 5 27 Inspection of Parts iis cs acue Rar ur kms yy xe euim a aE a Ee wee r c r ar is i 5 28 Test PIN 22s sag ex wa xx Re OE wor scq RE ERA RO wow eos a hi C RON RR D 5 29 Thermister Characteristic Curvve eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeee 5 30 W 2WAY ECO i SYSTEM 1 Contents of Remote Controller Switch Alarm Display Mouii Diegos ON O Blinking 7 OFF Wired remote control display Wireless remote controller receiver display Possible cause of malfunction errors address indoor unit address or indoor unit address Mis setting independent main sub unit setting has not been made Auto address is not completed Error in transmitting serial communication signal Indoor unit is detecting error signal from remote controller and system controller Indoor unit is detecting error Error in receiving serial communication signal signal from outdoor unit When turning on the power supply the number of connected indoor units does not correspond to the number set Except R C address is 0 E04 Group wiring failure of indoor units in the refrigerant system occurring when remote controller is operated immediately Serial Remote controller is detecting Error in receiving serial communication signal Signal from communication error signal from indoor unit main indoor unit in case of group control Outdoor system E0
20. CHECK flashes on the wired remote controller only to inform the user that operation is in backup mode However this is not displayed on any other control devices n order to cancel automatic backup mode it is necessary to reset the power on the control PCB of the outdoor unit where the outdoor unit No setting S007 on the control PCB is set to No 1 main unit It is also available by resetting power of all the outdoor units CAUTION If the power is not reset on the control PCB of the No 1 outdoor unit main unit backup mode operation will continue after the repairs are completed Backup operation is intended as emergency operation until repairs are made Have repairs made as soon as pos sible 4 2 Manual Backup This backup operation is the conventional method of backup operation It involves disconnecting the failed outdoor unit from the system and operating only the normal outdoor units 4 2 1 Backup operation by disconnecting the outdoor unit 1 Changing the outdoor unit control PCB settings If the failed outdoor unit is not the No 1 unit Settings at No 1 unit main unit Switch on outdoor unit control PCB Action System address S003 S002 No change No of indoor units 8005 S004 No change No of outdoor units S006 Subtract the number of failed units from the current setting Outdoor unit No S007 No change e Settings at normal outdoor units other than the No 1 unit
21. Compressor for detailed procedures 3 3 Checking the Oil Acceptance rejection criteria for the oil Condition of Condition of oil Judgment criteria for changing oil refrigeration cycle Color Odor Total acid value Hue Normal Yellowish None 0 02 or less 3 5 or less 0 06 or over 4 0 or over Abnormal overheat Brouch Smells somewhat Changing iheailand system cleaning operation not as strong as below with dry cores are necessary Brownish Pungent burnt odor Changing the oil and system cleaning blackish with dry cores are necessary It is difficult to measure the total acid value in the field therefore oil hue and odor are the rule of thumb Checking for carbon deposits and abrasive metal powder can additionally be used to assess the system condition Motor burnout W 2WAY ECO i SYSTEM 4 Backup Operation Outdoor Unit Repair Procedures This system includes an emergency automatic backup function that allows the A C to operate during the period after trouble occurs until repairs are made However during repair and at other times use manual backup opera tion 4 1 Automatic Backup For details refer to the control functions section After the alarm details are sent to the control device control for automatic backup operation begins when the ON OFF button of the wired remote controller is pressed again operation is started after the alarm is cleared During this operating mode
22. sensor Fig 29 W 2WAY ECO i SYSTEM 12 Repl acing 4 way Valve Outdoor Unit Repair Procedures When replacing 4 way valve of type 96 for type with 1 or 2 compressor be sure to protect check valves which are located adjacent to the 4 way valve while performing replacement work Type 72 for type with 1 compressor is not located near to the check valves therefore no protection is necessary 12 1 When the replacement is available from the right side of the unit 1 Remove the front panel of the outdoor unit then remove the right side panel of the unit 2 Follow the instructions in 9 Pumping Out Refrigerant from Outdoor Unit recover the refrigerant of the out door unit where the 4 way valve is located 3 Connect the manifold gauge to the high and low pressure outlet ports at the outdoor unit where the 4 way valve will be replaced Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replace ment 4 Prepare the brazing kit to disconnect the brazed parts 4 locations JN sm Protect the check valves as shown in the figure 30 Check valve 4 way valve Brazed parts 4 locations Fig 30 5 After replacing the 4 way valve follow the instructions in 6 Checking for Leakage After Repair and 7 Evacuating System The outdoor unit after replaced 4 way valve shall be checked for gas leakage and per form system evacuation 6 Fully open service valves on the o
23. the presence of electrical noise may result in a new alarm However it is believed that this occurs for a comparatively short time only In these cases a mode automatic backup mode that limits operation may be engaged Control is not possible when a communications system alarm has occurred Automatic backup mode is not engaged in order to avoid causing secondary damage W 2WAY ECO i SYSTEM 5 Blinking Inspection Display on the Remote Controller Trouble Diagnosis Blinking inspection display 2 compressor magnet SW seizing detection Alarm code Blinking inspection display Alarm meaning Compressor magnet SW seizing detected Status Although an outdoor unit exists where the outdoor unit fan is running no compressors in the system are operating yy Because the fan is running only at the outdoor unit where seizing was detected check the corresponding outdoor unit The fan may also run on its own when fan cracking prevention control is in effect or when snowfall sensor input is present Therefore monitor for approximately 10 minutes if the outdoor unit fans are operating at multiple units Alarm conditions Current is detected in the CT circuit when the compressor is stopped 1 This control is not engaged for the first 30 seconds after the compressor turns ON gt OFF 2 For 1 minute following the first 30 seconds after the compressor turned ON gt OFF the threshold for the detected current is 10 A or more continuing for 2 sec
24. through F above 6 4 Bypass Valve BPV This valve flushes the oil from the balance tubes In addition it is used for recovering refrigerant from stopped out door units during cooling operation 1 When unit is stopped This valve is always OFF 2 When unit is operating This valve is ON at the oil supply outdoor unit when unit refrigerant oil recovery control is in progress This valve repeatedly turns ON OFF at regular intervals during unit refrigerant oil recovery control It is not constantly ON 7 Outdoor Unit Electronic Thermostatic Expansion Valves 7747 ECO i SYSTEM MOV1 MOV2 amp MOV4 Control Functions 7 1 Types of Electronic Thermostatic Expansion Valves CHDX07263 CHDX09663 Capacity 72 96 Electronic Heat exchanger Heat exchanger control valve 1 1 valve 1 valve Electronic Electronic Heat exchanger Heat exchanger control valve control valve 2 2 valve 2 valve Electronic e M control valve 4 For SC circuit For SC circuit 7 2 Power Initialization If no indoor units have started even once after the power was turned ON the outdoor unit electronic control valve operates at 480 pulses 7 3 Heat Exchangers which are controlled by each Electronic Thermostatic Expansion Valve The configuration of heat exchangers is as shown in the figure below MOV3 is excluded Heat exchanger 1 Heat exchanger 2 Operation of Electronic Thermostatic Expansion Valve during normal uni
25. INV compressor center H11 H12 H13 Compressor 2 constant speed compressor 1 left side when viewed from front H21 H22 H23 Compressor 3 constant speed compressor 2 right side when viewed from front not present in type 90 A judgment is made based on factors that include the following coil resistance varies depending on the compressor insulation resistance current leakage breaker operation oil and refrigerant fouling odor pressure and noise Reference Insulation resistance Use a DC 500 V insulation resistance meter and measure the insulation resis tance between the electrified and non electrified parts a Motor Min 300 MQ b Compressor Min 100 MQ servicing part c Unit Min 10 MQ This is due to the presence of refrigerant which decreases the insulation resistance Minimum insulation resistance as required by generally accepted requirements is 1 MQ JUDGMENT START Y Is there burning of the failed Follow the instructions in compressor motor NO 8 Discharging Compressor Oil YES and drain the oil from the failed compressor Then inspect Follow the instructions in Is the color phase 4 0 or above or isa 3 Discharging Compressor Oil and YES sharp odor present drain the oil from all compressors in the same system Then inspect NO Are there 2 or more outdoor units where the co
26. It is therefore unnecessary to install and wire multiple snowfall sensors 1 Snow fall sensor settings Setting Operation 0 Sensor input not present Control is performed Setting at time of factory shipment 1 Sensor input present Control is performed 2 Sensor input not present Control is not performed 3 Sensor input present Control is not performed If the snowfall sensor is used then depending on the circumstances it is necessary to make the correct setting at all outdoor units in the system If control is not performed is set control by the above signal is ignored This setting is used in order to conserve energy at outdoor units that include a snowfall protection hood Recommended If a low speed fan mode is required for all year cooling or other reasons install a snowfall pro tection hood and set this setting to ON 2 Control operation 1 Outdoor units where sensor input present is set send the snowfall sensor input information every 10 min utes to all linked systems if the system wiring is linked At systems where control is performed is set the above information is used to control operation of the out door fan 2 8 At systems where control is not performed is set the snowfall sensor input and above information ignored and the outdoor fan does not operate 4 In case of W 2WAY ECO i system control can be performed when snowfall sensor inpu
27. LCD display Fig 1 At this time the indoor unit fan or all indoor unit fans in the case of group control begins operating 9 If group control is in effect press the button and select the address unit No of the indoor unit to set At this time the fan at the indoor unit begins operating If unit No Ai is displayed the same setting will be made for all indoor units Press the temperature setting Ca Wes 2 buttons to select the item code to change Press the timer time 4 v buttons to select the desired setting data For item codes and setting data refer to the following page 6 Press the button The display stops blinking and remains lit and setting is completed Press the button to return to normal remote controller display W 2WAY ECO i SYSTEM Remote Controller Functions Remote Controller Functions Section DU XX md SET DATA LN CODE No RC No RCS TM80BG Fig 1 W 2WAY ECO i SYSTEM 1 Simple Settings Function Remote Controller Functions List of Simple Setting Items Setting data Item code No Description 0000 Not displayed Filter sign ON time fitter life time 0004 0005 0000 Standard setting at time of shipping 0001 Highly fouled mE Filter sign ON time is reduced to one half the set time 0001 Central control address 1 0002 Central control address 2 0003 Centr
28. Mode All the inverter compressors are firstly selected simultaneously ODU 1 ODU 2 Comp 1 1st 1st Comp 2 3rd 4th Vid Compressor Selection Sequence in Heating Mode First the inverter compressor with the shortest amount of operating time is selected And then the remained other compressors are selected and start in the order of shortest amount of operating time ODU 1 ODU 2 Comp 1 3rd 1st Comp 2 4th 2nd W 2WAY ECO i SYSTEM 3 Compressor Control Control Functions 3 3 Compressor Capacity Control The compressor operating conditions vary depending on the indoor unit operating conditions and the effects of indoor heat load outdoor temperature and other factors Unit No 1 CCU calculates the required capacity accord ing to these operating conditions and allocates the capacity requirement among the outdoor units according to the compressor start stop rules Fine adjustments to system capacity control are made by the inverter compressors Depending on the conditions all inverter compressors may be operating for fine adjustment 3 4 Inverter Compressor Capacity Control 1 The inverter compressor has a center limit value and upper limit value for the operating frequency These limits are set for each outdoor unit capacity 2 The inverter frequency during operation may be lower than the frequency listed above due to overload current protection control f Quiet mode is selected t
29. Service hvac sci sanyo com Service hvac service 0 sna sanyo com 201002
30. detection trouble when it is judged that no current is flowing after start DCCT is damaged In this case the cause is a DCCT failure Example J gt O Notes d gt o O P22 Alarm Fan motor trouble Fan motor start failure fan motor Hall IC input failure Possible causes are a Hall IC input circuit failure and a fan HIC failure Check Check the fan motor wiring the Hall IC wiring and the connector connections If the wiring and connectors are normal then check that the capacitor of the Hall IC input circuit is securely soldered on the outdoor unit control PCB Also use a tester and measure the resistance between fan HIC power HIC and ground HIC If there is a short circuit there is an HIC malfunction P gt DON T TOUCH e INN ee en m LAMNAMMANNM T Fan circuit on the outdoor unit control PCB Correction If the fan does not start the below corrections may be effective 1 If there is a fan HIC failure or circuit failure replace the PCB 2 If the fan motor is locked replace the fan motor UC ERU EEN Notes Turn OFF the power and check the continuity of and on the fan circuit PCB W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis P26 Alarm Mamexe Je Alarm meaning Inverter compressor high frequency overcurrent alarm Alarm conditions This alarm occurs when current trouble or current detection trouble occurs at an inverter frequency of 80 Hz or higher after start
31. has not returned as a result of refrigerant circuit clogging or valve leakage at the stopped outdoor unit 5 A valve ORVR BALV BPB in the oil circuit has malfunctioned or there is clogging of the circuit capillaries which returns oil from the oil separator to the compressor 6 If an excessive amount or liquid returns to the compressor oil foaming may increase oil discharge The same occurs when the refrigerant proportion in the compressor is high at start due to an open circuit in the crank case heater Check the tubing length and height differences Check the operation of system circuit valves Check that there is not an excessive amount of liquid return Check that there is no mechanical valve leakage W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis H08 H27 Alarm Trouble open circuit with the oil sensor connection at compressor 1 compressor 2 Alarm conditions This alarm occurs when a connector connection pins 1 and 2 for compressor 1 pins 4 and 5 for compressor 2 is open Probable cause isconnected connector Check Check that the connector is securely connected Correction 1 Connect the connector 2 Correct the connection at connector pins 4 and 5 Example J o f Notes Le H31 Alarm alarm code Je O O O HIC trouble alarm Alarm conditions This alarm occurs when the microcomputer identifies a trouble signal indicating abnormal HIC temperature or other trouble from the HIC
32. in the figure The compressor rear leg is not anchored 6 Prepare to disconnect the 3 brazed locations shown in the figure P p s ORE AY MS SAYS fea e us TE SA SE E Epis i Soul d Constant speed compressor left side Brazed locations 3 UY Remove discharge sensor Protect the oil L Al LX ufa Bolt equalizer tube Washer 1 d i connectors Rubber washer 1 l at k 1 each at the 3 locations bss bt LEN gt Crankcase heater Fig 25 Protect the sensors and surrounding plates rubber lead wires clamps and other items Pay particular attention to protection of the oil equalizer tube connector parts and removal of the discharge sensor An O ring is mounted inside the oil equalizer tube connector parts It must be protected and do not lose it 7 Disconnect the 3 brazed locations shown in the figure 25 First disconnect the 1 4 66 35 mm tube then disconnect the 21 2 012 7 mm and 97 8 622 22 mm tubes 8 Pull the compressor toward you W 2WAY ECO i SYSTEM 10 Com pressor Outdoor Unit Repair Procedures E Installation 1 Remove the 2 brazed tube caps 2 pieces from the compressor 2 Remove hexagonal caps from the compressor When removing the hexagonal caps hold the fixing nut at the main unit side so as not to loose it with a wrench or spanner And then loosen and remove the hexagonal cap Hex
33. model Q ty Pre charged amount of oil liters CHDX07263 C 9RVN273H0S 1 1 9 Inverter controlled rotary compressor CHDX09663 C 9RVN273H0S 1 1 9 Inverter controlled rotary compressor JT160G KTTJ 1 2 1 Constant speed scroll compressor When replacing a faulty compressor be sure to first measure the amount of remaining oil in the compressor Charge additional new oil equal to the difference in the remaining oil and the rated amount as listed above For example Type of replaced compressor JT160G KTTJ Remaining oil in the removed compressor 0 58 gal Additional oil to be charged 0 58 gal remaining oil in the removed compressor 0 55 gal rated oil amount 0 026 gal fthe result is a negative amount remaining oil in the removed compressor is less than the rated amount it is not necessary to discharge the extra oil from the system For the method used for additional oil charging after compressor replacement refer to 8 1 If Refrigerant Has Already Been Charged to Outdoor Unit W 2WAY ECO i SYSTEM 9 Pumping Out Refrigerant from Outdoor Unit Outdoor Unit Repair Procedures Required equipment and tools Jumper wire with clips adjustable wrench set of manifold gauge valves for the refrigerant R410A refrigerant recovery unit pre purged refrigerant cylinder for recovery flat head screwdriver and outdoor unit maintenance remote controller This work is performed in order to collect the
34. not occur or the compressor will not run with a groaning sound 2 CT circuit failure PCB failure Trouble Check e Check for poor connector contact Check the continuity of the CT circuit Install a normal CT in place of this CT and check If current is detected then the PCB can be jedged OK gt CT circuit failure Check that current is flowing in the phase where the CT circuit is connected Check voltage and current 3 Missing power phase Trouble This alarm primarily occurs when the T phase is missing When the R phase or S phase is missing CT trouble or PCB continuity trouble occur However this may not be true in the case of a missing phase caused by magnet SW trouble Check There is the possiblility of a magnet SW failure Therefore check the phase voltage at a location that is as close to the compressor as possible 4 Low power voltage Trouble In most cases this occurs when another constant speed compressor including compressors in other units or other dvice starts It also occurs when the power wiring is extremely long Check Check the voltage between each of the phases However if this troube occors when other devices or compressors start then an oscilloscope is required 5 PCB failure Trouble Check Check that the current value measured with the clamp meter is not lower than the value measured with the PC or remote controller 6 If the cause is still unknown after checking the above then it is possible that noi
35. operate in heating mode ON status Fan operates at the set fan speed stops or operates at a very low speed Fan depending on the indoor unit operation mode When the above operation is finished normal operation starts at the horsepower determined by the indoor units where thermostats are ON 4 2 System Refrigerant Oil Recovery Control 4 2 1 System refrigerant oil recovery cycle This control is performed using the cooling cycle during cooling operation and using the heating cycle during heat ing operation 4 2 2 Start of System Refrigerant Oil Recovery Control When the oil level in an operating compressor is detected as 0 zero the compressor stops in 120 seconds If this compressor repeats this operation 3 times and the oil level does not reach 2 system refrigerant oil recovery con trol is started When the compressor has stopped because the oil level is 0 a count is added to the alarm counter The counter for this compressor is not cleared unless the oil level for that compressor reaches 2 or else alarm output occurs W 2WAY ECO i SYSTEM 4 Special Controls Control Functions 4 2 3 Refrigerant Oil Recovery Control between Systems 1 Simplified flow of system refrigerant oil recovery control Refrigerant oil recovery control between systems shall be performed as the flow mentioned below Normal operation 3 minute stop Refrigerant oil recovery control between systems Max 3 minutes
36. pressor Outdoor Unit Repair Procedures 14 Perform steps 1 4 and remove all dry cores Then connect the tubing between the liquid narrow tube valves and the ball valves 15 At all outdoor units where dry cores were removed pressurize with 478 6 psi of nitrogen from the liquid tube service port and check for leaks 16 After evacuating all nitrogen gas from the tubing apply vacuum to all outdoor units where dry cores were removed until the pressure is 14 7 psig 5 Torr or less 17 INSTALLATION Refer to the Information for the Person in Charge of Installation items Charge with an amount of refrigerant equal to the amount that was recovered B If a ball valve is not installed on the outdoor unit 1 Refer to 5 2 3 Refrigerant recovery procedures 2 Indoor unit with no ball valve equipped Perform pump down of the refrigerant from all indoor units and inter unit tubing to the outdoor unit side 2 Cut the liquid narrow tube at all outdoor units where dry cores will be attached then attach the dry cores and ball valves as shown in Fig 21 3 For the next steps refer to 6 17 in A on the previous page Cleaning dry core Liquid tube service valve Outdoor unit Normal unit A Lk ll kb SSS EE ff SCH GEES s t 5 7a HE EE
37. provided for general judgment of the refrigerant amount Symptoms of insufficient gas Cooling There is an indoor unit where the position of the electronic control valve is much higher open by operation 300 pulses or more than it was at start and the difference E3 E1 at that indoor unit is large 30 F or more Heating There is an outdoor unit where the position of the electronic control valve is much higher open by operation 300 pulses or more than it was at start and the difference Liquid temp Gas temp at that outdoor unit is large 30 F or more Symptoms of overcharge Cooling The high pressure sensor temperature is 134 F or higher and the difference Pressure sensor operation temp Liquid temp at that outdoor unit is large 30 F or more Heating There is an indoor unit where the position of the electronic control valve is much higher open by operation 300 pulses or more than it was at start and the difference Pressure sensor temp E3 at that indoor unit is large 50 F or more These are only guidelines therefore the judgment may vary depending on the installation conditions load char acteristics and other elements W 2WAY ECO i SYSTEM Contents Outdoor Unit Repair Procedures 2 OUTDOOR UNIT REPAIR PROCEDURES 1 REMOVING Panels vsu pede Rom OCC RR OR QC och OR OR CR OC Cn e OR Dn n d 2 2 2 Removing Electrical Component Box and Duct
38. system it is important that you carry out this step 6 Carry out refrigerant recovery To determine the completion of refrigerant recovery follow the instructions that CAUTION came with the refrigerant recovery unit Manifold auge i 9 Hi Sg High pressure outlet port For 5 16 7 94mm dia connector Refrigerant recovery unit Refrigerant recovery cylinder 7 a Low pressure outlet port For 5 16 7 94mm dia connector W 2WAY ECO i SYSTEM 5 Recovering Refrigerant Outdoor Unit Repair Procedures 5 2 Refrigerant Recovery Procedures Indoor Unit The flowchart below shows the refrigerant recovery procedures you must follow when replacing or repairing the indoor unit due to trouble in the refrigerant circuit START Y 5 2 1 Cooling operation for all units 1 Eoi valves provided lathe indoor unit g 5 2 3 Refrigerant recovery m Turn off all equipment in system YES NO procedures 2 i 5 2 2 Refrigerant recovery Replace or repair faulty unit procedures 1 i Y heck for leak i d unit Turn off all equipment in system Check rorleakage inrepairediuni Y Y When replacing or repairing a faulty Evacuate air from repaired unit unit let other normal indoor units run Fig 8 Y excluding indoor unit where refrige
39. than 4 F when the compressor has operated for 10 minutes immediately after start When outdoor air temperature is below 50 F Alarm occurs if the temperature detected by the discharge sensor has changed by less than 4 F when the compressor has operated for 30 minutes immediately after start Probable cause 1 Discharge sensor temperature detector is not inserted into the tube s sensor holder 2 Discharge sensor itself has suffered some kind of malfunction other than a cut wire Check 1 Check that the discharge temperature sensor is inserted into the sensor holder 2 Check that sufficient heat conducting putty is applied 3 Remove the discharge sensor from the sensor holder and expose the sensor to the outside air for approximately 5 minutes Check that the temperature detected by the sensor changes to match the outside air temperature However the sensor cannot detect temperatures at or below 32 F 1 Install the sensor into the holder and apply sufficient heat conducting putty 2 If the sensor is malfunctioning replace it Correction Example W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis HO6 Alarm Mamexe ME Low pressure switch activated Alarm conditions A report occurs during A C operation when the low pressure sensor installed at constant low pressure parts detects a pressure of 7 3 psi or less continuously for 2 minutes or an instantaneous pressure of 2 9 psi or less Thes
40. the resistance between sensor No 1 and No 3 Resistance of less than 10kQ indicates a short circuit or other trouble Resistance of 10kO 200kO is normal Resistance of more than 200kQ indicates an open circuit or other trouble Connect a gauge to the high pressure outlet and check for changes in the value dispalyed by the monitoring software and for large deviation of the gauge pressure During heating check whether the temperature is lower than the highest indoor unit E1 temperature The pressure detected by the high pressure sensor is the highest pressure in the system Therefore during heating the converted saturation temperature will never be lower than any indoor unit E1 temperature During cooling this temperature will never be lower than the outdoor unit liquid temperature 2 Failure to open the service valve clogged tubing valve leakage over charging In all of these cases an alarm occurs when there are rapid pressure fluctuations and tracking of the detected pressure is poor Check the open closed status of the valve Check for clogging of the tubing To check for clogging disconnect the high pressure sensor from the PCB and check whether the high pressure SW activates Check for valve leakage and over charging When valve leakage or over charging occurs refrigerant is likely to accumulate in the outdoor units or indoor units resulting in a sudden rise in pressure at start that occurs before the refrigera
41. to be repaired and connect the manifold gauge to the refrigerant recovery device Be sure that no air enters the tubing at this time 11 Open both Hi and Lo side valves on the manifold gauge valves and recover the refrigerant remaining in the outdoor unit After that measure the amount of recovered refrigerant NOTE To determine the completion of refrigerant recovery follow the instructions that came with the refrigerant recovery unit Faulty outdoor unit Other outdoor unit High pressure outlet port Low pressure outlet port Liquid tube service port For 5 16 7 94mm dia For 5 16 7 94mm dia For 5 16 7 94mm dia connector connector connector Manifold auge Lo Hi Refrigerant recovery cylinder Measuring scale Connect from here to refrigerant recovery unit Fig 20 W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures 10 1 Compressor Trouble Diagnosis and Check Methods Generally compressor failures can be classified into the following categories 1 Mechanical trouble A Locking intrusion of foreign objects galling etc B Pressure rise failure damaged valve seal bearing or other component C Noise damaged stator rotor valve or other component A Coil burning B Open circuit C Insulation failure D Short circuit 2 Electrical trouble gt Trouble diagnosis is based on the following remote controller displays HO3 Compressor 1
42. 009 IMC 2009 or more recently revised ASHRAE 15 ASHRAE 34 Section 1 Section 2 Section 3 Section 4 CONTENTS CONTROL FUNCTIONS 52 22 x RR Rn rmm mE RR LEES Esas 1 1 A IntroducHorn sceacha eygur Beet oe xk ee Rie WEG eee edged peed eee heehee yee RC REN 1 2 2 Selecting Outdoor Unit for Operation 1 3 3 Compressor Control 1 4 4 Special ControlS ic ssa beu sx AER LEE WEE ENEE EE sts Re ES dus 1 9 b Other Gontrols iex eoa doops EE ot awl peli S me acsi a RR Resid weeds s 1 14 6 Operation of Solenoid Valves 1 15 7 Outdoor Unit Electronic Thermostatic Expansion Valves MOV1 MOV2 amp MOV4 1 17 8 Outdoor Fan Control 1 19 9 Demand Control ageet EE ERR EE ACEL UPPER ND E 1 20 10 Indoor Unit Control of the Electronic Control Valve 0 000 ccc ee 1 21 11 Rap Valve Kit Control r Jee fs ERG WR re 9 ER MERC Ee ANE SE ANEN e H 1 23 12 Indoor Unit Refrigerant Oil Self Recovery Control 1 24 13 Discharge Temperature 1 25 14 Current Protection voe 00224008 Re pp Ee HO DR sagen die Baai a Ege agen we 1 26 15 Pressure Sensor Failure 1 27 16 Backup Operation veses repera wae Exe NU Ar eee bea bee eee ea m ke XR a e 1 28 17 Service Maintenance Functions 1 30 18 Other Functions ENN ENTREE x R es bed eset A arr RATE i a E ed 1 32 OUTDOOR UNIT REPAIR PROCEDURES s 2 1 1 Removing Panels Sie CA CH EEN er ENT eee Or a d Eos RR RR NUR A Rcx ie E 2 2
43. 1 after automatic address setting Outdoor unit is detecting error Error in receiving serial communication signal signal from indoor unit There is an indoor unit which does not send signals when the power is ON Indoor unit address setting is duplicated Duplicated remote controller main setting lt lt E09 gt gt Improper setting Automatic address setting start is prohibited AP pin was short circuited at time when automatic address E12 setting was started Error of main indoor unit in receiving serial communication error of group control wiring signal from sub indoor units During auto address setting number of connected units does not correspond to number No indoor unit is connected during auto address setting E20 iid Mismatch in No of outdoor units setting Error of sub outdoor unit in receiving serial communication E29 signal from main outdoor unit Improper setting Connected indoor unit is not a multi unit Duplication of main indoor unit address setting in group control Duplicated indoor unit priority priority indoor unit outdoor unit Operation for heating Operating lamp blinking Xtie e Heating ready lamp blinking ere Operating lamp blinking x1 o o Heating ready lamp blinking e o 1 1 Operating and heating ready lamps blinking simultaneously X X Capacity code of indoor unit is not set L09 Mismatch of outdoor unit type L17 Duplica
44. 2 Discharge temperature 1 Outside air temperature Discharge temperature 2 CT2 High pressure sensor temperature Low pressure sensor temperature Outdoor unit Heat exchanger gas 1 Detected reservoir tank temp Heat exchanger liquid 1 Detected oil temp 1 Heat exchanger gas 2 Detected oil temp 2 Heat exchanger liquid 2 W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis With type 96 the INV compressor is compressor 1 and the constant speed compressor is compressor 2 With type 72 the INV compressor is compressor 1 E06 Outdoor unit failed to receive serial communication signals from indoor unit 5 9 Automatic address setting start is prohibited 5 9 Automatic address setting alarm too few units Automatic address setting alarm too many units 5 10 Outdoor unit INV failed to receive communications from another outdoor 5 10 unit constant speed Outdoor unit address setting failure duplication Mismatch in outdoor unit quantity Outdoor unit failed to receive communication from outdoor unit main F24 Liquid temperature sensor trouble at outdoor heat exchanger 2 Out 5 13 F31 Outdoor unit non volatile memory EEPROM trouble 5 16 Compressor 1 oil detection sensor connection trouble Compressor 2 oil detection sensor connection trouble Outdoor system address duplication Outdoor unit capacity not set E24
45. 2 A D step is 1014 steps or more open circuit 1 Sensor malfunction including connector 2 PCB malfunction 1 Measure the sensor resistance Check that the sensor is operating normally 2 Use a remote controller monitor or PC monitor to check the temperature that is recognized by the microcomputer Example E F07 F24 Alarm at outdoor heat exchanger 2 1 A D step is 10 steps or less short circuit 2 A D step is 1014 steps or more open circuit Probable cause 1 Sensor malfunction including connector 2 PCB malfunction Check 1 Measure the sensor resistance Check that the sensor is operating normally 2 Use a remote controller monitor or PC monitor to check the temperature that is recognized by the microcomputer Correction J s O Example J gt O Notes LI W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis F08 Alarm Sul mm 1 A D step is 10 steps or less short circuit 2 A D step is 1014 steps or more open circuit Probable cause 1 Sensor malfunction including connector Pecas g om matneton oso Check 1 Measure the sensor resistance Check that the sensor is operating normally 2 Use a remote controller monitor or PC monitor to check the temperature that is recognized by the microcomputer Correction E AE Example PB O Notes e O F12 Alarm Alarm code F12 1 A D step is 10 steps or less short circuit 2 A D step is 1014 steps o
46. Adjustment Control will be performed This control is intended to changeover the 4 way valve of outdoor unit When the unit has been stopped for long period and if refrigerant has accumulated somewhere in the tubing recovery of the refrigerant is performed This control can also compensate for tubing thermal loss by radiation during heating start as well as for oil recovery 1 Cooling control when the outdoor unit heat exchanger is acting as a condenser Control time 60 seconds Outdoor units All outdoor units operate at the maximum horsepower Electronic Thermostat Expansion Valve Valves at all indoor units operate at a fixed pulse according to the indoor unit capacity Indoor units RAP valve kit Valve kits at all indoor units operate in Cooling mode OFF status Fan operates at the set fan speed or stops depending on the indoor unit operation F n mode When the above operation is finished normal operation starts at the horsepower determined by the indoor units where thermostats are ON 2 Heating control when outdoor unit heat exchanger is acting as an evaporator Control time Minimum 1 min Maximum 10 min until max pressure sensor temp E1 gt 95 F Outdoor units All outdoor units operate at the maximum horsepower Electronic Thermostat Expansion Valve Valves at all indoor units operate at 250 pulses as a default Indoor dits RAP valve kit Valve kits at all indoor units
47. Cooling control according to indoor unit capacity Reverse cycle NR o Lais Fixed pulse for heating according to indoor unit defrost control 9 capacity ZS Thermostat Heating control according to indoor unit capacity OFF However position is 20 pulses for Type D Stopped 60 pulses Fan 60 pulses Outdoor cycle Cooling E Thermostat e pulses defrost control heating ON S Thermostat i OFF 60 pulses System refrigerant Cooling All indoor units So for cooling according toindoor unit oil recovery control Heating All indoor units 250 W 2WAY ECO i SYSTEM 11 Rap Valve Kit Control Control Functions A gas tube valve kit may be connected to the Type D indoor unit When the gas tube valve kit is connected operations of gas tube valve kit and indoor unit electronic thermostatic expansion valve are as shown in the table Gas tub I Electronic thermostatic as EE vave expansion valve Stopped OFF 20 pulses Fan OFF 20 pulses Thermostat ON 20 pulses ON P o 8 us ON Superheat control 65 480 Thermostat g ON OFF 20 pulses bel ee OFF Superheat control 50 480 W 2WAY ECO i SYSTEM 12 Indoor Unit Refrigerant Oil Self Recovery Control COO erg This control is carried out regularly in cooling mode only 1 During stopped fan or thermostat OFF condition indoor unit expansion valve is opened regularly for 1 to 2 min utes regularly at an interval of once every 2 hours
48. Cooling operation for all units fully close the liquid tube ball valve 3 Run the unit in Cooling mode for 10 to 20 minutes more 4 Fully close the gas tube ball valve and stop the operation of all units 5 Use hoses to connect the manifold gauge valves refrigerant recovery unit and refrigerant recovery cylinder with each other Fig 10 Do each connection quickly to prevent air from entering the tubing AN eme Remaining refrigerant may create internal pressure therefore care should be taken when connecting the hoses 6 Recover the remaining refrigerant from the indoor unit using the refrigerant recovery unit To determine completion of refrigerant recovery follow the instructions that came with the refrigerant recovery unit Manifold gauge Lo Hi Refrigerant recovery unit Refrigerant recovery cylinder Ball valve separately purchased Gas tube Bb O tdoor Service port unit side Liquid tube W 2WAY ECO i SYSTEM 5 Recovering Refrigerant Outdoor Unit Repair Procedures 5 2 3 Refrigerant recovery procedures 2 Indoor unit with no ball valve equipped Refrigerant in all indoor units and the refrigerant tubing circuit must be pumped into the outdoor unit The maximum refrigerant storage capacity per a single outdoor unit is approx 529 oz Thus in order to collect all refrigerant from the system a separate refrigerant recovery unit is necessary Follow these procedures to
49. Display Controls and Functions B Concerning the 7 segment 4 digit display remote controller timer display The unit Nos of connected units are indicated by four 7 segment digits HH HE and a colon e Display of unit Nos 1 20 OFF OFF OFF OFF 1 6 11 16 Meaning of display colon IR IR 4 pd S x ae ae vafa a0 LU LI LE D Bech E EE SE EE 21 40 41 60 61 80 ON ON ON ON is not displayed Display of unit Nos 21 40 LI ag or MP OFF se OFF Meaning of display colon b IRA be pf Le Le EGLI Kame 25 En 30 E ANE IA 40 ON ON ON ON The meaning of the colon changes in the same way to indicate unit Nos up to 80 Sample displays of the connected indoor unit Nos Display of unit No 1 Display of unit Nos 1 and 2 Display of unit Nos 1 2 and 3 Ie J b J ap TC Display of unit Nos 1 2 3 and 4 The change of the colon display between unit Nos 1 20 to unit Nos 21 40 occurs automatically every 10 seconds However the display does not change if there are no higher number units connected To change the display to the higher number units before 10 seconds have passed press the FLAP button W The total compressor operating time is displayed A in 1 hour units using 8 digits When the first 4 digits are displayed the top dot of the colon is illuminated Figure A When the last 4 digits are displayed the
50. No particular changes Settings at the failed outdoor unit No particular changes However close all service valves gas tubes liquid tube and balance tube at the failed outdoor unit and dis connect the wiring between the outdoor units W 2WAY ECO i SYSTEM 4 Backup Operation Outdoor Unit Repair Procedures If the failed unit is the No 1 outdoor unit main unit If the No 1 unit main unit has failed a different outdoor unit must be set as the No 1 unit main unit Settings at the failed No 1 outdoor unit No particular changes However close all service valves gas tube liquid tube balance tube at the failed outdoor unit and dis connect the wiring between the outdoor units e Settings at No 1 unit main unit Switch on outdoor unit control PCB Action System address S003 S002 Make the same settings as on the failed No 1 unit No of indoor units 8005 S004 Make the same settings as on the failed No 1 unit No of outdoor units S006 Subtract the number of failed units from the current setting Setting outdoor unit No S007 Change to 1 To this outdoor unit connect the inter unit communication line which was previously connected to the No 1 unit main unit After recovery work is completed wire the communication lines between CAUTION indoor and outdoor units again If it not finished yet an alarm is emitted immediately Settings at other outdo
51. SERVICE MANUAL NYO 2 WAY ECO i MULTI SYSTEM 410 CONSE EL a em ae em ae CHDX07263 T CHDXR07263 CHDX09663 CHDXR09663 SANYO SANYO SANYO p P p Outdoor Units Class 72 96 FE CHDX07263 CHDX09663 BEN da eee E ECO i W 2WAY GHDxR07263 CHDXR09663 Refrigerant R410A is used in the outdoor units Salt Air Damage Resistant Specifications Indoor Units Class 7 9 12 15 18 19 24 36 48 54 x 4 Way Air Discharge XHX1252 XHX1852 XHX2452 XHX3652 Semi Concealed xui T Way Air Discharge XMHX1252 XMHX1852 Mini Semi Concealed A 1 Way Air Discharge ixozc5 AHXO952 AHX1252 Semi Concealed U Concealed Duct Type UHX0762 UHX0962 UHX1262 UHX1562 UHX1862 UHX2462 UHX3662 UHX4862 UHX5462 UM Slim Concealed UMHX0762 UMHX0962 UMHX1262 UMHX1562 UMHX1862 Duct Type p Concealed Duct High DHX3652 DHX4852 Static Pressure T Ceiling Mounted THX1252 THX1852 THX2452 K Wall Mounted Type KHX0752 KHX0952 KHX1252 KHX1862 KHX1962 KHX2452 F Floor Standing Type FHX0762 FHX0962 FHX1262 FHX1562 FHX1862 FHX2462 FM Concealed Floor FMHX0762 FMHX0962 FMHX1262 FMHX1562 FMHX1862 FMHX2462 Standing Type Necessary to install the External Electronic Expansion Valve Kit Optional ATK SVRK56BA 85464849280000 REFERENCE NO SM830180 00 IMPORTANT Please Read Before Starting This air cond
52. T on the outdoor unit control PCB Because of the pulse output a simplified measurement method is used Set the tester to the 12 V range if the value displayed is approximately 4 V then the voltage is normal When the voltage is normal measure the resistance between each pair of pins on the electronic control valve connector The connector is normal if all results pin 5 pin 1 pin 5 pin 3 pin 6 pin 2 pin 6 pin 4 are approximately 460 If the results are OQ or co replace the coil e MOV2 Measure the voltage between plug pin 5 and pins 1 through 4 at the CNO16 connector 6P RED on the outdoor unit control PCB Because of the pulse output a simplified measurement method is used Set the tester to the 12 V range if the value displayed is approximately 4 V then the voltage is normal When the voltage is normal measure the resistance between each pair of pins on the electronic control valve connector The connector is normal if all results pin 5 pin 1 pin 5 pin 3 pin 6 pin 2 pin 6 pin 4 are approximately 460 If the results are OQ or co replace the coil e MOV4 Measure the voltage between plug pin 5 and pins 1 through 4 at the CN230 connector 6P BLU on the outdoor unit control PCB Because of the pulse output a simplified measurement method is used Set the tester to the 12 V range if the value displayed is approximately 4 V then the voltage is normal When the voltage is normal measur
53. W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions Simple setting items Filter sign ON time setting Changes the indoor unit filter lifetime when a high performance filter or other filter lifetime optional product is installed e EE E Reduces the filter sign ON time to 1 2 of the standard time setting at the time of 9 9 shipping for cases when filter fouling is more severe than normal Filter sign ON times for each model Filter Pierson One SOS FiltersignONtime ii time Pressure differential switch ET ted Air EE HD K Slim Concealed Duct U UM U UM Concealed Duct 0007 Ceiling Mounted T Mounted 2 x E ov 9008 Wo ERI MEAT Coo KEES EE Unit hour NOTE e X indicates that there is no corresponding filter e indicates the filter sign ON time that is set at shipment e High fouling Set when HEK I is selected for the degree of filter fouling item code He W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions ze nm J eet Set when using a central control device Central control address Used when setting the central control address manually from the remote controller 0 Operating mode priority change Note 1 1 Explanation of operation mode priority change Enabled only in 2WAY MULTI heat pump models Function With indoor units that are installed in combination with an outdoor unit model where either heating or coolin
54. WAY ECO i Alarm Codes Trouble Diagnosis 3 Leakage from the discharge tube check valve Trouble Although the other compressor is operating and this compressor is stopped the discharge temperature of this compressor rises together with the temperature of the other compressor 4 The ambient temperature around the outdoor unit when it is stopped is 109 F or higher 5 If the cause is still unknown after checking the above then it is possible that electrical noise is the cause of the trouble It is necessary to provide a line filter or carry out other noise countermeasures Correction 1 Replace the sensor 2 Replace the outdoor unit PCB 3 Carry out noise countermeasures 4 Repair the refrigerant tubing 5 Adjust the amount of refrigerant 6 Correct the trouble Example 1 Sensor wiring is partially cut This alarm does not indicate that the sensor is disconnected In order to prevent overheating during operation the outdoor units in this system will not allow a compressor to start if the discharge temperature does not decrease while the compressor is stopped If a sensor malfunction results in continuous detection of a high discharge temperature then the compressor may stop for no apparent reason The purpose of this alarm is to facilitate identification of the problem in this case F06 F23 Alarm m ege FREE outdoor heat exchanger 2 Alarm conditions 1 A D step is 10 steps or less short circuit piene d
55. acity increase decrease values that were calculated from control based on the temperature at the indoor unit heat exchanger coil roadmap control In some cases the control shown below may stop the compressor issue a warning or reduce the compressor capacity 1 Discharge Temperature Protection During operation when only a single outdoor unit is installed the air discharge temperature level is determined the highest value is used and the compressor capacity is limited by using the air discharge temperature of the operating compressor as shown in the tables below Air discharge temperature level Highest level among the air discharge temperature levels of all compressors Air discharge temp level Discharge temp F Horsepower limit 5 221 Decrease by 2 horsepower 4 219 Decrease by 1 horsepower 3 217 Decrease by 0 5 horsepower 2 212 Less than 217 Prohibit horsepower increase 1 208 Less than 212 Permit horsepower increase slowly 0 Less than 208 No control The values shown in the table above are reduced to the values calculated by roadmap control 3 Compressor Control 2 Current Protection Inverter compressor current control is composed of W 2WAY ECO i SYSTEM Control Functions primary current control and secondary current control Current protection control for the inverter compressor is performed by self protection in the inverter circuit and does not increase or dec
56. afe without the toxicity or combustibility of ammonia and is not restricted by laws imposed to protect the ozone layer However since it contains more than air it poses the risk of suffocation if its density should rise excessively Suf focation from leakage of refrigerant is almost non existent With the recent increase in the number of high density buildings however the installation of multi air conditioner systems is on the increase because of the need for effec tive use off loor space individual control energy conserva tion by curtailing heat and carrying power etc Most importantly the multi air conditioner system is able to replenish a large amount of refrigerant compared to conventional individual air conditioners If a single unit of the multi air conditioner system is to be installed in a small room select a suitable model and installation pro cedure so that if the refrigerant accidentally leaks out its density does not reach the limit and in the event of an emergency measures can be made before injury can occur ASHRAE and the International Mechanical Code of the ICC as well as CSA provide guidance and define safe guards related to the use of refrigerants all of which define a Refrigerant Concentration Level RCL of 25 pounds per 1 000 cubic feet for R410A refrigerant For additional guidance and precautions related to refrigerant safety please refer to the following documents International Mechanical Code 2
57. agonal cap Oil equalizer tube connector parts Fig 26 3 Remove the oil equalizer tube connector parts along with the O ring from the removed compressor and mount them on the replaced new compressor 4 Install the crankcase heater onto the new compressor 5 Temporary mount 2 cushion rubbers with bolts at the position as shown in the figure 27 Set up the leg of the new compressor onto the 2 cushion rubbers ET TEN P an REIS SERE f LLL See ru Gare TA AS ui o I E A Cushion rubbers Bolts Temporary mounting 2 locations at back side each 1 piece W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures Brazing locations 3 Bolt Washer 1 Rubber washer 1 1 each at the 3 locations it d ee AA PL is re amp av weg a bel Protect the oil equalizer tube connectors Cushioning rubber guide Front view Fig 28 Set the remaining cushioning rubber beneath the new compressor leg at the locations shown in the figure 28 a Remove the bolts which are temporarily fastening the 2 pieces of cushioning rubber and anchor the 3 com pressor legs using the bolts washers and rubber washers C Insert the pre shaped tube assembly at the 3 brazing locations indicated Ei Connect the manifold gauge to the high and low pressure outlet ports at the outdoor unit where the compres sor was replaced Connect the manifold gauge to a nitrog
58. al control address 3 Degree of filter fouling Central control address d 0064 Central control address 64 0099 No central control address set setting at time of shipping Bu Operating mode C0 Normal setting at time of shipping priority change ComprssorON CompresorOFF Fan speed when heating thermostat is OFF M 0002 Shifts intake temperature 4 F down M accu 0006 Shifts intake temperature 12 F down ma Electric heater 0000 No heater ot installation 0001 Heater installed Humidifying when 0000 No setting at time of shipping heater thermostat is Permit prohibit 0000 Permit automatic heating cooling 0001 Cool onl 0000 _ Normal y 0001 Cool only Set 1 for item code OD n order to avoid water leakage and damage to the fan do not set for humidifying when the thermostat is OFF unless a vaporizing humidifier is used Consider the device purpose and type when changing the settings Incorrect settings may result in malfunction Do not change any setting data that does not appear in this list The 10 hp 4 way ceiling cassette has 2 indoor unit addresses Set both of them W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions This allows the system address indoor unit address and other settings to be made for the individual or group control indoor unit to which the remote controller used for detailed settings is connected When detailed se
59. altemately Compressor 2 constant speed discharge temp trouble xt e Xt Outdoor unit fan trouble DCCT ACCT over current 80 Hz or more NV compressor start failure Missing phase or lock alarm Failure of nonvolatile memory IC EEPROM on indoor unit control PCB Operating and timer lamp blinking simultaneously xix Failure of nonvolatile memory IC EEPROM on outdoor unit control PCB Operating and timer lamp blinking simultaneously pein Protective Overload current detected Compressor 2 constant speed H11 No current detected when Compressor 1 INV GT amem 2 constant speed Hi Compressor 2 constant speed H15 Low pressure trouble HO6 e xie Outdoor unit protection HIC trouble alarm Timer lamp blinking Low oil alarm H07 i Connection failure of oil detection sensor Compressor 1 INV Compressor 2 constant speed i Fusing of electromagnetic contact Current detected when compressor was OFF CHECK Automatic backup operation only inking No display changes alarm indication Does not affect the operation of other indoor units lt alarm indication In some cases may affect the operation of other indoor units 2 Outdoor Unit Control Panel LED Display LED RED Blinking alternately W 2WAY ECO i SYSTEM Trouble Diagnosis O ON Blinking OFF Display meaning After the power is turned ON and automatic address setting is not in progress no communication with
60. ant from the inter unit tubing and indoor units using the refrigerant recovery unit To determine the completion of refrigerant recovery follow the instructions that came with the refrigerant recovery unit W 2WAY ECO i SYSTEM 5 Recoveri ng Refrig erant Outdoor Unit Repair Procedures Manifold auge o2 9 Hi Liquid tube service port For 5 16 7 94mm dia connector L Refrigerant recover unit w Refrigerant recovery cylinder Gas tube service port For 5 16 7 94mm dia connector Fig 11 5 3 Recovery of Refrigerant from Entire System 1 Turn off power to the entire outdoor system 2 Short circuit the AP Air Purge pins CN102 on the outdoor control PCB of all outdoor units then supply power to the outdoor units By short circuiting the AP pins and supplying power to the outdoor units the solenoid valve in each unit is forcibly opened and all remaining refrigerant can be recovered 3 If any unit has encountered a power failure follow the instructions in 5 1 Refrigerant Recovery Procedures from Outdoor Units and perform refrigerant recovery for the faulty outdoor unit 4 Connect the manifold gauge to the high and low pressure outlet ports Schrader type valves on any outdoor unit Fig 11 Remaining refrigerant may cause internal pressure Check that each valve on the Nm manifold gauge valves is tightly closed The connection port uses a Schra
61. areful not to allow contact of the refrigerant gas with a flame as this will cause the generation of poisonous gas Keep all tubing runs as short as possible 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 con nection 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 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 after installation that no refrigerant gas is leak ing If the gas comes in contact with a burning stove gas water heater electric room heater or other heat Source it can cause the generation of poisonous gas Check of Density Limit The room in which the air conditioner is to be installed requires a design that in the event of refrig erant gas leaking out its density will not exceed a set limit The refrigerant R410A which is used in the aircondition er is s
62. atile memory is not present when power initialization occurs 2 Read values do not match after writing to non volatile memory is complete Probable cause 1 Memory was not inserted after the PCB was replaced 2 The lifetime of the non volatile memory has been reached 3 Non volatile memory is installed incorrectly wrong direction bent pins etc Correction 1 Example J gt O Ntes TI W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis H11 H12 Alarm H11 Constant speed compressor 2 overcurrent alarm H12 Constant speed compressor 2 lock current alarm Alarm conditions H11 During operation the compressor current value exceeded 20 A for 30 seconds or longer However this alarm is not detected for 4 seconds after the compressor starts H12 During operation the compressor current value exceeded 29 A for 4 seconds or longer However this alarm is not detected for 2 seconds after the compressor starts Probable cause 1 Compressor failure locked or partially locked 2 CT circuit failure including cut wiring 3 Missing power phase 4 Low power voltage 5 PCB failure 1 Compressor failure partially locked Trouble Current value during operation greatly exceeds the value shown above Check When the current for each phase is measured with a clamp meter or similar instrument check that the current value for all phases is not high If MG was forced ON use caution check that compressor noise will
63. ause the amount of time that the unit operates as an evaporator is very short there is little danger of frost forming again quickly Rather because the heat source is very powerful it is possible to shorten the defrost operating time 2 Defrost sequence Outdoor unit cycle defrost is always completed in 2 defrost operations A When there are 2 outdoor units Defrost Evaporator Defrost outdoor unit outdoor unit outdoor unit First operation Second operation Defrost flow E Evaporator operation C Condenser operation S Shut off E C Switching from evaporator operation to condenser operation C E Switching from condenser operation to evaporator operation Defrost Defrost in Switch Defrost in Defrost preparation progress progress preparation Outdoor unit s where defrost occurs first E C C C E E EorS Outdoor compressor s where defrost occurs first OFF ON OFF ON OFF Outdoor unit s where defrost follows later E E E C C C Eors Outdoor compressor s where defrost follows later ON ON Defrost OFF ON Defrost OFF Stopped indoor unit s S s end S s end S Indoor units where fan is operating S s judgment S g judgment S Heating mode indoor Thermostat ON C C C C C units Thermostat OFF C C C C C Time 1 min Max 6 min 1 min Max 6 min 1 min 1 12 W 2WAY ECO i SYSTEM 4 Special Controls Control Functions 4 3 7 Defrost end judgment conditi
64. ay be subject to internal pressure from the refrigerant inside the out JN eme door unit A Schrader type push to release valve is provided at each connection port Since the DPR valve opens at pressures of 362 6 psi and above be sure to con nect the DPR to the gas tube service port low pressure side 7 I T LI S w Pi Low pressure i let port High pressure if out t outlet port 1 For 5 16 a For 5 16 7 94mm N 7 94mm d dia connector dia connector d 1 E Upper valve Service port P z 5 16 7 94mm e dia connector ein Lo gaug Hi Qo if ch emm Y Lower at W 2WAY ECO i SYSTEM 8 Charging Compressor Oil Outdoor Unit Repair Procedures Next follow the instructions in 5 2 1 Cooling operation for all units at the outdoor unit where oil will be charged and start cooling operation at all units When the operating conditions have stabilized perform steps 1 2 and 3 in sequence and open the valves When this is done the refrigerant pressure from operation forces the oil out of the oil charge tank and oil is charged into the outdoor unit from the low pressure outlet port From time to time close the upper valve on the top of the oil charge tank only this valve and shake the tank to check the amount of remaining oil
65. azed part and briefly inspect for any leakage If there are any leaks bubbles will show on the tubing surface To continue the air tight check after the brief leak inspection turn on power while short circuiting the AP pins Again feed nitrogen gas to obtain a system pressure of 72 5 psi Then measure both the outdoor ambient temperature and the pressure in the system Leave the system in this state for 1 full day and night and again measure the outdoor ambient temperature and pressure to determine any reduced values During the inspection it is recommended that an awning or cover be used to shield the unit in case of rain If no problem is found purge all nitrogen from the system Manifold gauge a ro High pressure outlet port For 5 16 7 94mm dia connector Nitrogen gas D a Low pressure outlet port For 5 16 7 94mm dia connector Fig 12 6 2 Checking for Leakage in Refrigerant Tubing Between Indoor and Outdoor Units Refer to the Installation Instructions that came with the outdoor unit W 2WAY ECO i SYSTEM 7 Evacuati ng System Outdoor Unit Repair Procedures This procedure is carried out to ensure there is no remaining refrigerant or other gases nitrogen etc in the repaired outdoor unit and tubing 7 1 Evacuating Repaired Outdoor Unit 1 Check that each service valve of the gas tubes liquid tube and balance tube in the outdoor unit are fully closed 2 Connect the manifol
66. c oe Auto heat cool W 2WAY ECO i SYSTEM 2 Detailed Settings Function CANCE I IAS Item code Setting data No Description 0000 No forced operation Automatic drain pump 0001 Forced operation for 1 minute operation H 0060 Continuous operation 0000 None ERR EEN operation f 5ga 0001 Ventilation fan operated by remote controller 33 Wired remote controller 0000 Not used Body sensor is used 2c sensor 0001 Remote control sensor is used Operation change 0000 Normal displayed control in progress display 0001 Not displayed OFF reminder function 0000 None for when weekly timer is used 0001 Only stop time setting is enabled Discharge temperature 0000 Discharge temperature control OFF temperature control Discharge temperature control OFF control 0001 Discharge temperature control ON Heat exchanger Control temperature 55 F temperature for cold air Control temperature 57 F discharge H Heat exchanger control point for control to Control temperature 77 F prevent cold air 0026 Control temperature 78 F Fani output switchin ECA Output linked with fan ON when indoor unit fan is operating P 9 0001 Fan mode operation output uer start time 0000 dies output OFF Drain pump stopped 0001 Humidifier output ON Drain pump operates Humidifier setting 0002 Humidifier output ON Drain pump operates for 1 minute when total humidifier operating time reaches 60 minutes 0003 Hu
67. colon dot is OFF Figure B The display of the first 4 digits and last 4 digits changes automatically after 10 seconds The display can also be changed by pressing the CE FLAP button 10 lt Compressor s total operating time A and B are displayed alternately NOTE The example here 0000 0062 indicates 62 hours With the outdoor unit maintenance remote controller when connected to the outdoor unit the unit remote controller check functions will not operate 3 8 W 2WAY ECO i SYSTEM 4 Monitoring Operations Outdoor Unit Maintenance Remote Controller Display the indoor unit and outdoor unit sensor temperatures Operating procedure p Press and hold the CHECK button and E buttons simultaneously for 4 seconds or longer to engage temperature monitor mode During temperature monitoring is illuminates The display and operations are the same as for monitor mode using the indoor unit remote controller Press the UNIT J button and select the indoor unit J ae to monitor mees Press the temperature setting C amp D and v D buttons and select the item code of the temperature to monitor The unit No of the selected indoor unit and the temperature data are displayed To end monitoring press the CHECK button The display returns to the n
68. completed If initial communications have not been completed alarm E04 occurs E12 Alarm Mameode fe Automatic address setting start is prohibited Alarm conditions Automatic address setting was started when automatic address setting was in progress at another outdoor unit in the same link Probable cause Automatic address setting is in progress at another outdoor unit Check This alarm is not displayed on the remote controller Therefore check the blinking on the outdoor RR inten ee enn ori ereak e Binan on fecun progress Then start automatic address setting again Gegen EE EE ll Notes Le E15 Alarm Alarm meaning Automatic address setting alarm too few units Alarm conditions The number of indoor units was too few when automatic address setting was performed Probable cause 1 The number of indoor units set at the indoor unit quantity setting SW S004 S005 on the outdoor unit PCB is too many 2 The inter unit control wiring between indoor units has been cut Check 1 Refer to the test run servicing materials and check the indoor unit quantity setting SW S004 S005 2 Check the inter unit control wiring at the indoor and outdoor units After correcting the indoor unit quantity setting or the inter unit control wiring perform automatic address setting again Example J ooo W 2WAY ECO i switch position W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis E16 Alarm ge
69. compressors is able to operate then this outdoor unit operates only when the operation of all outdoor units is required for special control such as 4 way valve adjustment or other system purposes 4 Alarm display If a wired remote controller is present N display blinks during operation 5 Canceling automatic backup operation Repair the outdoor unit where the failure occurred When repairs are completed reset the power on outdoor unit No 1 lt Caution gt After automatic backup mode has been engaged it will not be canceled automatically when the repair of the failed outdoor unit is completed Automatic backup mode will be canceled only when the power on outdoor unit No 1 is reset Therefore after repair work is completed be sure to check whether or not automatic backup mode has been canceled How to check 1 Use test run or other means to verify that all outdoor units operate continuously 2 If a wired remote controller is present check that A display has disappeared 16 2 Manual Backup If an alarm that does not result in automatic backup occurs frequently possible causes include failure such as refrigerant leakage of a functional part at an outdoor unit other than the unit where the alarm occurs In this case because the outdoor unit service valve must be closed backup operation must be performed manually 1 Backup operation procedure 1 Disconnecting the failed outdoor unit A Reduce the number of outdoor uni
70. correctly perform pump down Perform work correctly according to the work procedures given below CD Connect the manifold gauge to the high and low pressure outlet ports on the outdoor unit where pump down will be performed Be sure that no air enters the tubing at this time 2 Follow the instructions in 5 2 1 Cooling operation for all units and operate all units in Cooling mode for approximately 5 minutes Then fully close the liquid tube valve on the outdoor unit where pump down will be performed 8 When the high pressure gauge reaches 406 1 psi or higher or the low pressure gauge reaches 72 5 psi or below at the outdoor unit where pump down is being performed press the ON OFF button on the outdoor unit maintenance remote controller to stop operation at all units Then immediately fully close the suction tube valve on the outdoor unit where pump down is being performed f the outdoor unit maintenance remote controller is unavailable follow the procedure below to stop all of the units Pull out the SCT connector 2P YEL CN231 on the outdoor unit control PCB of the unit where pump down is being performed When the SCT connector is pulled out immediately alarm F12 sensor trouble occurs and all outdoor units stop operating Be sure that you do NOT grasp the lead wire when pulling out the con nector Removing any other connector may not cause the units to stop Therefore be sure to pull out the SCT connector only It is
71. d Functions 3 4 4 Monitoring Operations 0 ccc eee 3 9 5 Outdoor Unit Alarm History Monitor eeeeeeeeeeeeeeeeeeeeeeeeeeeeee 3 11 6 Mode Settings uua a dla ei eee ferae e eee iR b Pie ae OO Enna 3 12 W 2WAY ECO i SYSTEM 1 Overview Outdoor Unit Maintenance Remote Controller OUTDOOR UNIT MAINTENANCE REMOTE Service Checker Section CONTROLLER RCS TM80BG for W 2WAY ECO i W About the outdoor unit maintenance remote controller The outdoor unit utilizes nonvolatile memory EEPROM on its PCB This allows EEPROM data to replace the setting switches that were present on previous PCBs The outdoor unit maintenance remote controller is used to set and change these EEPROM data In addition to setting and checking the outdoor unit EEPROM data this remote controller can also be used to monitor the outdoor unit alarm history monitor the various indoor and outdoor temperatures and check the indoor unit connection status number of units operating mode etc Outdoor unit maintenance remote controller does not function as an ordinary remote controller It is therefore only used for test runs and during servicing RCS TM80BG Outdoor unit maintenance remote controller System diagram Outdoor unit Special service checker wiring Inter unit control wiring Servicing No 6231785082 i Outdoor unit control PCB Ind
72. d gauge valves to the high pressure and low pressure sensor outlets of the outdoor unit Fig 13 8 Connect the manifold gauge valves to the vacuum pump f the AP pins CN102 on the outdoor control PCB have already been short circuited step 4 is not neces sary 4 Turn off power to the repaired outdoor unit and short circuit the AP Air Purge pins on the outdoor control PCB By short circuiting the AP pins and turning on power to the outdoor unit all elec AN eme tronic valves in the outdoor unit are forcibly opened and any remaining nitrogen gas can be recovered Failure to perform this procedure may result in nitrogen gas remaining in the refrigerant circuit and causing operating problems Therefore never skip this step b Turn the power ON at the outdoor unit where vacuum will be applied Then run the vacuum pump and continue evacuation until the vacuum condition falls to less than 14 7 psig 5 Torr To ensure proper evacuation refer to the operating instructions that came with the vacuum pump Manifold auge isa H High pressure outlet port For 5 16 7 94mm dia Vacuum pump connector Low pressure outlet port For 5 16 7 94mm dia connector Fig 13 7 2 Evacuating Refrigerant Tubing Between Indoor and Outdoor Units Refer to the Installation Instructions that came with the outdoor unit W 2WAY ECO i SYSTEM 8 Charging Compressor Oil Outdoor Unit Repair Procedures 8 1 If Refri
73. d tube cap brazed from the new compressor 2 Install the crankcase heater onto the new compressor 3 Place the 2 pieces of cushioning rubber in the designated positions on the compressor 4 Place the 2 pieces of cushioning rubber onto the legs of the new compressor Jare When setting the compressor into the unit be careful not to cause any abnormal deformation of the tube with flare nut 5 Place the remaining cushioning rubber onto the new compressor at the position shown in the figure below 6 Remove the bolts that are temporarily fastening the pieces of cushioning rubber inner 2 legs and anchor the 3 compressor legs using the bolts washers and rubber washers 7 Remove the flare nut from the new compressor and connect the tube with flare nut 8 Shape the tubes and insert them at the 2 brazing locations 9 Connect a manifold gauge to the high and low pressure outlet ports at the outdoor unit where the compres sor was replaced Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement 10 Perform copper brazing at the 2 brazing locations 11 Follow the instructions in 6 Checking for Leakage After Repair and check for leaks at the outdoor unit where the compressor was replaced Jare At this time also check for leaks at the flare nut connection on the tube with flare nut 12 Re install all components that were removed Re install the electrical component box in the same pos
74. ddress and service monitor 00XX sensor temperature See figure at right Press the temperature setting GD an LC e buttons to change the item mi to the sensor address of the sensor you wish to monitor For the relationship between the sensor address and sensor type refer to the sensor temperature relationship table on next page If group control is in effect press the button to change to the unit you wish to monitor Press the CHECK button to return to normal remote controller operation Note The temperature display for units that are not connected appears as f monitor mode is engaged during ordinary operation the only parts of the LCD display that change are those shown in in the figure The other parts remain unchanged during normal operation W 2WAY ECO i SYSTEM Trouble Diagnosis Example 1 Unit No Un Item code sensor address DU XX Discharge temp TD aa W 2WAY ECO i SYSTEM 3 Remote Controller Servicing Functions Trouble Diagnosis Sensor Temperature Relationship Table Location where Sensor Sensor address Sensor type Sensor address Sensor type is installed Remote controller temperature Discharge temperature sensor Indoor unit intake temperature Indoor unit heat exchanger Indoor unit electronic expansion Indoor unit temperature E1 valve position Indoor unit heat exchanger temperature E3 Unit No
75. defrost was once completed 3 If all indoor units are stopped while defrost control is in effect or if the outdoor unit is stopped due to protection control or another reason then defrost control will not start for a minimum of 10 minutes after restart occurs 1 10 W 2WAY ECO i SYSTEM 4 Special Controls Control Functions 4 3 3 Frost detection A Frost detection does not occur for 5 minutes after operation starts B Frost is detected when either condition 1 or 2 below is met Condition 1 L2 line or below is detected twice each time continuously for 4 minutes when the compressor is operating Condition 2 L1 line or below is detected for a total of 60 minutes when the compressor is operating Heat exchange liquid temperature F Defrosting operation The end temperature 50 end temperature is different from the above detection temperature 6 5 50 External temperature F 30 3 r L1 gege L2 The frost detection area is located under the thick lines 4 3 4 Outdoor units where defrost occurs Even if the total time has not reached 35 minutes if there is 1 or more outdoor units that fulfills the defrost detec tion conditions all operating outdoor units perform defrost control at the same time Defrost control is also performed at outdoor units where the outdoor unit heat exchanger is not functioning as an evaporator such as stopped outdoor units 4 3 5 Reverse Cycle Defrost If th
76. der type push to release valve 5b Connect the manifold gauge valves refrigerant recovery unit and refrigerant recovery cylinder Quickly connect each part to prevent air from entering the tubing 6 Check that each service valve of the gas tubes liquid tube and the balance tube for the outdoor unit has opened then perform refrigerant recovery If only a single outdoor unit is installed the balance tube is not used Therefore leave this valve closed To determine the completion of refrigerant recovery follow the instructions that came with the refrigerant recovery unit W 2WAY ECO i SYSTEM 6 Checking for Leakage After Repair GeO ALN NEON eer 6 1 Pressure Check for Leakage of Outdoor Unit After completing repair of the outdoor unit carry out the following leakage check 1 Check that all service valves for gas tubes liquid tube and balance tube in the repaired outdoor unit units necessary to carry out the pressurized leak check are fully closed 2 Connect the manifold gauge valves to the high and low pressure outlet ports of the outdoor unit 3 Feed nitrogen gas into the circuit until 72 5 psi pressure is reached If it is apparent that the nitrogen gas is not entering the repaired section interrupt the feeding Short circuit the AP pins CN102 on the outdoor unit control PCB turn on power to run the outdoor unit then resume feeding nitrogen 4 Apply soapy water to the repaired part such as a newly br
77. ds C The fan mode may be increased when the outdoor liquid temperature drops to 44 F or below 8 5 Snow Removal Control 1 When the outdoor air temperature is 50 F or below the fan operates for 30 seconds every 2 hours in fan mode 8 even when the outdoor unit is stopped or the heat exchanger is not in use This control is intended to prevent snow from accumulating on stopped fans Because the outdoor air temperature cannot be accurately detected when the unit is stopped a higher outdoor air temperature is used for the control condition in order to ensure correct operation 2 If the fan mode becomes 0 during cooling operation the fan mode is changed to 1 This control is predictive control Use a snowfall sensor as necessary according to the installation conditions 8 6 When the Compressor Magnet Switch Seizing Alarm Occurs Because there is the possibility that the high pressure has increased the fan operates in Max fan mode 8 7 Other This unit includes settings for high static pressure and for Quiet mode For information about these settings refer to the field application functions 1 19 W 2WAY ECO i SYSTEM Control Functions 9 Demand Control Serial parallel UO must be connected in order to perform demand control The below input is received by serial parallel I O and demand control is performed The demand values can be set as needed with this device For more information refer to the field application func
78. e high pressure outlet port and monitor the pressure during operation to check the pressure when the high pressure switch is activated Check valve failure is likely if the pressure is less than 478 6 psi The following describes checks to be made when the pressure is high During cooling check whether the outdoor unit heat exchanger is clogged Remove any foreign material that prevents ventilation During cooling check whether an air short blockage has occurred in the outdoor unit The system is operating normally unless the temperature around the outdoor unit is excessively high During cooling check for outdoor fan failure Check whether the screws securing the fan are loose and whether the fan connector in the outdoor unit PCB is properly connected During heating check whether the air filters in the indoor unit are clogged If clogged clean the filters During heating check whether an air short blockage has occurred in the indoor unit The System operates normally unless the temperature around the indoor unit is excessively high During heating check for indoor fan failure Check whether the refrigerant circuit is clogged Check that all service valves are closed Check whether welded locations are clogged 10 Check for mechanical valve failure Check whether the mechanical valves make a clattering sound when the power is reset Since the mechanical valve in the indoor unit is in a location that makes aural inspection difficult use an el
79. e 0206 20 R RR Orne tend shed sere saved 1 26 15 Pressure Sensor Failure 1 27 16 Backup Operation uus auda x Rm oso sine adee se CRURA be OR ese ewes ws 1 28 17 Service Maintenance Functions 1 30 18 Other F ncti ns t a ore RALIS ri rmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmmria 1 32 W 2WAY ECO i SYSTEM 1 Introduction Control Functions The W 2WAY ECO i is a system that allows multiple outdoor units to be connected The outdoor units all contain inverter compressors and the system does not utilize the sub units that were used in earlier systems The outdoor unit where the unit No is set to 1 includes the CCU command controller unit functions that are used to control the entire system As a result the system will not operate if no outdoor unit has been set as unit No 1 Required settings for Test Run Outdoor unit No 1 Outdoor unit No 2 At time of shipment On site setting At time of shipment On site setting System address 1 System 1 30 1 Not necessary No of indoor units 1 1 40 units 1 Not necessary No of outdoor units 1 1 3 units 1 Not necessary Unit No 1 Unit No 1 1 Unit No 2 This system can be expanded to connect a maximum of 3 outdoor units The max system capacity shall be within 24 Ton The CCU functions are disabled at all units except the unit that is set as unit No 1 Therefore no problems will result even if the system address No o
80. e 2 are used to make the outdoor EEPROM setting W 2WAY ECO i SYSTEM Outdoor Unit Maintenance Remote Controller 3 Ordinary Display Controls and Functions B Functions on the ordinary display Connect the special service checker wiring to the outdoor unit PCB The connection is shown in the figure below Outdoor unit PCB RC 3P BLU PCB connector 3P BLU Special service checker wiring Relay connector 2P WHT Remote controller Ass y f the communications line in the inter unit control wiring is connected it can be left as is n case of an independent outdoor unit 1 maintenance remote controller connected to 1 outdoor unit automatic address setting for indoor units not completed both setting mode 1 and setting mode 2 can be used The overall system status for that refrigerant system is displayed W 2WAY ECO i SYSTEM 3 Ordinary Display Controls and Functions Outdoor Unit Maintenance Remote Controller 9 All units start stop Fig 1 Operation The ON OFF operation button can be used to start and stop all the indoor units e The LED illuminates if any indoor units is operating The LED blinks if an alarm at any of the operating indoor units occurs LED 9 Cooling heating change Fig 1 Operation MEE The MODE button can be used to change 1 LESE a Jun JC J between heating and cooling
81. e Sensor element malfunction Sensor wiring is partially disconnected resulting in increased electrical resistance xr This alarm does not occur when the wiring is cut or when the connector is not connected to the outdoor unit PCB 2 Crossed wiring or installation error The discharge temperature sensor of that compressor is connected to the discharge tube of the other compressor The connector for the discharge temperature sensor of the problem compressor is connected to the outdoor unit PCB connector for the other compressor 3 Outdoor unit PCB failure 4 The check valve on the discharge tube for that compressor is wet 5 An air short blockage in the area around the outdoor unit has increased the outdoor unit ambient temperature reducing the cooling effects after the compressor stops 6 There is a cause that results in PO3 P17 or PO2 alarm 7 Electrical noise 1 Sensor malfunction and outdoor unit PCB failure Trouble e Constantly indicates a high temperature When monitoring software or other means are used for monitoring the discharge temperature at times fluctuates suddenly and wildly In some cases the precise temperature may not be known even when monitoring software is used Wiggle the sensor and check whether the trouble continues Check whether the connector is partially disconnected from the PCB yy An F04 alarm will not result if the connector is completely disconnected circuit is open e f the cause is st
82. e failed outdoor unit release the short circuit at the vacuum application pin and close the liquid tube valve at the failed outdoor unit Refrigerant recovery is not affected by the power status of the failed outdoor unit However collecting refrigerant in the failed outdoor unit is affected by whether the power at that outdoor unit can be turned ON If the power cannot be turned ON use a refrigerant recovery device and recover the refrigerant into a recovery cylinder in order to adjust the amount of refrigerant in the system 4 Backup Operation W 2WAY ECO i SYSTEM Outdoor Unit Repair Procedures 4 2 2 Backup operation by setting the failed compressor not to operate Backup operation settings for each compressor INV compressor AC1 compressor Setting for backup operation DIP switch S010 OK Failed Turn BACK UP and AC1 ON DIP switch S010 Failed OK Turn BACK UP and INV ON SS Failed DIP switch S010 Turn BACK UP INV and AC1 ON W 2WAY ECO i SYSTEM 5 Recovering Refrigerant Outdoor Unit Repair Procedures The following equipment and tools are required Jumper wire with clips adjustable wrench set of manifold gauge valves specially designed for refrigerant R410A only vacuum pump refrigerant recovery unit pre purged refrigerant cylinder for recovery flathead screwdriver and outdoor unit maintenance remote controller 5 1 Refrigerant Recovery Procedures from outdoor unit 1 Tu
83. e gauge valve on the manifold gauge When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrig erant or when charging with the same amount of new refrigerant has not been completed but no more refriger ant will enter the unit first turn the power OFF at the repaired outdoor unit then remove the short circuit at the AP pin CN102 Then fully open all valves on the gas tube liquid tube and balance tube However leave the balance tube fully closed if only a single outdoor unit is installed 8 If backup operation was engaged follow the instructions in 4 Backup Operation and perform backup opera tion recovery 9 If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible fully close the high pressure gauge valve on the manifold gauge Then while the unit is operating in Cooling mode open the low pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant area When charging with liquid refrigerant add refrigerant a little at a time in order to prevent liquid back flow 10 Fully close the low pressure gauge valves on the manifold gauge follow the instructions in 8 Charging Com pressor Oil and charge with the necessary amount of oil Also add an amount of oil that is equivalent to the amount that was drained from the oil separators 11 Remove the manifold gauge The connecting po
84. e the resistance between each pair of pins on the electronic control valve connector The connector is normal if all results pin 5 pin 1 pin 5 pin 3 pin 6 pin 2 pin 6 pin 4 are approximately 460 If the results are 0Q or co replace the coil 3 Crank case heater e Connect a clamp meter to 1 of the 2 crank case heater wires and measure the current The current is normal if the result is 0 15 A or higher As a guide the current should be 0 14 A 180 V 0 17 A 220 V W 2WAY ECO i SYSTEM T Test Pin Trouble Diagnosis When the test pin on the outdoor unit control PCB is short circuited each part can be operated individually e After turning OFF the main unit power short circuit the test pin CNO22 WHT then turn the power back ON Output is performed in the sequence shown in the table below for 0 5 seconds each M e meu e Sa o n eserceg Dom an meme aeee e Relay RY007 Recovery vave ORV ee RR 9 Relay RYO17 Refrigerant balance valve RBV Relay RYO16 Refrigerant adjustment valve RCV W 2WAY ECO i SYSTEM 8 Thermister Characteristics Curve Trouble Diagnosis 8 1 Room temp sensor Temperature sensor A o Resistance kQ NO A ODN o O 10 15 20 25 30 35 40 45 50 55 Temperature C 8 2 Indoor heat exch c
85. e values represent abnormal low pressure which may damage the compressor However the alarm does not actually occur the first 2 times that the above operation takes place At these times the outdoor unit is stopped and the conditions are monitored The alarm occurs when the above operation occurs for the fifth time The first 4 times before the alarm occurs are called pre trip After pre trip occurs if the low pressure sensor detects a pressure of 21 8 psi or more for 3 minutes of continuous operation the pre trip count is reset to 0 If the low pressure sensor detects a pressure of 23 2 psi or less continuously for 30 minutes when the compressor is stopped an alarm occurs immediately no pre trip Probable cause The A C unit low pressure has dropped to a level that does not occur under ordinary conditions 1 The absolute amount of gas in the system is too low as a result of insufficient refrigerant charge or leak 2 The refrigerant has accumulated in the circuit and has not returned to the compressor Refrigerant has accumulated in a location of one way flow and cannot escape High pressure level is low resulting in poor flow of refrigerant in the circuit A lower high pressure level results in a smaller difference between low pressure and high pressure that may be insufficient to cause refrigerant flow 3 The refrigerant circuit has become closed and refrigerant has not returned to the compressor In some cases when m
86. ecause the capacity has not been set Check Connect the outdoor unit maintenance remote controller On the outdoor unit EEPROM detailed setting mode screen check the value for the outdoor unit capacity item code 81 Check that it is EE not set to 0 or to a capacity that is not allowed Correction If item code 81 is incorrect use the outdoor unit maintenance remote controller and set it correctly After changing the setting be sure to reset both the indoor and outdoor power Example Notes The outdoor unit maintenance remote controller is required in order to set the capacity in the outdoor unit EEPROM L17 Alarm Outdoor unit model mismatch Alarm conditions This alarm occurs when a unit other than a R410A refrigerant model is connected Probable cause 1 A unit that uses R407C refrigerant or a R22 model unit was connected by mistake 2 The connected unit is correct however the refrigerant type setting in the outdoor unit EEPROM item code 80 is incorrect Check 1 Check the refrigerant type at the connected unit 2 Use the outdoor unit maintenance remote controller and check the item code 80 refrigerant type If the setting is incorrect change it to R410A Correction J o O ICON E Notes The outdoor unit maintenance remote controller is required in order to set the refrigerant type in the outdoor unit EEPROM L18 Alarm Alarm conditions During heating operation Comp ON the highest detected temperature at a
87. ecovery unit 8 2 If Outdoor Unit Has Not Been Charged with Refrigerant When a compressor has been replaced or in any other case where the outdoor unit has not been charged with refrigerant first charge with refrigerant then follow the instructions in 8 1 If Refrigerant Has Already Been Charged to Outdoor Unit and charge with oil Or alternatively follow the procedure below 1 Connect a tube to the oil outlet port on the outdoor unit to be charged with oil Insert the other end of the tube into the oil container 2 Follow the instructions in 7 Evacuating System and apply vacuum to the outdoor unit to be charged with oil When this is done oil is charged into the outdoor unit through the oil outlet port 8 When the unit has been charged with the designated amount of oil stop the vacuum pump AN zm The oil absorbs moisture readily This work must be completed quickly 2 18 W 2WAY ECO i SYSTEM 8 Charging Compressor Oil Outdoor Unit Repair Procedures Oil tube outlet port For 1 4 6 35mm dia connector High pressure outlet port For 5 16 7 94mm dia connector Oil Manifold auge Lo s Hi e i Vacuum pum i E Low pressure outlet port For 5 16 7 94mm dia connector Fig 19 8 3 Charging Additional Compressor Oil after replacing compressor The rated amount of oil is pre charged in the compressors as given below Model name Compressor
88. ectric means to check Check that the connector pin of the mechanical valve on the PCB outputs 4 V In addition check that the coil resistance of the mechanical valve is several tens of Ohm Q 11 Check for solenoid valve kit failure Removing a coil that is on will result in a clicking sound Also removing a coil that is off will not produce such a sound 12 Check whether too much refrigerant has been charged Too much refrigerant has been charged if the sub cool temperature of the condenser is 59 F or more Replace damaged components and correct the amount of charged refrigerant Example P05 Alarm Alarm code POS Alarm meaning Reverse phase or missing phase detected Alarm conditions This alarm occurs when a reverse phase or missing phase is detected in the L1 L2 L3 N phases Probable cause Correction Switch the phases and reinsert Check if the result is OK Example e ee EE Notes W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis P16 Alarm Alarmcode PIS Compressor 1 INV overcurrent alarm Alarm conditions This alarm occurs when current trouble or current detection trouble occur at an inverter frequency of less than 80 Hz after start when trouble judgment current is detected in the primary or secondary current or when an instantaneous secondary current of 13 5 A or higher is detected Probable cause There is a strong possibility of a compressor failure An alarm occurs for current
89. emand 1 current Demand 2 current W 2WAY ECO i SYSTEM 6 Mode Settings Outdoor Unit Maintenance Remote Controller B Setting mode 2 Operating procedure Press and hold the CHECK button button and button simultaneously for 4 seconds or longer ES ut No ds of RC No SETDATA Press the temperature setting Cas and v 7 buttons to change the item i 0008 code The item codes and setting data are shown in the table below Press the timer time 4 and Ce buttons to change the setting data To confirm the changed setting data press the button At this time all displays stop blinking and remain lit During this mode Band is displayed blinking The display shows the set outdoor unit address System XX YY System XX System address YY Address at outdoor unit sub bus item code number DN value in the table below and the setting data 8 digits The setting data is displayed in 8 digits The display changes between the first 4 digits Fig and the last 4 digits Fig When the first 4 digits are displayed the top point of the colon is lit To exit setting mode press the CHECK button Returns to the normal display mode Display of first 4 digits Display of last 4 digits Le RR SS UNIT UNIT No No 4014 I 4014 Tt wm DEUS 4 I et 84g RC No SETDATA
90. en cylinder and perform nitrogen gas replacement 10 Perform copper brazing at the 3 brazing locations In the same way as during removal pay particular attention to protection of the oil JN sm equalizing tube connector parts shown in the figure 28 An O ring is mounted inside the oil equalizer tube connector parts It must be pro tected and do not lose it 11 Follow the instructions in 6 Checking for Leakage After Repair and check for leaks at the outdoor unit where the compressor was replaced 12 Re install all components that were removed Re install the electrical component box in the same position as it was before Be sure to check for looseness of the power terminal connection at the compress or Nim terminal plate and to check by pulling vertically on the connections If the termi nals become disconnected easily replace the wiring Assy 13 Follow the instructions in 7 Evacuating System and apply vacuum to the outdoor unit where the compres Sor was replaced W 2WAY ECO i SYSTEM 10 Compres sor Outdoor Unit Repair Procedures C Replacing multiple compressors E Removal 1 Follow the instructions in A Replacing the inverter compressor B Replacing constant speed compressor and remove the compressors There is no predetermined sequence for removal any compressor may be removed first B installation 1 Follow the instructions in A Replacing the inverter compressor B R
91. eplacing constant speed compressor and install the compressors There is no predetermined sequence for installation any compressor may be installed first 2 34 W 2WAY ECO i SYSTEM 11 High and Low Pressure Sensors Outdoor Unit Repair Procedures The outdoor unit connection ports for the high and low pressure sensors employ Schrader type push to release valves Therefore it is not necessary to recover refrigerant when removing and installing them 11 1 Removing the High and Low Pressure Sensor 1 Follow the instructions in 1 Removing Panels and 2 Removing Electrical Component Box and Duct and remove the corresponding components from the outdoor unit where the high pressure sensor will be removed 2 Disconnect the high amp low pressure sensor connector socket 3P BLK A WHT from terminals CN009 and CNO24 on the outdoor unit control PCB of the outdoor unit where the high A low pressure sensor will be removed 3 Use 2 adjustable wrenches in combination to remove the high amp low pressure sensors When removing the high amp low pressure sensors internal pressure will be applied by AN eme the refrigerant in the outdoor unit The high amp low pressure sensor connection ports on the outdoor unit employs a Schrader type valve 11 2 Installing the High and Low Pressure Sensors 1 Use 2 adjustable wrenches in combination to install the high and low pressure sensors High pressure sensor Low pressure
92. er outdoor unit constant speed Alarm conditions Probable cause 1 After initial communications were completed the control wiring between main and sub outdoor units was cut 2 After initial communications were completed the outdoor unit power was turned OFF Check W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis E25 Alarm Mamexe Te Outdoor unit address setting failure duplication Alarm conditions Communication by outdoor unit main sub control wiring was received that contained the same address as that unit 5 times or more within 3 minutes Probable cause The unit number is set incorrectly Check Check the unit number again Correction Correct the incorrect unit number setting Example fo Notes Recovery from this alarm occurs automatically when communication that contains the same address is not received for 3 minutes E26 Alarm es CE UL DEEEEEEEEEEELl3 Alarm conditions After power initialization the set outdoor unit quantity did not match the number of outdoor units amc detected on the outdoor unit main sub control wiring for 3 minutes or longer 1 The outdoor unit quantity is set incorrectly 2 The outdoor unit main sub control wiring is cut Check 1 Check the outdoor unit quantity setting again 9 JI Correction 1 Correct the incorrect outdoor unit quantity setting 2 Repair the outdoor unit main sub control wiring Example fe Notes Recovery from this alarm occur
93. ercurrent peck current current Alarm display H11 H12 4 CT circuit detection trouble Alarm Description Compressor 1 inverter H03 Occurs when an open CT circuit is detected in the inverter compressor compressor Compressor 2 constant H13 Occurs when a current value of 1 5 A or less is detected speed compressor when the constant speed compressor is operating If the inverter compressor operating frequency is low the current value is also low Therefore this alarm is detected only when the compressor is stopped The operating current of the constant speed compressors is always higher than 1 5 A Therefore this alarm occurs as the result of an open circuit or failure W 2WAY ECO i SYSTEM 15 Pressure Sensor Failure Control Functions This system contains 2 types of pressure sensors a high pressure sensor and a low pressure sensor 1 High pressure sensor failure Alarms are emitted when the high pressure sensor becomes an electrical open circuit or a short circuit condi tions and a broken wiring short circuit or poor connection to the PCB in the high pressure sensor circuit 2 Low pressure sensor failure Alarms are emitted when the low pressure sensor becomes an electrical open circuit or a short circuit condi tions and a broken wiring short circuit or poor connection to the PCB in the low pressure sensor circuit High pressure sensor failure Low pressure sensor failure Alarm display F16 F17
94. ere is 1 outdoor unit and no thermal storage tank in a refrigerant system a reverse cycle defrost will be carried out Defrost flow E Evaporator operation C Condenser operation E C Switching from evaporator operation to condenser operation C E Switching from condenser operation to evaporator operation Defrost preparation Defrost in progress Defrost end Outdoor unit status E C E C C CE Stopped indoor units CE E E E C Indoor units where fan is operating CE E E Defrost E C Cooling mode Thermostat ON CE E E end E C indoor units Thermostat OFF CE E E judgment E C Heating mode Thermostat ON CE E E E C indoor units Thermostat OFF CE E E E C Compressor Stopped Operating Operating Stopped Time 1 min 1 min Max 10 min 1 min 1 11 W 2WAY ECO i SYSTEM 4 Special Controls Control Functions 4 3 6 Outdoor unit cycle defrost Outdoor unit cycle defrost is performed in systems where 2 outdoor units are connected to the refrigerant system 1 Description of outdoor unit cycle defrost With this defrost method when 1 outdoor unit operates in defrost mode heat exchanger operating as a con denser another outdoor unit operates as an evaporator in the same way as in ordinary heating mode In this way the other outdoor unit is heating the unit where defrost is occurring When 1 outdoor unit completes defrost the other outdoor unit performs defrost in the same way Bec
95. es 3 types of Quiet modes However when they are engaged operation is in Quiet mode 24 hours a day Selecting a Quiet mode results in operation that gives priority to reducing noise Because these modes involve restrictions on outdoor unit fan modes and the operation frequency the capacity will be somewhat reduced Setting Max fan mode Effect Amount of capacity reduction Normal operation setting at time of 0 14 0 factory shipment 1 12 Noise reduced by approx 1 2 dB from Approx 0 5 hp the catalog value 2 11 Noise reduced by approx 2 3 dB from Approx 1 2 hp the catalog value 3 10 Noise reduced by approx 5 dB from the Approx 1 8 hp catalog value f Quiet mode is set the capacity will begin to decrease during heating operation at low outdoor temperatures when the outdoor air temperature is below standard conditions 17 2 Anti slime countermeasures EEPROM setting OC set only on the main unit This setting controls the operation of the drain pump Setting Description 0 Normal control setting at time of factory ship ment 1 The drain pump operates for 20 minutes at 2 hour intervals 2 The drain pump operates for 20 minutes at 20 minute intervals 3 The drain pump operates constantly 17 3 Delayed Start for Each System Outdoor EEPROM 3E set only on outdoor unit No 1 The operation start time can be delayed according to the set system addresses
96. essure sensor Liquid refrigerant SC 0 F Gas refrigerant returns to the accumulator ia Refrigerant on the outer side evaporates i cooling the liguid refrigerant on the inner side Liguid refrigerant Electronic control valve 4 large SC expansion valve controls the flow 2 Operation when discharge temperature is high When the discharge temperature increases the SC circuit electronic thermostatic expansion valve opens to 480 pulses to cool down the compressor This operation takes priority over operation intended to increase SC It is performed at top priority in all operating modes In addition the valve opening adjustment will be made when the discharge temperature falls SCH l T Liquid refrigerant Liquid refrigerant returns to the accumulator i Does not fully evaporate i resulting in liguid back up Liquid refrigerant sw Electronic control valve 4 opens to 480 pulses 1 18 W 2WAY ECO i SYSTEM 8 Outdoor Fan Control Control Functions 8 1 Fan mode These outdoor units utilize a DC fan motor that can be controlled in a maximum of 16 steps 16 modes However fan modes 15 and 16 can only be used if high static pressure mode has been set For information concerning EEPROM settings refer to the field application functions 8 2 Outdoor Fan Min Fan Mode and Max Fan Mode Min fan mode Max fan mode Outdoor air temp gt 59 F 1 Outdoor air temp 59 F 0 Heating operation 1 14
97. etected due to an error in the installation of the discharge thermistor Discharge sensor failure list Compressor No Compressor 1 Compressor 2 Type Inverter Constant speed Alarm display F04 F05 W 2WAY ECO i SYSTEM Control Functions 14 Current Protection 1 Fan motor Alarm Description P22 Occurs when the fan motor detects over current or when the motor is locked and does not turn 2 Inverter compressor Alarm Description P16 Occurs during ordinary operation when overcurrent 27 A is detected P26 Occurs under the same conditions as P16 when the inverter compressor is operating at or above 80 Hz P29 Occurs when missing phase or overcurrent 48 A is detected at inverter compressor start the alarm at frequencies below 25 Hz H31 Occurs when HIC detects overcurrent 75 A or when an abnormal high temperature 302 F is reached The inverter current includes a primary current and secondary current The alarm judgment utilizes both cur rents Generally the secondary current is larger that the primary current 3 Constant speed compressor An alarm occurs when overcurrent or lock current is detected List of overcurrent and lock currents Outdoor unit Constant speed Overload Lock current type compressor current A A 96 Compressor 2 23 1 27 3 List of Alarms Compressor Compressor 2 No Detected Ov
98. ether or not 200 V is output from the PCB to the magnet SW If the voltage is output there is a PCB failure 3 Installation error CT1 connector is connected to the compressor 2 side CT1 circuit is connected to the compressor 2 side CT2 connector is connected to the compressor 1 side CT2 circuit is connected to the compressor 1 side 4 Electrical noise Correction 1 Replace the CT circuit 2 Replace the magnet SW 3 Replace the PCB If the above probable causes are not the cause of the alarm it is possible that in rare cases the alarm may be caused by the effects of noise See notes The effects of electrical noise are difficult to identify unless a PC is connected and the conditions are monitored for a long period of time W 2WAY ECO i SYSTEM 6 Inspection of Parts Trouble Diagnosis 1 High pressure switch 63PH1 63PH2 e 63PH1 Disconnect the CNO42 connector 3P WHT from the outdoor unit control panel Measure the resis tance between socket pins 1 and 3 The resistance is OK if the result is 0 Q e 63PH2 Disconnect the CNO44 connector 3P RED from the outdoor unit control panel Measure the resis tance between socket pins 1 and 3 The resistance is OK if the result is O O 2 Electronic control valve MOV1 MOV2 MOV4 After removing the connector from the PCB use the following methods to check the valves e MOV1 Measure the voltage between plug pin 5 and pins 1 through 4 at the CNO15 connector 6P WH
99. f indoor units and No of outdoor units settings are made at the other units However making these settings may be convenient for manual backup operation as it eliminates the necessity of making the settings again if unit No 1 fails W 2WAY ECO i SYSTEM 2 Selecting an Outdoor Unit for Operation Control Functions 2 1 Outdoor Unit Operating Rules Because in this system all outdoor units contain an inverter compressor ordinarily there is no absolute order of priority for compressor operation Therefore there is no order of priority for the outdoor units However it is possible to operate the outdoor units in sequence beginning with unit No 1 by using the outdoor unit maintenance remote controller to change the outdoor unit EEPROM settings For information concerning EEPROM settings refer to the field application functions 2 2 Delayed Start of Outdoor Units 1 Delayed start of outdoor units in the same system If it is necessary to operate the compressors simultaneously at multiple outdoor units each outdoor unit will start beginning with unit No 1 after a delay of a number of seconds equivalent to the outdoor unit address The units do not start simultaneously This is in order to reduce the load on the power receiving equipment Outdoor unit gt Outdoor unit address 1 address 2 Starts after 1 second Starts after 2 seconds 2 Delayed start for each system At the
100. f the No 1 unit Then short circuit the stop pin CN104 to stop operation 7 Short circuit the mode change pin CN101 on the outdoor unit control PCB of the No 1 unit Switching of the 4 way valve occurs immediately before operation starts Therefore it does not change at this time Mode change cannot be judged from the sound 8 Short circuit the test run pin CNO23 to start operation leave the unit running for a while Touch the gas tubing with fingers to determine whether the unit is running in cooling W 2WAY ECO i SYSTEM 9 Pumping Out Refrigerant from Outdoor Unit Outdoor Unit Repair Procedures 9 Close the gas tube and balance tube on the outdoor unit to be repaired Then slowly close the liquid tube ser vice valve When the low pressure at the outdoor unit to be repaired reaches 72 5 psi or below pull out the SCT connec tor 2P YEL CN231 from the outdoor unit control PCB of that outdoor unit Then immediately fully close the gas tube valve on that outdoor unit Pulling out the SCT connector immediately stops all of the outdoor units While closing the valves the rise in discharge temperature or another factor may cause a protective device to activate stopping the operation of the outdoor unit If this occurs immediately fully close the gas tube valve on the outdoor unit to be repaired 10 Connect the high pressure gauge side of the manifold gauge to the high pressure outlet port on the outdoor unit
101. g operation can be selected the operating mode of the indoor unit that starts first takes priority The first indoor unit to operate can select any operating mode When any mode other than fan mode is selected then the operating modes that cannot be selected are not displayed on all remote controllers that are subsequently operated Operation change control in progress is displayed indicating that there are restrictions on the operating modes that can be selected Controlling the operating mode from a specific remote controller When there are multiple remote controllers in the same refrigerant system it is possible to set one remote controller as the priority remote controller the remote controller which is given priority for selecting the operating mode If 2 or more remote controllers are set as priority remote controllers an alarm will occur at the remote controllers and operation will not be possible When the priority remote controller is set to the operating mode for control then all other remote controllers can select only the permitted operating mode regardless of whether the priority remote controller is operating or stopped When a controlled remote controller is operated Operation change control in progress is displayed Set mode at priority remote controller Modes that can be selected at other remote controllers Cooling or dry Cooling dry fan Fan Whichever mode heating cooling is selected first The
102. ge valve closed When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrigerant or when charging with the same amount of new refrigerant has not been completed but no more refrigerant will enter the unit fully close the high pressure gauge valve on the manifold gauge Next turn the power OFF at the repaired outdoor unit then remove the short circuit at the AP pin CN102 Finally fully open all valves on the gas tube liquid tube and balance tube However leave the balance tube fully closed if only a single outdoor unit is installed 7 If backup operation was engaged follow the instructions in 4 Backup Operation and perform backup opera tion recovery 8 If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible fully close the high pressure gauge valve on the manifold gauge Then while the unit is operating according to 5 2 1 Cooling operation for all units open the low pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant Nm When charging with liquid refrigerant add refrigerant a little at a time in order to prevent liquid back flow 9 Fully close the low pressure gauge valves on the manifold gauge follow the instructions in 8 Charging Com pressor Oil and charge with the necessary amount of oil Also add an amount of oil that is equivalent to the amount that was drai
103. gerant Has Already Been Charged to Outdoor Unit Be sure to use an exclusive oil charging tank for charging compressor oil Prior to charging carry out vacuum drying inside the tank and take care that no air in the form of bubbles is permitted to enter the tank The oil charging procedures are given below The receiver tank used for maintenance may be used as an exclusive oil charging tank When installing the oil charging tank to the refrigerant system to Serve as a safety bypass circuit for refrigerant connect it to the gas DPR 623 081 7937 tube service port carefully to Nipple avoid releasing refrigerant into the atmosphere P Receiver tank Perform oil charging 638 015 2988 work carefully so that no liquid refrigerant enters Packless valve BS the charging tank Fig 14 1 Evacuation drying in oil charging tank With the lower side valve fully closed open the upper side valve and connect it to the vacuum pump via the manifold gauge valves as shown below Run the vacuum pump and evacuate the tank until the pressure falls to below 14 7 psig 5 Torr for the evacuation drying After the evacuation drying is finished fully close the upper valve Next fully close the manifold gauge valves and stop the vacuum pump To ensure proper evacuation refer to the operating instructions that came with the vacuum pump Manifold te gange Hi Upper side valve Lower side valve Vac
104. gether They cannot be operated individually Ventilation fan operation from remote controller This setting is used to switch from the body sensor to the remote controller sensor Check that remote controller sensor is displayed Do not use this setting with models that do not include a remote controller sensor Do not use this setting if both the body sensor and remote sensor are used Switching to remote controller sensor In a MULTI system with multiple remote controllers switching between heating and cooling is restricted and Operation change control in progress is displayed This setting is used to prevent this display from appearing Refer to the item concerned with operating mode priorities ON OFF of Operation change control in progress display This setting switches the operation when the weekly timer is connected to the remote controller This can be used to prevent cases in which the unit is accidentally left ON There is no change when this setting is ON however it is necessary to set the weekly timer ON time OFF reminder function for weekly Continued W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions Continued from previous page Item Description Heat exchanger temperature for The heat exchanger temperature control point for prevention of cold air cold air discharge discharge during heating operation can be changed The indoor unit PCB optional ou
105. h section in the Installation Instructions on refrigerant charging leak checking and evacuation procedures 5 2 1 Cooling operation for all units 1 If the remote controller RCS TM80BG is used for maintenance of the outdoor unit Connect the outdoor unit maintenance remote controller to the RC connector CNOO06 3P BLU on any one of the outdoor unit control PCBs Then start a test run of all units Press and hold the CHECK button for 4 seconds or longer Press the MODE button and change to cooling operation and ensure that the cooling is performed Refer to the test run service manual for the detail of the outdoor maintenance remote controller operation It may be possible to determine whether operation is cooling or heating by touching the gas tubing Cooling low temperature 68 F or lower Heating high temperature 140 F or higher CAUTION The gas tubing becomes hot 140 F or higher in heating mode Be careful so as not to be burnt when touching the tubing 2 10 W 2WAY ECO i SYSTEM 5 Recoveri ng Refrigerant Outdoor Unit Repair Procedures 2 If the remote controller RCS TM80BG is not available for maintenance of the outdoor unit D Determine the outdoor unit where the unit No setting S007 3P DIP switch Blue on the outdoor unit control PCB is set to No 1 2 Short circuit the test run pin CNO23 on the PCB to start test run operation 3 Leave the unit running for a while and touch the ga
106. h to release valve Perform the connection work quickly so that no air is allowed to enter Fig 20 Connecting the refrigerant recovery cylinder is done to prevent pressure from rising excessively during the backup operation by recovering the refrigerant from the outdoor unit to be repaired Measure the weight of the refrigerant and cylinder itself beforehand and provide sufficient safety measures such as installing a high pressure cutout in the circuit The hoses may be subject to internal pressure from the refrigerant inside the out door unit Check that the manifold gauge valves are fully closed beforehand A Schrader type push to release valve is provided at each connection port 3 Determine the outdoor unit where the unit No setting S007 3P DIP switch BLU on the outdoor unit control PCB is set to No 1 4 Short circuit the test run pin CNO23 to start operation b Leave the unit running for a while and then touch the gas tubing with fingers to determine whether the unit is running in cooling or heating mode If it is in heating follow the step 6 and later procedures Cooling low temperature 68 F or lower Heating high temperature 140 F or higher The gas tubing becomes hot 140 F or higher in heating mode Be careful so as caution not to be burnt when touching the tubing 6 When the unit is operating in heating mode release the short circuit at the test run pin on the outdoor unit con trol PCB o
107. hat are operating in Cooling Mode if one unit is selected for a test run mode the room temper ature control by the set temperature cannot be performed Areas B and C are assumed to be area A for control purposes instead By this reason the compressor continues its operation regardless of the low evaporation temperature This is used for additional charging of refrigerant test run checking etc Vapor may be discharged if the test run continues for a long time However this does not indicate problems 2 Even within the same area the compressor capacity varies depending on the refrigerant temperature 3 For 6 minutes after the compressors start area C is considered to be area B for control purposes 4 During special control control of the compressor capacity according to Te is not performed 5 If the thermostat turns OFF while Te is within area C the next time the compressor starts it may restart from a lower capacity 6 When the area changes to area C area C is considered to be area B for control purposes for the first 6 min utes even if the horsepower is the minimum value within the range where capacity control is possible opera tion with inverter frequency of 25 Hz only Subsequently if C area continues the thermostat turns OFF W 2WAY ECO i SYSTEM 3 Compressor Control Control Functions 3 6 2 Condensation Temperature Tc Control Control of Indoor Units Operating either in Cooling Mode or Heating Mode PX 125 6 F T
108. he inverter may stabilize at a frequency lower than those stated above For information about Quiet mode refer to the field application functions f the Power Demand Mode is selected the inverter may stabilize at a frequency lower than those stated above Refer to the Field Application Function for the detail 3 5 Forced Compressor Stop Once a compressor stops it will not start for a period of 3 minutes 3 minute forced OFF However this does not apply when the compressor was forced to stop as the result of a control operation during the special controls start control defrost control refrigerant oil recovery control etc which are described later 3 6 Roadmap Control 1 The below mentioned Roadmap Control are performed according to the pressure sensor on the outdoor unit and the 2 temperature sensors attached to the indoor unit heat exchanger coil With the roadmap control in heating mode the pressure detected by the pressure sensor at high pressure side is converted to the saturation temperature This converted saturation temperature is called the High Pressure Saturated Temperature 2 This control is performed every 15 seconds 3 The evaporation temperature control and the temperature used to determine the area A AB B C for the con densation control shown in the figure on the next page may vary depending on the relationships among factors including the difference between the room temperature setting and the ai
109. he sound of refrigerant flowing into an outdoor unit that was stopped for a long time When an outdoor unit starts after being stopped for a long time the start is accompanied by much vibration Check e Representative parts include the liquid capillaries secondary side of capillaries will be cool during cooling operation mechanical valve mechanical valve bypass check valve sound of refrigerant flow can be heard and stops when the liquid valve is closed hot gas defrost valve if valve secondary side remains hot even after much time has passed be careful not to mistake transmitted heat for a valve failure ce is growing on the lower parts of some outdoor unit heat exchangers but not on others Because this trouble may occur even in outdoor units with a high operating rate under conditions of insufficient gas caution is needed 6 Sensor failure Check e This alarm is likely to occur when wiring is partially cut It is difficult to identify even when continuity is checked The detected discharge temperature is high Although such conditions rarely occur a PO2 alarm is likely if the detected discharge temperature is low Replace the sensor with another discharge sensor and compare the temperature conditions 7 If the cause is still unknown after checking the above then it is possible that electrical noise is the cause of the trouble Correction 1 Replace the sensor 2 Replace the outdoor unit PCB 3 Correct the pr
110. hermostat OFF Area D PX 0 1 Horsepower decrease Area C 118 Sa EE 118 4 Horsepower increase gt prohibited Area B 116 6 116 4 Horsepower increase Area AB 109 4 113 0 Permitted 112 8 Horsepower increase Area A 100 4 107 6 permitted 98 6 Depending on the maximum requirement level I of the indoor unit the judgment temperatures 0 La 30 for each area may vary as shown in the figure Maximum requirement level L example 1 For indoor units which are operating in Heating mode if one unit is selected for a test run the air intake tem perature difference is ignored however Tc control is performed according to the figure above in order to pre vent excessive load This is used for test run checks etc 2 Even within the same area the compressor capacity varies depending on the refrigerant temperature 3 Temperature PX is the coefficient value used to correct for any deviation with the high pressure or condensa tion temperature It may vary At the time of shipment it is 127 F 4 If the condensation temperature Tc enters area D and the thermostat turns OFF the next time the compressor starts it may restart from a lower capacity 3 6 3 Protection control Protection control consists of 2 types of protection discharge temperature protection and current protection The limit values from this protection control are incorporated into the output compressor cap
111. ill uncertain check the following to determine whether a sensor or PCB failure has occurred Step 1 Connect the other compressor discharge sensor or a discharge sensor where the F04 alarm has not occurred to the connector for this compressor on the PCB Measure the temperature at the same point a location where temperature fluctuations are small and check whether there is a temperature difference Difference A PCB or sensor failure is possible No difference gt PCB and sensor are normal If an abnormality was found at Step 1 connect the problem compressor sensor to the other compressor connector on the PCB or to the PCB connector of a device where the F04 alarm has not occurred Measure the temperature at the same point a location where temperature fluctuations are small and check whether there is a temperature difference Difference Sensor failure No difference gt PCB failure yw It is convenient at this time to have a discharge temperature sensor on hand 2 Crossed wiring or installation error Trouble Although the other compressor is operating and this compressor is stopped the discharge temperature of the other compressor does not increase and the discharge temperature of this compressor rises The discharge temperature remains high immediately after the compressor stops Wait for some time after the compressor stops and observe Check for crossed wiring and installation errors Continued W 2WAY ECO i SYSTEM 4 W 2
112. ilure 6 Accumulation of refrigerant at stopped outdoor units 7 Compressor discharge sensor failure 8 PCB failure A D conversion failure 9 Electrical noise 1 Clogging of capillaries Trouble Compressor discharge temperature does not decrease even when the liquid valve is ON Check When the liquid valve is operating and the liquid valve is ON check that the secondary side of the liquid capillaries is cold 2 Insufficient refrigerant Trouble Liquid effectiveness is poor Check Check whether or not the superheating temperature is declining if the evaporator mechanical valve is opened to 300 pulses or more after checking for foreign object intrusion 3 Foreign object intrusion Trouble Liquid valve effectiveness is poor Check Check that there is no difference in the condensation or frost conditions between the strainer primary side and secondary side tubing 4 Crossed thermistor Trouble The discharge temperature of the other compressor is high although only this compressor is operating When the liquid valve turns ON the discharge temperature of the other compressor decreases 5 Accumulation of refrigerant in stopped outdoor units Trouble e System is OK when all outdoor units are operating however symptoms of insufficient gas occur when a certain outdoor unit is stopped Condensation or frost is visible up to the top of the accumulator of the stopped outdoor unit After an outdoor unit stops there is t
113. ion with ER forced thermostat Press and hold the button ON for 4 seconds or longer Sensor Temperature Press and hold the and temperature display from each EN buttons for 4 seconds or Current operation is display sensor anget maintained Press and hold the and Servicing check Alarm history i display display bei buttons for 4 seconds or Press the onger i Unit status Functions Test run Filter life time button operating mode Press and hold the and Simple settings E Ge E buttons for 4 seconds or When settings are made Se Ser Ge longer from a remote controller 9 the indoor unit where that System address i CAN remote controller is indoor unit address Press and hold the A connected stops Detailed settings central control and SET buttons for 4 seconds i address and other mE settings Automatic address setting based on Press and hold the and command from the timer operation 4 buttons Automatic reset EENEG for 4 seconds or longer controller Entire system stops P hold the 2 i ress and hold the and Preshi or longer Automatic address Change of indoor Address change nit address the timer operation Le buttons for 4 seconds or longer button W 2WAY ECO i SYSTEM 3 Remote Controller Servicing Functions Remote Controller Functions Test Run Function Operates the unit with the thermostat forced ON Procedure
114. iption Description 1 Way Air Discharge 4 Way Air Discharge Mini Slim Concealed Duct 9999 Semi Concealed A Sech Semi Concealed X XM 9095 U UM Concealed Duct High T Static Pressure D 0007 Ceiling Mounted T 0008 Wall mounted K Concealed Floor 0010 Wall mounted F 0011 Standing FM iJ 0001 22 Type 7 0003 28 Type 9 0005 36 Type 12 5 71 Type 24 For 0007 45 Type 15 0009 56 Type 18 19 0011 Indoor unit FHX2462 and FMHX2462 capacity 80 Type 24 0012 Except FHX2462 0015 112 Type 36 0017 140 Type 48 FMHX2462 ed se 1 0001 Unit No 1 0002 Unit No 2 0003 Unit No 3 0030 Unit No 30 0099 Not set 0001 Unit No 1 0002 Unit No 2 0003 Unit No 3 address d H 0064 Unit No 64 0099 Not set 0000 Individual 1 1 Indoor unit with no group wiring Group control Main unit One of the group control indoor units address 0002 Sub unit All group control indoor units except for main unit 0099 Not set Shifts intake temperature by 20 F 009 Shifts intake temperature by 18 F Cooling Shifts intake temperature by 2 F Seain 0000 No intake temperature shift 0001 Shifts intake temperature by 2 F 0009 Shifts intake temperature by 18 F 0010 Shifts intake temperature by 20 F Automatic 0000 Function disabled stop time 0001 Stops automatically 5 minutes after operation starts en operation 0002 Stops automatically 10 minutes after operation star
115. is not disconnected Check the continuity of the CT circuit Install a normal CT in place of this CT and check If current is detected then the PCB can be judged OK CT circuit failure Check that current is flowing in the phase where the CT circuit is connected gt Check voltage and current 2 Crossed wiring or installation error Trouble When the compressor is stopped the current value at the other compressor is high When this type of condition occurs seizing detection control takes priority 3 If the cause is still unknown after checking the above then it is possible that noise is the cause of the trouble It is necessary to connect a PC or other instrument Correction 1 Replace the CT circuit 2 Replace the outdoor unit PCB d Correct the problem 1 The connector was not inserted after the PCB wasreplaced IE EE chee Ze Use a normal CT as a tool to determine whether the trouble is a PCB failure or CT failure H15 Alarm Alarm code Alarm meaning ERREUR 1 discharge temperature sensor disconnected Compressor 2 discharge temperature sensor disconnected Alarm conditions This alarm occurs when the discharge sensor temperature detector is not inserted into the tube s sensor holder or when the sensor itself has suffered some kind of malfunction other than a cut wire When outdoor air temperature is 50 F or higher Alarm occurs if the temperature detected by the discharge sensor has changed by less
116. ition as it was before Be sure to check for looseness of the power terminal connection at the compressor Jare terminal plate and to check by pulling vertically on the connections If the termi nals become disconnected easily replace the wiring Assy 13 Follow the instructions in 7 Evacuating System and apply vacuum to the outdoor unit where the compres sor was replaced Brazed locations 2 LA LIEU fi T 4 E CH Wes Ki AIR ld iv Cushioning rubber Temporary fastening Crankcase Cushioning rubber Bolt bolts 2 inner legs heater Inner 1 leg Washer 1 Rubber washer 1 Fig 23 Fig 24 W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures B Replacing the constant speed compressor 1 Compressor 2 on remote controller alarm display E Removal 1 Connect the manifold gauge to the high and low pressure outlet ports at the outdoor unit where the compres sor will be replaced Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement 2 Follow the instructions in 1 Removing Panels and 2 Removing Electrical Component Box and Duct and remove the corresponding parts from the outdoor unit where the compressor will be replaced Remove the cap at the compressor terminal plate Disconnect the power terminal Remove the crankcase heater as Remove the bolts 3 locations washers and spacers 1 each at the 3 locations shown
117. itioning system meets strict safety and operat ing standards As the installer or service person it is 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 e Carefully read this instruction booklet before beginning e Follow each installation or repair step exactly as shown e Observe all local state and national electrical codes e Pay close attention to all warning and caution notices given in this manual a AN If Necessary Get Help These instructions are all you need for most installation sites and maintenance conditions If you require help for a special problem contact our sales service outlet or your certified dealer for additional instructions This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death This symbol refers to a hazard or unsafe practice which can result in personal injury or product or property damage In Case of Improper Installation The manufacturer shall in no way be responsible for improper installation or maintenance service including fail ure to follow the instructions in this document 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 com
118. its Press and hold the CHECK button for 4 seconds or longer 4 Use the outdoor unit maintenance remote controller to check the operating status of the indoor units Check that all units are operating in Heating mode For details concerning operation of the outdoor unit maintenance remote controller refer to the Outdoor unit maintenance remote controller item It is also possible to check the operating conditions either in cooling or heating mode by touching the gas tube Cooling mode low temperature 68 F or lower Heating mode high temperature 140 F or higher The gas tubing becomes hot 140 F or higher in heating Be careful so as not to be burnt when touching the tubing b Close the suction tube and balance tube on the outdoor unit to be repaired Then slowly close the liquid tube service valve 6 When the low pressure at the outdoor unit to be repaired reaches 72 5 psi or below press the ON OFF button on the outdoor unit maintenance remote controller to stop all the units Then immediately fully close the gas tube valve on that outdoor unit While closing the valves the rise in discharge temperature or another factor may cause a protective device to activate stopping the operation of the outdoor unit If this occurs immediately fully close the gas tube valve on the outdoor unit to be repaired 7 Connect the high pressure gauge side of the manifold gauge to the high pressure outlet port on the outdoor unit
119. limit 24 Lower limit setting range temperature setting is to be a single point set the upper limit and lower limit to the same temperature 25 Upper limit 26 Lower limit Auto heat cool During heating operation the humidifier operates when the heat Humidifier operation which ignores exchanger temperature is suitable for humidifying This setting is the heat exchanger temperature used to ignore this condition for humidifier operation and operate the humidifier more a Filter input switching This setting switches the filter input according to the purpose of use This setting indicates whether or not an indoor unit electronic control valve is present At the time of shipping this setting is set according to the conditions of the indoor unit Indoor unit electronic control valve Ordinarily the T10 terminal is used as the HA terminal at the time of T10 terminal input switching shipping However this setting is used when the T10 terminal is used for OFF reminder or for fire prevention input It is possible to install a total heat exchanger and ventilation fan in the system which can be started and stopped by the wired remote controller The ventilation fan can operate linked with the start and stop of the indoor unit or can be operated even when the indoor unit is stopped Use a ventilation fan that can accept the no voltage A contact as the external input signal In the case of group control the fans are operated to
120. midifier output ON Drain pump stopped Flatvasatatian moda 0000 Standard setting Pop 0001 Draft reduction mode Flap lower limit position is shifted upwards 0000 Smudging reduction mode Flap swing upper limit position is shifted downwards Flap swing mode 0001 Normal mode 0002 Draft reduction mode Flap swing lower limit position is upwards W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions Setting data em code Een mode 0000 Standard setting at shipment High ceiling use High ceiling setting 1 with standard panel 0001 For low Ultra long life filter oil guard panel ammonia deodorizing Fan tap setting static pressure filter filter optical regenerative deodorizing filter Fan tap change in order High ceiling use High ceiling setting 2 with standard panel to prevent drop in air Antibacterial high performance filter 9096 discharge caused by For low Antibacterial high performance filter 6596 filter installation static pressure filter Air cleaning unit air cleaning unit optical regenerative deodorizing filter deodorant activated charcoal filter For air blocking i material For 3 way discharge when discharge duct is connected For air blocking 0006 material For 2 way discharge 0000 No humidifier output 0001 Humidifier ON time 0002 oe 0058 0059 0060 Continuously ON Function disabled Function enabled Function disabled prohibit Function enabled
121. mpressor oil color phase is 4 0 or higher or where a sharp odor is NO present Y YES Y Go to 10 2 3 Replacing all Go to 10 2 2 Replacing all Go to 10 2 1 Replacing only the compressors in a system compressors in a failed unit failed compressor Follow the instructions in 10 2 4 Dry Follow the instructions in core cleaning and perform dry core 10 2 4 Dry core cleaning and cleaning of all outdoor units perform dry core cleaning of the failed outdoor unit Reference Symptoms of motor burning 1 Ground fault results in breaker operation 2 Short circuit results in different coil resistance at different phases 3 Open circuit W 2WAY ECO i SYSTEM 10 Compres sor Outdoor Unit Repair Procedures 10 2 Replacing the Compressor s 10 2 1 Replacing only the failed compressor 9 If backup operation is required follow the instructions in 4 Backup Operation and engage backup operation Follow the instructions in 10 3 Removing and Installing Compressors and replace the failed compressor Fully close the high and low pressure gauge valves on the manifold gauge then stop the vacuum pump Disconnect the manifold gauge from vacuum pump Connect the manifold gauge to the cylinder where the refrigerant was recovered At this time be careful that air does not enter the tubing Open the valve on the refrigerant recovery cylinder and the high pressure gauge valve on the manifold gauge t
122. n outdoor unit heat exchanger EXG 1 EXG 2 EXL 1 or EXL 2 was 40 F or more above the outdoor air temperature Air Temp continuously for 5 minutes or longer or the detected suction temperature SCT was 40 F or more above the outdoor air temperature continuously for 5 minutes or longer 1 The 4 way valve connector 20S CN060 has become disconnected from the control PCB 2 The 4 way valve circuit is locked malfunctioning 1 Check the 4 way valve connector 20S CNO60 2 If the connector is normal check the 4 way valve wiring and the PCB circuit Example J gt O Notes d gt o O W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis P03 P17 Alarm Alarm code P03 P17 Alarm meaning Compressor 1 discharge temperature trouble Compressor 2 discharge temperature trouble Alarm conditions Temperature is 222 F or higher and pre trip stop has occurred The alarm occurs when pre trip stop occurs more than once However the pre trip counter is cleared if the compressor operates continuously for a specified length of time Probable cause 1 Clogging of liquid valve capillaries 2 Insufficient amount of refrigerant including trouble resulting from an insufficient initial charge and from gas leakage 3 Blocking of low pressure parts caused by intrusion of foreign objects moisture scale etc 4 Crossing tubing or PCB connectors with the other compressor thermistor 5 Expansion valve operation fa
123. nctions mr LILI SET DATA XX U Uo Sum RCS TM80BG Display shows a discharge temperature of OOXX at unit No 1 1 In case for example the display shows 0185 in the figure above a discharge temperature from the outdoor unit stands for 185 F Fig 4 The temperature display appears as for units that are not connected If monitor mode is engaged while normal operation is in progress only the parts of the LCD display shown in the figure will change Other parts continue to display the same information as during normal operation W 2WAY ECO i SYSTEM 3 Remote Controller Servicing Functions GEE CBO E 02 Intake temp Discharge temp Discharge temp setting Position of indoor unit electronic control valve SS KS MCN UnNoi UntNog 12 o8 28 Dsmagetmpa op 2D Hexexagegasi 12 3 y y Ex eee ee 18 38 39 Foimsedon a Forinspection 3 Ress Nan cR NM NES xe i I 3D Lowpressuesenortmp pee W 2WAY ECO i SYSTEM Contents Trouble Diagnosis DH Sr SE AU e Pe 5 TROUBLE DIAGNOSIS Contents of Remote Controller Switch Alarm Display 5 2 Outdoor Unit Control Panel LED Display leeren 5 4 Remote Controller Servicing Functions 00 0 eee ee eee eee 5 5 W 2WAY ECO i Alarm Codes
124. ned from the oil separator 10 Remove the manifold gauge The connecting port employs a Schrader type push to release valve When discon necting the hose pressure will be applied from the refrigerant in the outdoor unit 11 Follow the instructions in 10 2 4 Dry core cleaning and perform dry core cleaning of the outdoor unit that failed W 2WAY ECO i SYSTEM 10 Compres sor Outdoor Unit Repair Procedures 10 2 3 Replacing all compressors in a system 1 Follow the instructions in 3 Discharging Compressor Oil and drain the oil from the oil separators in all out door units Measure the amount of drained oil 2 Follow the instructions in 10 3 Removing and Installing Compressors and replace all compressors in the system 3 Follow the instructions in 6 Checking for Leakage After Repair and check for leaks at all outdoor units and in the tubing 4 Follow the instructions in 7 Evacuating System and apply vacuum to all outdoor units and tubing Ei Fully close the high and low pressure gauge valves on the manifold gauge then stop the vacuum pump Disconnect the manifold gauge from vacuum pump Connect the manifold gauge to the refrigerant cylinder Be especially careful that air does not enter the tubing Jare Do not reuse the recovered refrigerant Use a refrigerant cylinder that contains un used refrigerant 7 Open the valve on the refrigerant cylinder and open the high pressur
125. nee Je Automatic address setting alarm too many units e The number of indoor units was too many when automatic address setting was performed After initial communications were completed an unrecognized unit was detected Probable cause 1 The number of indoor units set at the indoor unit quantity setting SW S004 S005 on the outdoor unit PCB is less than the number set 2 The inter unit control wiring is wired incorrectly Check 1 Refer to the test run servicing materials and check the number of indoor units that is set e 2 Check the inter unit control wiring at the indoor and outdoor units Correction After correcting the indoor unit quantity setting or the inter unit control wiring perform automatic p address setting again E20 Alarm Mamexe Je 0000000 No indoor units at automatic address setting Probable cause 1 The inter unit control wiring from the outdoor unit to the indoor units has been cut 2 Serial connector 1 CNO001 is disconnected at the outdoor unit 3 The power is OFF at all indoor units in the system 1 Check whether the inter unit control wiring from the outdoor unit to the indoor units is cut Check whether serial connector 1 CNO01 is disconnected at the outdoor unit Check the power at the indoor units Reconnect the inter unit control wire from the outdoor unit to the indoor unit Example fe E24 Alarm Alarm code Outdoor unit INV failed to receive communications from oth
126. not necessary to recover the refrigerant from the balance tube Therefore do not operate the balance tube valve Turn off power to all equipment in the system Then pull out the RC1 connector 4P BLU CN106 on the out door control PCB in the outdoor unit for which pump down has been completed By pulling out the RC1 connector communication between the main and the sub outdoor units will be isolated Change the setting of controllable outdoor unit numbers reduce by 1 unit If the setting is incorrect the E30 alarm outdoor unit serial communication signal error occurs and the unit will not operate Turn on power for all equipment in the system and let the remaining outdoor units run in Cooling mode Repeat steps 1 and 2 and complete pump down for all outdoor units Using hoses with Schrader type push to release valves connect the manifold gauge valves to the suction line service port the discharge line service port and the liquid line service port in the next outdoor unit to undergo pump down Fig 11 Remaining refrigerant in the system may cause internal pressure Check that each Jare valve on the manifold gauge is tightly closed A Schrader type push to release valve is provided for each connection port 9 Use hoses to connect the manifold gauge valves refrigerant recovery unit and refrigerant recovery cylinder Quickly connect each part to prevent air from entering the tubing Recover remaining refriger
127. nt in the heat exchanger is discharged The representative valves to check are the liquid valves and mechanical valves 3 Outdoor unit PCB failure The check items are the same as for a high pressure sensor malfunction A normal PCB is needed to determine whether the problem is a PCB failure or a pressure sensor malfunction If an abnormality was found at the check items for a high pressure sensor malfunction first try replacing the PCB and check again Trouble is corrected Outdoor unit PCB failure Trouble is not corrected High pressure sensor malfunction Continued W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis Correction 1 Replace the high pressure sensor Caution Because the high pressure sensor connection employs a Schrader type valve it can be removed and replaced However the high pressure sensor can be easily damaged by high voltage therefore use sufficient caution with regard to static electricity 2 Replace the PCB 3 Correct the locations of problems in the refrigeration cycle Correct locations where clogging or leakage has occurred In the case of over charging recover refrigerant Adjust the amount of refrigerant Guide for over charging Be sure to connect the gauge to the high pressure outlet when checking for over charging During cooling The following does not apply when outdoor air temperature is low or when fan speed is controlled When both compressor 1 and compresso
128. nues to run and rest of the other outdoor units may be stopped W 2WAY ECO i SYSTEM 3 Compressor Control Control Functions 3 1 Compressors Mounted in the Outdoor Units CHDX07263 CHDX09663 Capacity 72 96 Installed Compressor 1 Rotary DC Inverter DC Inverter compressor Compressor2 Scroll 5hp hp horsepower Constant INV speed INV Compressor 1 Type 72 Compressor 2 Compressor 1 Type 96 3 2 Compressor Selection Rules In cooling mode all inverter compressors in the outdoor units are designed to operate simultaneously All the inverter compressors will stop at a time when the outdoor is stopped accordingly Constant speed compressors run in order of the shortest amount of operating time In heating mode the inverter compressor with the shortest amount of operating time runs at first followed by the compressors in order of the shortest amount of operating time including inverter units Immediately after installation all compressors have an operating time of zero In this case the compressors start in the following sequence Inverter compressor Constant speed compressor 1 Constant speed com pressor 2 Examples of accumulated operating time ODU Outdoor Unit Suppose the following tentative system ODU 1 ODU 2 Comp 1 100 hrs 70 hrs Comp 2 150 hrs 160 hrs ddd Compressor Selection Sequence in Cooling
129. o charge with refrigerant At this time the low pressure gauge valve on the manifold gauge remains fully closed If the recovered refrigerant becomes mixed with another refrigerant or another gas N sss such as nitrogen or air do not use the recovered refrigerant for charging Charge with the designated amount of new refrigerant When charging has been completed with an amount of new refrigerant equal to the amount of recovered refrigerant or when charging with the same amount of new refrigerant has not been completed but no more refrigerant will enter the unit fully close the high pressure gauge valve on the manifold gauge Next turn the power OFF at the repaired outdoor unit then remove the short circuit at the AP pin CN102 Finally fully open all valves on the gas tube liquid tube and balance tube However leave the balance tube fully closed if only a single outdoor unit is installed If backup operation was engaged follow the instructions in 4 Backup Operation and perform backup opera tion recovery If charging with an amount of new refrigerant equal to the amount of recovered refrigerant was not possible fully close the high pressure gauge valve on the manifold gauge Then while the unit is operating in 5 2 1 Cooling operation for all units open the low pressure gauge valve on the manifold gauge and charge with the designated amount of refrigerant Nm When charging with liquid refrigerant add refrigerant a li
130. oblem locations All of the probable causes Notes Operates continuously for a set length of time Indicates 2 5 minutes or longer for an inverter unit and 30 seconds or longer for a constant speed compressor W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis P04 Alarm Alarmcode POM Alarm meaning Alarm conditions The operation of the electronic circuit in the high pressure switch may short circuit the terminal depending on the pressure A pressure of 478 6 psi or above will short circuit the terminal Once the terminal is short circuited it will remain in that state until the pressure goes below 377 1 psi Probable cause 1 Failure of the check valve in the compressor discharge tube 2 The service valve is closed 3 Clogging of the outdoor heat exchanger during cooling 4 An air short in the outdoor unit during cooling 5b Failure of the outdoor fan during cooling 6 Clogging of the air filter in the indoor unit during heating 7 An air short in the indoor unit during heating 8 Failure of the indoor fan during heating 9 Clogging of the refrigerant circuit 10 Failure of the mechanical valve 11 Failure of the solenoid valve kit 12 Too much refrigerant has been charged 13 Failure of the high pressure switch Make sure that the high pressure switch connector has been properly connected If the high pressure switch is properly connected connect a high pressure gauge to th
131. oil sensor E1 E3 Indoor Heat Exchanger temperature sensor E1 E3 40 8 35 7 G 30 6 x lei x 8a gt 5 8 2 D 20 S 4 2 tc 15 o 3 c 10 2 5 E 1 0 0 20 15 10 5 0 5 10 15 20 20 30 40 50 60 Temperature C Temperature C W 2WAY ECO i SYSTEM 8 Thermister Characteristics Curve Trouble Diagnosis 8 3 Outdoor temp sensor Compressor suction gas temp sensor Outdoor heat exch coil sensor C1 C2 Outdoor temperature Suction gas temperature TS sensor Heat exchanger temperature Heat exchanger temperature sensor 40 35 30 N 25 Resistance kQ Resistance kQ O N WO A A OD 20 15 10 5 0 5 10 15 20 20 30 40 50 60 SE Temperature C Temperature C 8 4 Compressor discharge gas temp sensor Discharge gas temp sensor 7 6 OQ 5 x 9 9AA a 15 3 jag 2 1 80 90 100 110 125 130 Temperature C For Parts or Service Assistance please contact your local Sanyo HVAC Contractor or Distributor United States SCS HVAC Solutions Canada Sanyo Canada Inc Web www SanyoHVAC com Web www SanyoHVAC com Parts hvac parts 0 sna sanyo com Parts
132. oisture enters the refrigerant circuit it can freeze at the low pressure locations and the resulting ice can block the circuit vy If the alarm occurs when there is sufficient refrigerant in the system 1 and 3 liquid refrigerant has definitely accumulated somewhere in the system Liquid refrigerant generally accumulates in high pressure locations In this case the high pressure gradually increases however it may not increase if the location where the liquid accumulates is sufficiently large Depending on the refrigerant saturation temperature it may also accumulate in low pressure locations In this case the high pressure is unlikely to increase 1 Check that the service valve is open 2 Check that none of the valves solenoid valves mechanical valves in the main refrigerant circuit is closed due to an operation failure 3 Check that there is no possibility of foreign objects or water having entered the refrigerant circuit 4 Check that valve leakage at a stopped sub unit has not resulted in accumulation of refrigerant at that sub unit 5 Check that no refrigerant leakage has occurred Correction 1 If there was a valve operation failure in general it is necessary to replace the valve 2 If a foreign object or moisture has entered the circuit install a strainer or dry core depending on the degree of the problem 3 If refrigerant has leaked into stopped sub units it is likely that valve leakage has occurred The val
133. onds 3 All times other than the above e H the low pressure SW has not activated the threshold for the detected current is 7A or more continuing for 5 seconds e If the low pressure switch has activated the threshold for the detected current is 7A or more continuing for 2 seconds Probable cause 1 Magnet SW malfunction The magnet SW has seized and the compressor is continuing to run gt Even when the power is turned OFF the primary side and secondary side contacts remain together The conditions of magnet SW operation are poor difficult to open gt When a magnet SW is used in a DC circuit it may be difficult for the SW to open at times In an AC circuit the magnet SW should open instantaneously as long as the current is within the allowable range However this kind of trouble can occur if excessive current flows and may prevent the SW from opening 2 CT circuit failure or PCB failure A D failure CT circuit contact failure Check that the connector is not partially disconnected Wiggle the connector to check the connection These symptoms will not occur if the connector is completely disconnected or the wire is cut In these cases alarm Hx3 occurs Current of 7A or higher was detected although the compressor was stopped or a higher current was detected at occasional intervals The compressor continues to operate at a time when the outdoor unit should be stopped such as when all indoor units are stopped Check wh
134. ons Defrost ends when either of the below defrost end judgment conditions is met Condition 1 The temperatures are 50 F or higher at all temperatures sensors installed on the outdoor unit heat exchanger coils However if there is any other outdoor unit where the defrost end condition has not been met defrost control continues for all outdoor units and system defrost control is not ended Condition 2 The maximum defrost time listed in the table above has elapsed 4 3 8 System defrost end When all outdoor units where defrost control is in effect have met the defrost end conditions defrost control is ended for the system 1 13 W 2WAY ECO i SYSTEM 5 Other Controls Control Functions 5 1 Oil Control 5 1 1 Oil level Cil level Meaning Conditions of oil Judgement The compressor contains oil more than There is no problem 2 Sufficient the oil level which is necessary and sufficient for normal operation The compressor contains sufficient oil Confirm that oil is returned after 1 Slightly low but there is a possibility of shortage performing the oil control operation against the required oil level The compressor oil is short against Confirm that oil level is recovered to the 0 Extremely low the required oil level sufficient for normal required level after performing the oil operation recovery control between systems At the time immediately after the oil level changes from 2 to 1 there i
135. oor unit Remote Remote controller controller e The special service checker wiring is reguired in order to connect the outdoor unit maintenance remote controller to the outdoor unit PCB e Ordinary remote controllers or other controller are still reguired for the indoor units even when the outdoor unit maintenance remote controller is connected W 2WAY ECO i SYSTEM 2 Functions Outdoor Unit Maintenance Remote Controller E Functions on the ordinary display 1 Functions Button operations can be used to perform the following functions e Start stop of all indoor units Switching between cooling and heating Test run of all indoor units Double speed operation of indoor units Do not use for actual operation Doing so may damage the devices 2 Display The following can be displayed Alarm details display No of indoor outdoor units Unit Nos of connected indoor outdoor units e Indoor outdoor unit operating status blinks when an alarm occurs Indoor unit thermostat ON Display of individual outdoor unit alarms Total operating time of outdoor unit compressors Oil level of the outdoor unit oil sensor Total outdoor unit power ON time Outdoor unit microcomputer version other information B Temperature monitor Displays the indoor outdoor unit sensor temperatures Bi Outdoor unit alarm history monitor Displays the outdoor unit alarm history B Mode settings e Setting mode 1 and setting mod
136. operation Wi c3 E3 The display indicates the operating mode of the indoor unit with the lowest unit No All units test run Fig 2 Operation The CHECK button can be used to start and stop a test run for all indoor units Press and hold for 4 seconds to turn ON During the test run TEST is displayed The status of test runs performed from the indoor unit remote controller is not displayed on the outdoor unit maintenance remote controller Double speed Do not use for actual operation Doing so may damage the devices Operation c The timer button 4 can be used to change between double speed and normal operation During double speed operation the SLEEPING MODE Pd mark is displayed PI cS Ea d GE W 2WAY ECO i SYSTEM 3 Ordinary Display Controls and Functions Outdoor Unit Maintenance Remote Controller B Display functions e Use the temperature setting C zs and _ _ buttons to change the item code ttemcode ftom CC iii HG Outdoor unit alarm Alarm code display No of connected indoor units Quantity Unit Nos of connected indoor unit 7 segment display E E r1 rua Lu Operating status of indoor unit 7 segment display D E Ga c DI a TI bet un s I x 4 iB L L
137. or units No particular changes 2 Adjusting the refrigerant for backup operation During backup operation all of the service valves on the failed unit are closed However if a check of the backup operating conditions shows that the level of gas is low recover the refrigerant from the failed outdoor unit If the level of gas is too high collect refrigerant at the failed outdoor unit e Recovering refrigerant With the normal outdoor units operating monitor the operating condition and open close the gas tube ser vice valve on the failed outdoor unit where all the service valves were closed In this way recover refriger ant from the failed outdoor unit in order to adjust the amount of refrigerant in the system After adjusting the amount of refrigerant close the gas tube valve at the failed outdoor unit Collecting refrigerant in the failed outdoor unit Short circuit the vacuum application pin CN102 on the control PCB of the failed outdoor unit where the service valves are closed then turn the power ON Also disconnect the wiring between the outdoor units With the normal outdoor units operating monitor the operating condition and open close the liquid tube ser vice valve on the failed outdoor unit where all the service valves were closed In this way collect refrigerant in the failed outdoor unit in order to adjust the amount of refrigerant in the system After adjusting the amount of refrigerant turn OFF the power at th
138. ore the judgment display may change when later judgments occur Judgment mode is automatically canceled after 4 hours W 2WAY ECO i SYSTEM 18 Other Functions Control Functions 8 Outdoor unit PCB LED indications in judgment mode Judgment items LED1 LED2 Recommended response Judgment mode Blinking Blinking Normal ON ON Insufficient gas Blinking OFF Charge with refrigerant a little at a time Overcharge OFF Blinking Recover refrigerant a little at a time e n nor Blinking alternately When judgment mode is not engaged the LED indicates the normal display OFF or else indicates alarms or other information If the insufficient gas or overcharge judgment is not stable then recover refrigerant a little at a time when the overcharge display appears End refrigerant adjustment when the normal or insufficient gas display appears 4 Canceling judgment mode When judgment mode is cancelled the LED returns to the standard status display OFF unless an alarm or other event has occurred 1 Automatic cancel Judgment mode is canceled automatically when 4 hours have passed after it was started 2 Forced cancel Short circuit the CHECK pin while the judgment mode display is active in order to cancel judgment mode Reference General Guidelines for Insufficient Gas and Overcharge Judgment in automatic judgment mode can be problematic in some cases Therefore the following guidelines are
139. ormal display benz The display does not blink W 2WAY ECO i SYSTEM 4 Monitoring Operation e Outdoor Unit Maintenance Remote Controller B Display of unit No 1 main unit Bee Rem Indoor unit electronic control valve position ax Lu PC ERDEM be E L uc at En ru Ee D Discharge temp 1 E E ea Er Discharge temp 2 F Bd Ra LL R d F F F F 2 pore rt 4 I i i U I ve 5 aalas San F F rua X an an an an an LU 2 ri re or Du NOTE OA and subsequent items are outdoor unit data OA 22 are for unit No 1 2A 42 are for unit No 2 W 2WAY ECO i SYSTEM 5 Outdoor Unit Alarm History Monitor Outdoor Unit Maintenance Remote Controller Displays outdoor unit alarms only Check the indoor unit alarm histories separately using the indoor unit remote controllers or other control device Operating procedure D Press and hold the CHECK button and button simultaneously for 4 seconds or longer to engage outdoor unit alarm history mode During temperature monitoring illuminates PROGRAM The display and operations are the same as for the Lm alarm history monitor performed from the indoor unit remote controller However the unit No display shows the outdoor unit address Press the UNIT button and select the outdoor
140. pleted or reconnected and checked Highly dangerous electrical voltages are used in this sys tem Carefully refer to the wiring diagram and these instructions when wiring Improper connections and inad equate grounding can cause accidental injury or death Ground the unit following local electrical codes Connect all wiring tightly Loose wiring may cause over heating at connection points and a possible fire hazard When Transporting Be careful when picking up and moving the indoor 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 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 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 Ventilate the room well in the event that is refrigerant gas leaks during the installation Be c
141. r 2 are operating and the fan mode is 14 maximum fan speed then the high pressure saturation temperature should be approximately 30 F above the outdoor air temperature If it is 10 F or more above this level then it is possible that over charging may have occurred During heating There is an indoor unit where refrigerant flow is poor E1 temperature and discharge temperature are low and the mechanical valve of that unit is opened to 300 pulses or more and the E1 temperature is close to room temperature However be aware that this kind of data results often when there is a height difference between indoor units Reducing the amount of refrigerant will improve the refrigerant flow however reducing it too much will increase the likelihood of alarms related to low oil level scroll side the low pressure SW and discharge temperature Use caution Example This alarm may result when the service valve is closed or when valve leakage particularly from the mechanical valve occurs F17 Alarm gt Sensor short circuit 2 Sensor open circuit Probable cause e Sensor malfunction including connector Pasi St ey 2 9T Check d Measure the sensor resistance Check that the sensor is operating normally 2 Use a remote monitor or a PC monitor to check the temperature that is recognized by the microcomputer F31 Alarm Alarm code F31 Outdoor unit non volatile memory EEPROM trouble Alarm conditions 1 Non vol
142. r intake temperature air intake tem perature difference and the difference between the air discharge temperature setting and the air discharge temperature air discharge temperature difference 4 Definitions of evaporation temperature and condensation temperature Evaporation temperature Te Lowest heat exchanger temperature E1 E3 at any indoor unit Condensation temperature Tc Highest temperature among the outdoor unit pressure sensor temperature and the heat exchanger temperatures E1 at all indoor units where the heating thermostat is ON Ordinarily this is the outdoor unit pressure sensor temperature If multiple outdoor units are connected this is the highest outdoor unit pressure sensor temperature E3 temperature in heating mode is not used for the condensation temperature detection because it may indi cate the temperature of superheated gas W 2WAY ECO i SYSTEM Control Functions 3 Compressor Control 3 6 1 Evaporation Temperature Te Control Control of Indoor Units Operating in Cooling Mode F Horsepower increase 51 9 permitted Area A 518 Horsepower increase 41 1 Permitted Area AB 41 0 Horsepower increase prohibited Area B 35 6 8 35 4 Horsepower decrease Arca G 0 15 30 Maximum requirement level L Depending on the maximum requirement level of the indoor unit the judgement temperatures for each area may vary as shown in the figure 1 For indoor units t
143. r more open circuit 1 Sensor malfunction including connector 2 PCB malfunction Check 1 Measure the sensor resistance Check that the sensor is operating normally 2 Use a remote controller monitor or PC monitor to check the temperature that is recognized by the microcomputer Correction o CE Example l o f E Notes Le W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis F16 Alarm Alarm meaning High pressure sensor trouble abnormal rise in high pressure In some cases this may not be the result of a high pressure sensor malfunction Alarm conditions High pressure SW activated although the detected pressure was lower 439 4 psi or below than the high pressure SW activation pressure Undershift High pressure SW failed to activate although the detected pressure was higher 497 5 psi or above than the high pressure SW activation pressure Overshift The saturation temperature at the detected pressure is 10 F or more below the highest indoor unit E1 temperature continuously for 30 minutes High pressure sensor disconnected or open circuit Probable cause 1 High pressure sensor malfunction 2 Failure to connect the connector to the outdoor unit PCB 3 Failure to open the service valve 4 Clogged tubing 5 Valve leakage 6 Over charging 7 Outdoor unit PCB failure 8 Electrical noise 1 High pressure sensor failure Check the sensor resistance value Use a tester and measure
144. rant NO Charge refrigerant in repaired unit is recovered Amount of charge should equal that y YES recovered by refrigerant recovery unit Power can independently be turned off Modify power to permit turning off for indoor unit where refrigerant is m power to refrigerant recovered Ready f recovered NO indoor units independently eady for operation YES i Change controllable number of indoor END units including changes in group Is control and integrated control settings Y Other indoor units can operate normally Y Replace or repair faulty unit Y Check for leakage in repaired unit H x Replace or repair faulty unit Evacuate air from repaired unit H 1 Y Check for leakage in repaired unit H x Charge refrigerant in repaired unit H D Amount of charge should equal that gt Evacuate air in repaired unit H x recovered by refrigerant recovery unit D Charge refrigerant in repaired unit H x Amount of charge should equal that recovered by refrigerant recovery unit Change controllable number of indoor units including changes in group control and integrated control settings 1 Open um valve Open the ball valve 1 D Ready for normal operation Ready for normal operation i i END END Service work performed on indoor units is done simultaneously using the service ports at the liquid narrow tube side and the gas wide tube side ball valves Refer to eac
145. re are other methods to avoid control in which the mode selected first takes priority Methods of remotely controlling the operating mode 1 Use the central functions of a central control device 2 Use a remote control relay PCB at the outdoor unit W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions When the operating mode at the priority remote controller is changed the operating modes of other remote controllers change as shown below Mode change at priority remote controller Operating modes at other remote controllers Cooling or dr Heatin Cooling or dry Heating 9 3 Fan Fan not changed i Heating Cooling Heating Cooling Fan Fan not changed Cooling Cooling not changed Cooling Dry Dry Dry not changed Heating Cooling Heating Dry Fan Fan not changed Cooling Cooling not changed Cooling or dry Fan Dry Dry not changed Fan Fan not changed Heating Heating not changed Heating Fan Fan not changed enzege item 5 Bespion Fan speed setting when ew heating thermostat is OFF Changes the fan speed setting when the heating thermostat is OFF Heating intake temperature Shifts the intake temperature during heating i Can be set when the body thermostat is used Set when cost distribution is performed using an AMY central control system 07 Electric heater installation or similar system and when an optional electric heater is installed This is unrelated
146. rease the compressor capacity Primary current Secondary current Control 75 0A or 302 F Inverter compressors stop HIC auto protection Inverter compressors stop When 100ms is detected 16 0A 16 5A current protection works Hz decrease in the inverter compressor 14 5A A 13 5A i Sek 13 04 i 12 58 i 12 0A Prohibit Hz increase in the inverter compressor i i Permit Hz increase in the inverter compressor 80Hz 90Hz 3 6 4 Roadmap Control after Trip When restarting after the trip stop occurs the horsepower may increase slowly depending on the trip counter value 1 If trip counter 1 the horsepower increases at a speed that is 1 2 of ordinary roadmap control 2 If trip counter 22 the horsepower increases at a speed that is 1 3 of ordinary roadmap control The trip counter will be cleared if no trip occurs within 1 0 minutes after operation starts W 2WAY ECO i SYSTEM 4 Special Controls Control Functions In addition to ordinary heating and cooling operation this system also includes the following 3 types of special con trols for control of the system as a whole 1 4 way Valve Adjustment Control 2 System refrigerant oil recovery control 3 Defrost control 4 1 4 way Valve Adjustment Control When the microcomputer is initialized immediately after power ON after warning output and all outdoor units are kept stopped for a preset period standard 60 minutes the 4 way Valve
147. refrigerant from an outdoor unit where repairs other than compressor replacement will be performed into other outdoor units and indoor units and the refrigerant tubing 9 1 If Remote Controller RCS TM80BG is Used for Maintenance of Outdoor Unit 1 Refer to 4 Backup Operation and perform backup operation 2 Connect the manifold gauge valves at the Lo side to the low pressure outlet port of the outdoor unit to be repaired Also connect the refrigerant recovery cylinder to any one of the normal outdoor units at the liquid line service port Schrader type push to release valve Perform the connection work quickly so that no air is allowed to enter Fig 20 Connecting the refrigerant recovery cylinder is done to prevent pressure from rising excessively during backup operation by recovering the refrigerant from the outdoor unit to be repaired Measure the weight of the refrigerant and cylinder itself beforehand and provide sufficient safety measures such as installing a high pressure cutout in the circuit The hoses may be subject to internal pressure from the refrigerant inside the out door unit Check that the manifold gauge valves are fully closed beforehand A Schrader type push to release valve is provided at each connection port 3 Connect the outdoor unit maintenance remote controller to the RC connector CN006 3P BLU on the out door unit control PCB of the outdoor unit to be repaired Then start a test run of all un
148. refrigerant gas occur at an indoor unit e This valve turns ON when the outdoor air temperature is 59 F or below Under these conditions the high pressure is low and refrigerant flow becomes poor e This valve turns OFF when symptoms of refrigerant overcharge are detected at the outdoor unit B Mixed cooling heating operation e The RCV turns ON at stopped outdoor units when the heat exchanger at anoth er outdoor unit is functioning as a condenser Hp 6 2 Refrigerant Balance Valve RBV Gas Purge Valve The main purpose of this valve is to detect the flow of refrigerant refrigerant volume on the indoor unit side when the outdoor unit heat exchanger is functioning as an evaporator When the valve determines that there are signs of excess refrigerant refrigerant is recovered at the receiver tank This valve is ON during heating operation and when the outdoor unit heat exchanger is functioning as an evapora tor during mixed heating cooling operation It also turns ON in order to recover refrigerant at the outdoor unit after heating operation is stopped This valve is never turned ON at the same time with the RCV 1 The OFF conditions take priority over the ON conditions for this valve 2 This valve turns ON for 30 50 seconds after the outdoor unit stops and then turns OFF 3 This valve turns ON once after the outdoor unit starts A Heating operation Lp This valve is ON during heating operation and
149. res will be attached Then attach the dry cores 6 Atall outdoor units where dry cores are attached pressurize with 478 6 psi of nitrogen from the liquid tube service port and check for leaks 7 After evacuating all nitrogen gas from the tubing apply vacuum from the liquid tube service port to all outdoor units where dry cores are attached until the pressure is 14 7 psig 5 Torr or less E Fully open the liquid tube valve and ball valve on all outdoor units where dry cores are attached ES Operate all outdoor units for approximately 3 hours in either Heating or Cooling mode or mixed Cooling and Heating mode 10 Follow the above procedure and replace all dry cores with new dry cores 11 Operate all outdoor units for approximately 20 minutes in either Heating or Cooling mode or mixed Cooling and Heating mode 12 Follow the instructions in 3 Discharging Compressor Oil and drain a small amount of the oil from the oil separators of all outdoor units where dry cores are attached Check the color phase odor and other characteristics 13 If the results show that dry core cleaning is still necessary for example a color phase of 4 0 or higher return to Step 11 and repeat until the results are normal including a color phase of 3 5 or less Color sample sheet for degree of stain JNa Perform another dry core replacement after approximately 30 hours of system operation W 2WAY ECO i SYSTEM 10 Com
150. rigerant is gradually returned to the outdoor unit 85 ian at pulses ranging from 55 to 80 Thermostat Liquid refrigerant is gradually returned to the outdoor unit 85 Heatin OFF at pulses ranging from 55 to 80 9 Thermostat Performs SC distribution control within the range of 55 E ON 480 pulses The SC target value is controlled so that the high pressure saturated temp E1 becomes between 10 F to 40 F depending on the operating conditions B Type D Position of electronic control valve i Outdoor unit Outdoor unit operating stopped Stopped 20 20 Fan 20 20 ia ud 20 20 Heating Thermostat Performs SC distribution control within the range of 55 8 ON 480 pulses The SC target value is controlled so that the high pressure saturated temp E1 becomes between 10 F to 40 F depending on the operating conditions However if installation is combined with except Type D the high pressure saturated temp E1 may be controlled between 10 F to 80 F W 2WAY ECO i SYSTEM Control Functions 10 Indoor Unit Control of the Electronic Control Valve 10 2 Special Control Control Nina Subject indoor units Position of electronic control valve 4 way valve Cooling Allindoor units 2 for cooling according to indoor unit adjustment control e SES Heating All indoor units 250 Stopped Cooling control according to indoor unit capacity Fan
151. riod of No of outdoor units minus1 x 5 minutes In addition oil supply is ended if the oil receiving outdoor unit oil level changes to 2 or if the oil supply outdoor unit oil level becomes low 3 The supply of oil is received from 1 unit at a time in sequence according to the order of priority of their inverter compressors 4 Operation during unit refrigerant oil recovery A Oil receiving outdoor unit The recovery valve turns ON and remains ON B Oil supply outdoor unit The balance valve turns ON and remains ON The bypass valve repeatedly turns ON and OFF according to a constant cycle 5 1 5 Indoor unit refrigerant oil self recovery control Refer to the items concerned with indoor unit special control 1 34 W 2WAY ECO i SYSTEM 6 Operation of Solenoid Valves Control Functions 6 1 Refrigerant Control Valve RCV The main purpose of this valve is to detect the flow of refrigerant refrigerant volume on the indoor unit side when the outdoor unit heat exchanger is functioning as a condenser When the valve determines that there are signs of a low refrigerant level refrigerant is supplied from the receiver tank to the system 1 The OFF conditions take priority over the ON conditions for this valve 2 This valve is OFF when the outdoor unit is stopped 3 This valve is ON when special control is in progress 4 Control during normal operation A Cooling operation This valve turns ON when symptoms of insufficient
152. rn off the power of the outdoor unit beforehand at power mains 2 Fully close each service valve on the liquid tube gas tubes and the balance tube of the outdoor unit 3 Connect the outdoor unit s high pressure and low pressure outlet ports with the Hi and Lo sides of the manifold gauge valves using hoses Fig 9 The remaining refrigerant in the faulty outdoor unit may create internal pressure Before connecting hoses be sure to confirm that each of the manifold gauge valves is tightly closed Note that the connection ports employ Schrader type push to release valves 4 Connect the manifold gauge valves refrigerant recovery unit and recovery cylinder using hoses To avoid the entry of air into the refrigerant tubing carry out this connection work carefully Fig 9 For detailed procedures such as connecting the refrigerant recovery unit with the CAUTION recovery cylinder and methods used for recovery follow the specific instructions that came with the refrigerant recovery unit 5 Locate the AP Air Purge pins on the control PCB in the faulty outdoor unit and short them using the clips of the jumper wire Then restore electrical power to the outdoor unit By short circuiting the AP pins each solenoid valve in the outdoor unit is forcibly CAUTION opened as soon as power comes on which releases all remaining refrigerant into the recovery cylinder Since neglecting this procedure may leave some refrigerant in the
153. rt employs a Schrader type valve When disconnecting the hose pressure will be applied from the refrigerant in the outdoor unit 12 Follow the instructions in 10 2 4 Dry core cleaning and perform dry core cleaning of all outdoor units W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures 10 2 4 Dry core cleaning If burning or other failures occur repeatedly at compressors within the same system in many cases the cause is acid sludge carbon or other substances that remain in the refrigeration cycle as the result of insufficient cleaning If when the oil is inspected there is an outdoor unit where the oil color phase is 4 0 or higher or where a sharp odor is present carry out all steps below to perform dry core cleaning And use the bidirectional dry core for refrigerant R410A A If a ball valve is installed on the outdoor unit 1 Refer to 5 2 1 Cooling operation for all units and operate all outdoor units in either Heating or Cooling mode 2 Ifall units are operated in Cooling mode close first the liquid tube service valve then the ball valve on all out door units where dry cores will be attached If all units are operated in Heating mode close first the ball valve then the liquid tube service valve on all out door units where dry cores will be attached This step is performed in order to expel refrigerant from the tubing between the liquid tube service valve and the ball valve Approximately 4
154. s a specified amount of oil in the compressor Namely soon after the oil level is changed to 1 the oil in the compressor is not empty If the oil level 0 indication continues for more than 5 to 10 minutes it seems short of oil in the system Check for any oil leakage as well as the refrigerant tubing 5 1 2 Oil level detection Excess oil in the compressor is sent by bypass via a capillary tube to the low pressure circuit The temperature detected by a temperature sensor is used to determine whether it is oil warm or refrigerant cold 5 1 3 Self separator oil recovery control When a low oil level is detected this control recovers the oil which has accumulated in that oil separator and sends it to the compressor 1 Operation when oil level is not 2 30 seconds after the oil level changes from 2 to 1 the recovery valves turn ON However if the oil level becomes 2 this control is stopped 5 1 4 Unit refrigerant oil recovery control utilizing balance tubes fthe low oil level continues that outdoor unit oil receiving outdoor unit receives a supply of oil from operating outdoor units where the oil level is not low oil supply outdoor units 1 Control at the oil supply outdoor unit begins 3 minutes after the oil level at the outdoor unit dose not become 2 Oil supply is performed for a maximum of 5 minutes from each unit 2 When oil supply is ended oil supply from that outdoor unit will not occur again for a pe
155. s automatically when the set outdoor unit quantity matches the number of outdoor units detected on the outdoor unit main sub control wiring E29 Alarm Outdoor unit failed to receive communication from outdoor unit main Alarm conditions Outdoor unit communications from outdoor unit main were interrupted for 3 minutes or longer Probable cause 1 After initial communications were completed the outdoor unit main sub control wiring was cut 2 After initial communications were completed the RC connector became disconnected 3 The power at the outdoor unit main unit is turned OFF Check 1 Check the outdoor unit main sub control wiring 2 Check the RC connectors 3 Check the power at the outdoor unit main Correction 1 Repair the outdoor unit main sub control wiring 2 Correct the RC connector connection MT 3 Turn ON the outdoor unit main power paseo pee UJ Notes W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis F04 F05 Alarm Alarm meaning Compressor 1 discharge temperature sensor trouble compressor 2 discharge temperature sensor trouble Alarm conditions 1 Discharge temp of 212 F or higher was detected 20 minutes or more after that compressor stopped operating 2 Discharge temp of 158 F or higher was detected after all compressors had been stopped for 60 minutes or longer 3 A D step is 10 steps or less short circuit Probable cause 1 Sensor malfunction
156. s time all displays stop blinking and remain lit During this mode MAAMA is displayed blinking The outdoor unit address display section displays ALL the item code and number DN value in the table and the setting data 8 digits The setting data is displayed in 8 digits The display changes between the first 4 digits Fig A and the last 4 digits Fig When the first 4 digits are displayed the top dot of the colon is illuminated To exit the setting mode press the CHECK button amp and are displayed alternately Example shows display of 0000 0001 oN Parameter Bespion 0 Sensor input not present Control is performed 1 Sensor input present Control is performed 2 Sensor input not present Control is not performed 3 Sensor input present Control is not performed Outdoor unit fan Quiet 0 Disabled 1 Quiet mode 1 2 Quiet mode 2 3 Quiet mode 3 mode 4 Quiet mode 4 0 None 1 Discharge temp control only Mode 3 2 Demand only Mode 2 3 Discharge temp control Demand Mode 1 ECNMF GRIS COREMEEMMMMM plug 1 All indoor units linked 02096 1240 42 70 72100 8 120 9 140 10 2 160 11 200 12 1 no limit 02096 1240 42 70 72100 8 120 9 140 10 160 11 200 12 1 no limit 3 12 Snowfall sensor usage Energy saving mode D
157. s time cover the tube in place with waste cloth while watching out for oil leaks Then cap the disconnected tube and mount the flare nut on the compressor Tighten the flare nut with a seal bonnet 1 4 in it NOTE If oil remaining in the compressor reaches the equalized oil level oil will come pouring out when the tube with flare nut is removed 7 Prepare to disconnect the 2 brazed locations shown in the figure Protect the sensors and the surrounding plates rubber lead wires clamps and other items Remove the discharge sensor shown in the figure 22 8 Disconnect the 2 brazed locations shown in the figure below 9 Pull the compressor toward you JN eme When pulling the compressor toward you be careful not to cause any abnormal deformation of the tube with flare nut Remove the discharge sensor COE e x Inverter compressor L yar a Cd ANSA MIR S n 3B H M x g D L a l ru d BUE Brazed locations 2 fi a n Bp Bolt FELIPE H El EL washer 1 K S is Bull Rubber washer 1 Tube with flare nut h f i a CE N A DI Tu M Ort Bolt Washer 1 Rubber washer 1 i 5 d Lia 6 d Bolt Washer 1 Rubber washer 1 Crankcase heater Front view Fig 22 2 29 W 2WAY ECO i SYSTEM 10 Com pressor Outdoor Unit Repair Procedures Bi Installation 1 Remove the rubber stopper an
158. s tubing with fingers to determine whether the unit is running in cooling or heating mode If itis in heating follow the step 4 and later procedures Cooling low temperature 68 F or lower Heating high temperature 140 F or higher AN sse The gas tubing becomes hot 140 F or higher in heating mode Be careful so as not to be burnt when touching the tubing Release the short circuit at the test run pin CNO23 on the outdoor unit control PCB of the No 1 unit Then short circuit the stop pin CN104 to stop operation Short circuit the mode change pin CN101 on the outdoor unit control PCB of the No 1 unit Switching of the 4 way valve occurs immediately before operation starts Therefore it does not change at this time Mode change cannot be judged from the sound 6 Short circuit the test run pin CNO23 on the PCB to start test run operation Leave the unit running for a while and touch the gas tubing with fingers to determine that the unit is running in cooling mode 5 2 2 Refrigerant recovery procedures 1 using indoor unit ball valve 1 If a ball valve with a service port has been provided in the indoor unit as shown in Fig 10 follow the instructions given in 2 through 6 below If the service port is instead located in the outdoor side follow the instructions in 5 2 3 Refrigerant recovery procedures 2 2 After running the unit in Cooling mode for about 5 minutes as described in 5 2 1
159. se is the cause of the trouble It is necessary to connect a PC or other instrument Correction 1 Replace the compressor 2 Replace the CT circuit 3 Repair the power circuit 4 Adjust the primary side power Repair the power wiring 5 Replace the outdoor unit PCB 6 Correct the trouble n the case of a compressor failure it is likely that steps must be taken to correct the cause of the compressor failure such as liquid back up in order to prevent recurrence Be sure to check that there is no cause which may resuit in compressor locking Example Pe W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis H03 H13 Alarm H13 Compressor 2 CT sensor disconnected or short circuit Alarm conditions Compressor 1 Current value of more than 18 0 A is detected while the compressor 1 is stopped Compressor 2 Current value at compressor 2 is less than 2 0 A when 2 seconds or more had passed after the compressors began operation and output No current is detected even though the compressor is operating Probable cause 1 CT circuit failure including cut wiring etc 2 Disconnected CT circuit connector 3 Missing phase where CT circuit is connected 4 This CT circuit is connected to the connector of the other CT circuit 5 PCB failure 6 Electrical noise 1 CT circuit failure PCB failure Trouble e Current value during compressor operation is below the threshold value Check e Check that the connector
160. start can be set in increments of 5 minutes Use this setting to change the time for forced operation at installation or Forced thermostat ON time servicing from 5 minutes to 4 minutes Enabled only with PAC i models Cooling discharge Shifts the set value for models which perform discharge temperature control Discharge temperature control models Floor discharge wall built in direct expansion coil outdoor air treatment high fresh temperature shift Auto heat cool selects the operating mode automatically based on the Temperature shift for difference between the room temperature and the temperature set on the cooling heating change in remote controller This setting establishes a shift temperature for the heating auto heat cool mode cooling temperature setting relative to the remote controller temperature setting Cooling temperature setting 4 Shift temperature Remote controller temperature setting Shift temperature Heating temperature setting T W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions mes mm 1F Upper limit 20 Lower limit Heating This setting changes the temperature range upper limit and lower limit Change to the remote which is set from the remote controller or central control device control temperature The set upper limit must be greater than or equal to the lower limit If the 21 Upper limit 22 Lower limit 23 Upper
161. t Outdoor Unit Repair Procedures Be sure to turn off the power before removing the electrical component box Then check that the power LED D53 on the control PCB of the outdoor unit is not lit 1 Remove the electrical component box cover remove 6 screws Fig 3 e When closing the cover after the repair work set the upper fringe of the cover should come to align inside the electrical component box Fig 3A Electrical component E box cover i SET 2 Remove power and control wires from terminals 3 Remove internal wires with extended connectors on the outdoor control PCB Solenoid valves thermistors crankcase heaters and others 4 Disconnect power lines connected to the sec ondary terminals of the magnetic contactor for the compressor b Remove the electrical component box remove 2 screws Fig 4 Electrical component box CAUTION Be sure to release the locking mechanism before disconnecting each connector Upper duct 6 Remove the center duct Fig 5 The center duct is fitted into the upper and lower Center duet ducts and held in place by the electrical component box an arrangement that makes possible indepen dent removal of the center duct Lower duct W 2WAY ECO i SYSTEM 2 Removing Electrical Component Box and Duct Outdoor Unit Repair Procedures 7 Remove the lower duct remove 2 screws and a hook
162. t is connected to any outdoor unit Caution Snowfall sensor input information is detected once every 10 minutes Therefore the outdoor fan may continue operating for up to 10 minutes even when there is no snowfall sensor input In addition the outdoor fan may remain stopped for up to 10 minutes when snowfall sensor input is present 18 2 Function for Automatic Judgment of Insufficient Refrigerant Gas and Overcharge This system includes a simple function for judging the level of refrigerant However be aware that false judgments may occur if the control elements of the outdoor unit or indoor unit fail 1 Starting refrigerant level judgment mode Short circuit the CHECK pin on the No 1 outdoor for 4 seconds or longer to engage this mode The LED on the outdoor unit PCB begins blinking 2 Conditions for refrigerant level judgment After judgment mode starts judgment occurs when all outdoor units in the system have been operating contin uously for 30 minutes or longer Refrigerant level judgment requires that all outdoor units operate continuously for 30 minutes or longer This is in order to prevent incorrect adjustment of the refrigerant level based on false detection caused by refrigerant accumulation or recovery at stopped outdoor units which is due to failures of functional elements After the judgment is displayed repeated judgment will occur under new operating conditions if all outdoor units continue operating Theref
163. t operation e f any one compressor in the outdoor unit is operating the outdoor heat exchanger coil is used In cooling operation all the inverter compressors are designed to operate therefore all the outdoor heat exchangers in the outdoor units will be used e SH control controls the difference between the liquid temperature and gas temperature to 2 F 10 F e During heating mode SH operation in the heat exchanger 2 side in order to prevent a liquid back or high load operation from occurring a control may be implemented so that refrigerant may not flow intentionally to the heat exchanger 1 17 7 Outdoor Unit Electronic Thermostatic Expansion Valves 2741 ECO i SYSTEM MOV1 MOV2 amp MOV4 Control Functions 7 4 SC Circuit Electronic Control Valve MOV4 1 SC Control Cooling Mode only During cooling operation the liquid refrigerant which condenses at the outdoor unit heat exchanger flows into the receiver tank and SC sub cool supercooling approaches 0 F When SC is small and the length of the tubing connecting the indoor and outdoor units is long the refrigerant flow in the indoor unit will be reduced sig nificantly To prevent this trouble from occurring MOV4 operates so as to increase supercooling in the double tube coil near the outlet of the outdoor unit MOV4 controls refrigerant so that it will not flow back to the compressor in the liquid state with a suction tem perature sensor near the accumulator and a low pr
164. the indoor units in that system is possible After power is turned ON and automatic address setting is not in progress one or more indoor units are confirmed in that system however the number of indoor units does not match the number that was set Automatic address setting was completed successfully After the power is turned ON and automatic address setting is not in progress the number of detected indoor units connected to that system matches the number that was set and regular communications are occurring Automatic address setting is in progress At time of automatic address setting the number of indoor units did not match the number that was set Alarm display LED 1 blinks M times then LED 2 blinks N times The cycle then repeats M 2 Palarm 3 H alarm 4 Ealarm 5 F alarm GL alarm N Alarm No Example LED 1 blinks 2 times then LED 2 blinks 17 times The cycle then repeats Alarm is P17 3 Remote Controller Servicing Functions Sensor temperature display function displayed both when unit is running and stopped Use the following check procedure to display the sensor temperatures from the remote controller indoor unit and outdoor unit sensors on the remote controller display Check procedure D Press and hold the CHECK button and button simultaneously for 4 seconds or longer 2 The following appears on the remote controller LCD display unit No X X main unit No item code XX sensor a
165. time of factory shipment delayed start for each system is not set to occur Therefore when systems are linked and multiple systems are selected for start simultaneously by the central control device all systems will begin operating simultaneously For this reason a function is included to delay the start time for each system address when systems are linked and multiple systems are selected for start by the central control device In order to enable this delay time it must be set in the EEPROM for each system Those systems where this setting has been made will start after a delay according to their system addresses For information concerning EEPROM settings refer to the field application functions 2 3 Outdoor Unit Stop Rules 1 Simultaneous stop of multiple outdoor units When all outdoor units or multiple outdoor units must stop the units stop at the same time However depend ing on the communications timing a difference of approximately 10 seconds may occur 2 Stopping individual outdoor units e The last unit to stop operating is the outdoor unit that contains the inverter compressor with the shortest amount of operating time e In cooling mode all inverter compressors in the outdoor units are designed to operate simultaneously Therefore all the outdoor units will stop at a time when any one unit is stopped In heating mode the out door unit which has the inverter compressor with the shortest amount of operating time conti
166. tion of outdoor R C address setting L04 Capacity code of outdoor unit is not set 4 way valve operation failure L18 Indoor unit lt lt F01 gt gt lt lt F03 gt gt lt lt F10 gt gt lt lt F11 gt gt Compressor 1 INV discharge temp sensor F04 FOS F08 F07 F06 Operating and heating ready lamps blinking 1 1 Operating and timer lamps blinking alternately SES Operating and timer lamps blinking altemately xixtio Continued W 2WAY ECO i SYSTEM 1 Contents of Remote Controller Switch Alarm Display Trouble Diagnosis ON O Blinking X OFF Wired remote control display Wireless remote controller receiver display Possible cause of malfunction Operation Standby for heating Thermistor fault Outdoor unit ompressor intake temp sensor suction temp Cf e Operating and timer High pressure sensor lamps blinking Low pressure sensor altemately Heat exchanger 2 liquid temp sensor Xt xt Heat exchanger 2 gas temp sensor 1 Timer and heat Protective Indoor unit hermal protector in indoor unit fan motor is activated ready lamp blinking device loat switch is activated mE an inverter protection function activated e we 165 Outdoor unit Oxygen O gas sensor activated 1 Compressor 1 INV discharge temp trouble i i High pressure switch or Overload Protector OLR Operating and heat Reverse phase missing phase detected ready lamp blinking DCCT ACCT overcurrent compressor less than 80 Hz
167. to be repaired and connect the manifold gauge to the refrigerant recovery device Be sure that no air enters the tubing at this time W 2WAY ECO i SYSTEM 9 Pumping Out Refrigerant from Outdoor Unit Outdoor Unit Repair Procedures 8 Short circuit the vacuum application pin on the outdoor unit control PCB of the unit to be repaired Then turn ON the outdoor unit power When the vacuum application pin is short circuited and the power is turned ON all solenoid valves in the outdoor unit are forced open allowing the refrigerant to be recovered from all tubes which are separated by solenoid valves If this work is not performed it will not be possible to recover all of the refrigerant at the refrigerant recovery device Be sure to perform this step Open both Hi and Lo side valves on the manifold gauge valves and recover the refrigerant remaining in the outdoor unit After that measure the amount of recovered refrigerant To determine the completion of refrigerant recovery follow the instructions that came with the refrigerant recovery unit 9 2 If Remote Controller is Not Available for maintenance of Outdoor Unit 1 Refer to 4 Backup Operation and perform backup operation 2 Connect the manifold gauge valves at the Lo side to the low pressure outlet port of the outdoor unit to be repaired Also connect the refrigerant recovery cylinder to any one of the normal outdoor units at the liquid line service port Schrader type pus
168. to control of the electric heater Normally humidifying does not occur when the thermostat is OFF during heating operation However this setting can be changed in order to increase the amount of humidifying Caution In order to avoid water leakage and damage to the fan do not use this setting unless a vaporizing humidifier is used gs Permit prohibit automatic This setting can be used to prevent the automatic heating cooling display on Humidifying when heater thermostat is OFF the remote control if the unit configuration permits automatic heating cooling heating cooling operation This setting allows a heat pump indoor unit to be operated as a cooling only Cooling only unit W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions enzel en Beim y O mn Lime Set when the indoor unit EEPROM memory is replaced during servicing Indoor unit capacity System outdoor unit address These are not set at the time of shipping from the factory Indoor unit address These must be set after installation if automatic address setting is not performed Group address Shifts the intake temperature during cooling and dry operation Enabled only when the body thermostat is used Increase this value when it is difficult to turn the thermostat ON Cooling intake temperature shift Automatic stop time after The time at which an indoor unit is automatically stopped after operation starts operation
169. tput for the fan can be switched Fan outp t switching according to the purpose of use The drain pump starts after the set time delay after cooling operation Drain pump delayed start time stops Humidifier drain pump setting This specifies the humidifier and drain pump setting 3C 3d EN DC flap operation mode Changes flap operation to draft reduction mode EI DC flap swing mode Selects the swing operation mode for the flap Sets the DC fan tap according to the purpose of use DG fan tap setting Change the settings data at the same time Sets the humidifier output ON time for when the humidifier is operating Humidifier ON time ON OFF control is performed during humidifier operation This setting therefore sets the ON time per 60 second interval This setting enables a function that stops operation when the amount of time set for the OFF timer has passed after remote controller operation was started Stop at time set for OFF timer after operation starts This function prohibits changes from being made to the remote controller time setting Smudging control Smudging control is disabled when 0000 is set Timer function change prohibit W 2WAY ECO i SYSTEM Remote Controller Functions 3 Remote Controller Servicing Functions The remote controller includes a number of servicing functions Use these as needed for test runs and inspections List of Servicing Functions Button operation Reset operation Operat
170. ts 0123 Stops automatically 615 minutes after operation starts in 5 minute 0124 Stops automatically 620 minutes after operation starts 0125 Stops automatically 625 minutes after operation starts e Q e Oo System address W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions Description IL 0000 5 minutes a Forced thermostat ON time 0001 4 minutes 010 20 F 18 F Cooling discharge 008 16 F temperature shift 0010 20 F 009 18 F iii Heating discharge 0010 om Temperature shift for POP cooling heating change in 9008 auto heat cool mode 0007 0018 64 F Lower limit at shipment 0019 SECH aim cu 0029 Lower limit 0030 86 F Upper limit at shipment 7 I 0016 60 F Lower limit at shipment L I 0017 62 F Upper limit cc Lower limit Change to remote Z control temperature S D setting range 0018 64 F Lower limit at shipment Upper limit Lower imig 0026 78 F Lower limit 0027 80 F Upper limit at shipment 2n m 0000 REES 0001 lgnore heat exchanger temperature conditions 0000 Filter input differential pressure switch input Filter CN70 input 0001 Alarm input for trouble input about air cleaner or similar device switching 0002 Humidifier input Operates linked with drain pump when humidifier is ON Indoor unit electronic control valve m Drying Zh EE 25 Upper limit J
171. ts set at outdoor unit No 1 by the number of failed outdoor units B At the S010 switch on the PCB of the failed outdoor unit turn ON the switch for the compressor to dis able and turn ON the backup switch W 2WAY ECO i SYSTEM 16 Backup Operation Control Functions Outdoor unit tonnage 8 Ton Switches totum ON INV AC1 BU C Close all service valves at the failed outdoor units D Reset the power at outdoor unit No 1 When the PCB of the main unit is normal by implementing the above settings while leaving the communica tion lines between indoor and outdoor units as they are backup operation of units are possible In this case the outdoor unit that backed up all compressors is not identified as an outdoor unit however it can work as the command controller 2 Disabling operation of 1 compressor At the S010 switch on the PCB of the failed outdoor unit turn ON the switch for the compressor to disable and turn ON the backup switch S010 switch INV AC Ace Backup 1 FF S010 9 A Compressor 1 backup ON LH B Compressor 2 backup ON Ma E il OFF AC2 switch is not available W 2WAY ECO i SYSTEM Control Functions 17 Service Maintenance Functions The outdoor unit EEPROM settings can be used for the following functions 17 1 Outdoor Unit Noise Countermeasure EEPROM 05 set at each outdoor unit This unit includ
172. ttings mode is engaged operation stops at the individual or group control indoor unit where the remote controller used for detailed settings is connected Simple settings items can also be set at this time No SETDATA Procedure D Press and hold the A and buttons simultaneously for 4 seconds or longer Gama unit No or AE L in the case of group control item code 77 and settings data 41 XX are displayed blinking on the remote controller LCD display Fig 2 At this time the indoor unit fan or all indoor unit fans in the case of group control begins operating If group control is in effect press the UNIT button and select the address unit No of the Fig 2 indoor unit to set At this time the fan at the indoor unit begins operating 4 Press the temperature setting J ae buttons to select the item code to change Press the timer time 4 v buttons to select the desired setting data For item codes and setting data refer to the following page Press the button The display stops blinking and remains lit and setting is completed Press the button to return to normal remote controller display W 2WAY ECO i SYSTEM 2 Detailed Settings Function Remote Controller Functions List of Detailed Setting Items Setting data Item code UT PER Description No Descr
173. ttle at a time in order to prevent liquid back flow Fully close the low pressure gauge valves on the manifold gauge follow the instructions in 8 Charging Com pressor Oil and charge with oil if necessary 10 Remove the manifold gauge The connecting port employs a Schrader type push to release valve When discon necting the hose pressure will be applied from the refrigerant in the outdoor unit W 2WAY ECO i SYSTEM 10 Compressor Outdoor Unit Repair Procedures 10 2 2 Replacing all compressors in a failed unit 1 Follow the instructions in 3 Discharging Compressor Oil and drain the oil from the oil separator in the failed unit Measure the amount of drained oil 2 If backup operation is required follow the instructions in 4 Backup Operation and engage backup operation 3 Follow the instructions in 10 3 Removing and Installing Compressors and replace all compressors in the failed unit 4 Fully close the high and low pressure gauge valves on the manifold gauge then stop the vacuum pump 5 Disconnect the manifold gauge from the vacuum pump Connect the manifold gauge to the refrigerant cylinder At this time be careful that air does not enter the tubing JN sse Do not reuse the recovered refrigerant Use a refrigerant cylinder that contains new refrigerant 6 Open the valve on the refrigerant cylinder and open the high pressure gauge valve on the manifold gauge with the low pressure gau
174. unit for which to monitor the alarm history Press the temperature setting amp and Ces buttons and select the item code for the alarm history The select outdoor unit address the item code and the alarm history alarm data are displayed The outdoor unit address is displayed as R C XX YY System XX Outdoor unit system address R C XX Outdoor unit system address YY Outdoor unit sub bus address Item codes 01 08 are displayed 01 indicates the most recent alarm The alarm history displays the alarm code If no alarm are present then is displayed To clear the alarm history press the ES button The outdoor unit alarm history will be cleared 5 To exit press the CHECK button The display returns to the normal display W 2WAY ECO i SYSTEM 6 Mode Settings Outdoor Unit Maintenance Remote Controller E Setting mode 1 Operating procedure Press and hold the CHECK button and Display of first 4 digits ST VENTILATION button simultaneously for 4 up seconds or longer Fit Ud d j R C No SETDATA Q Press the temperature setting Cas and w buttons to change the item code The item codes and setting data are shown in the table of List of Item Codes on the next page 3 Press the timer time and CG buttons to Gen change the setting data coy To confirm the changed setting data press the button At thi
175. urrently the blinking inspection display can be displayed only on the wired remote controller and system remote controller Blinking inspection display 1 Automatic backup Blinking inspection display Alarm meaning Automatic backup is in progress A C units can be operated Status The compressor at one of the outdoor units where the outdoor unit fan is running should be operating Blinking inspection display also occurs when seizing of the compressor magnet SW is detected Because this may also be the case refer to Blinking inspection display compressor magnet SW seizing detection Alarm conditions When alarm P16 P22 P26 P29 Hx1 Hx2 or H31 has occurred correcting the control device remote controller etc input engages this mode Probable cause Because alarm P16 P22 P26 P29 Hx1 Hx2 or H31 has occurred check the alarm history then refer to the corresponding items Follow the instructions in the corresponding items to correct the trouble Recovery After repairing the malfunctioning locations reset the power for the system all outdoor units Caution Automatic backup mode will not be canceled until the power is reset Notes Automatic backup mode is not engaged in cases of alarms other than those listed above Reasons e There is no need for automatic backup if recovery is possible by correcting the remote controller input With alarms for which automatic recovery is possible such as sensor alarms
176. utdoor unit However if only one outdoor unit is installed leave the balance tube kept closed 7 Charge the recovered refrigerant with the Refrigerant Recovery Unit by referring to the Installation Instruc tions that came with the outdoor unit and the refrigerant recovery unit W 2WAY ECO i SYSTEM 12 Repl acing 4 way Valve Outdoor Unit Repair Procedures 12 2 When the replacement is not available from the right side of the unit 1 Follow the instructions of 10 Compressor and remove the constant speed compressor 2 2 Connect the manifold gauge to the high and low pressure outlet ports at the outdoor unit where the 4 way valve will be replaced Connect the manifold gauge to a nitrogen cylinder and perform nitrogen gas replacement 3 Prepare the brazing kit to disconnect the brazed parts 4 locations Nissen Protect the check valves as shown in the figure 31 Check valve Dem Ji i S ama TAC 4 way valve Brazed parts 4 locations 4 After replacing the 4 way valve follow the instructionsin 10 Compressor and reinstall the removed constant speed compressor 2 in the outdoor unit W 2WAY ECO i SYSTEM Contents Outdoor Unit Maintenance Remote Controller 3 OUTDOOR UNIT MAINTENANCE REMOTE CONTROLLER 1 OVervleW s c x pack o dO ar RC E CR Oe wees AR t C de e RC en e amp 3 2 2 PUNCUONS 2222 er d a E ENNEN ae OC UE Cae ee a CRANE UC OUR ms 3 3 3 Ordinary Display Controls an
177. utdoor unit static pressure of approximately 0 0085 psi 10 hp type only Setting No 0 1 2 3 4 5 6 Compatible static pressure psi 0 0014 0 0026 0 0037 0 0050 0 0061 0 0074 0 0085 Speed 600 630 670 710 740 770 800 17 7 Compressor Operating Sequence Outdoor EEPROM 46 set at outdoor units which include CCU functions When this setting is set to 1 the compressors start in sequence beginning from the No 1 outdoor unit The setting is O at the time of shipment With this setting compressors with lower operating time are started first in order to balance the compressor operating times 17 8 Demand Value Setting Outdoor EEPROM 1A 1B set at outdoor units that include CCU functions Demand setting Control Demand meaning Contact 1 Contact 2 Operates to the maximum x x No limit capacity O x Demand can be set from 40 20096 at Current is limited to the set EEPROM 14A values x O Demand can be set from 40 200 95 at Current is limited to the set EEPROM 1B values O O Remains stopped W 2WAY ECO i SYSTEM 18 Other Functions Control Functions 18 1 Snowfall Sensor Functions Outdoor EEPROM 04 A unit identified as having a snowfall sensor attached will periodically send a signal indicating the snowfall sensor input status to all outdoor units in the same system or all wired outdoor units in the case of linked systems
178. uum pump Fig 15 W 2WAY ECO i SYSTEM 8 Charging Compressor Oil Outdoor Unit Repair Procedures 2 Charging compressor oil into oil charging tank Connect a piece of pipe to the lower valve and then insert the other end deeply into the bottom of the oil con tainer Make sure you avoid letting any air be sucked into the tube Next run the vacuum pump and open the manifold gauge valves then open the upper and lower valves to begin charging oil into the charging tank Manifold Upper valve gauge us E Lo Hi Lower valve Vacuum pump Fig 16 When the predetermined amount of oil has been charged into the oil charging tank immediately close the lower valve Next run the vacuum pump until the system pressure reaches lower than 14 7 psig 5 Torr Close the upper valve and then stop the vacuum pump Nm Do this operation quickly because compressor oil easily absorbs moisture from the air 8 Charging compressor oil into outdoor unit Connect the lower valve to the low pressure outlet with Schrader type push to release valve in the outdoor unit to be oil charged and then connect the high pressure outlet with push to release valve to the upper valve via the manifold gauge valves at Hi pressure gauge side In addition connect the gas tube service port with push to release valve to the DPR Discharge Pressure Regulator Carry out the connection work quickly to avoid letting air enter The hoses m
179. ve must be replaced Example Notes Pt W 2WAY ECO i SYSTEM 4 W 2WAY ECO i Alarm Codes Trouble Diagnosis H07 Alarm Alarm code Alarm meaning Alarm conditions Probable cause Correction H07 No oil alarm This alarm occurs when oil does not flow for a specified amount of time in tubing where oil flow constantly The presence of oil is detected by a temperature sensor Judgment method Tcal calculated by the formula below from the oil temperature is compared with the discharge temperature If Tcal is higher than the discharge temperature then oil is judged to be present If Tcal is lower than the discharge temperature oil is judged to be not present Tcal 0 0254 T oil LP 0 0298 T oil LP 0 8842 T oil 2 9953 LP 11 091 LP 436 94 2 9953 HP 11 091 HP 436 94 0 0254 HP 0 0298 HP 0 8842 These points are calculated from the oil temperature and compared with the discharge temperature mam High pressure Lower than the il f temperature No oil Discharge temperature Higher than the discharge temperature Oil present Low pressure Oil temperature Insufficient amount of oil in the system 1 The length of system tubing exceeds the allowable tubing length 2 The difference in height between system units exceeds the allowable value 3 A large amount of oil was drained when a compressor was replaced 4 Oil has accumulated in a stopped outdoor unit and
180. when it turns ON for the purpose of recovering refrigerant in the outdoor unit at the end of the heating operation After the valve turns from ON to OFF it will not turn ON again for 15 minutes e This valve turns ON when poor refrigerant flow at an indoor unit is detected and when symptoms of overcharge are detected if the heat exchanger at the outdoor unit is functioning as an evaporator 4 This valve turns OFF when an abnormal drop in discharge gas temperature is detected b This valve turns OFF when a drop in the detected receiver tank temperature contin ues for a set length of time and when liquid back flow is judged to be occurring e 1 15 W 2WAY ECO i SYSTEM 6 Operation of Solenoid Valves Control Functions 6 3 Recovery Valve ORVR This valve recovers refrigerant oil from the balance tube to the compressor 1 When unit is stopped This valve is always OFF 2 When unit is operating A This valve turns ON when separator oil self recovery control is in progress B This valve is ON when unit refrigerant oil recovery control is in progress oil receiving unit C This valve is ON when control the system in case of insufficient refrigerant gas D This valve turns ON for 60 seconds after a constant speed compressor starts E This valve turns ON for 120 seconds after defrost control ends F This valve turns ON for 10 seconds after the outdoor unit stops G This valve remains OFF at all times other than A
181. when trouble judgment current is detected in the primary or secondary current or when an instantaneous secondary current of 13 5 A or higher is detected Probable cause The detection methods are the same as for P16 However the fact that operation up to high frequencies is possible does not necessarily mean that a compressor failure is the cause of the trouble Start the compressor several times If alarm P26 occurs every time and alarm P16 does not occur at all then the possibility of a compressor failure is low Check the power wiring and connector wiring It is possible to resolve this trouble by limiting the maximum frequency Example Notes P29 Alarm Alarm meaning Inverter compressor missing phase or lock alarm Alarm conditions This alarm may occur at start and occurs when missing phase or lock is detected and when a DCCT failure occurs Probable cause Generally this alarm occurs when the refrigerant pressure balance is uneven at start or when inverter compressor lock occurs there is a missing phase in the inverter compressor wiring or a DCCT failure occurs This can be judged to be starting trouble which is not caused by HIC Check the power wiring and connector wiring DCCT failure replace PCB or compressor failure BET DEES Notes Use a tester to measure the voltage between the DCCT output terminal on the rear of the PCB and the ground If the voltage is not within 2 3 V then the DCCT has malfunctioned CAUTION C

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