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SPLIT-TYPE, HEAT PUMP AIR CONDITIONERS SPLIT-TYPE, AIR CONDITIONERS November 2010 No. OCH483 SERVICE MANUAL Indoor unit [Model names] [Service Ref.] NOTE: • This manual describes only service data of the indoor units. • RoHS compliant products have <G> mark on the spec name plate. PKA-A12HA4 PKA-A18HA4 PKA-A12HA4 PKA-A18HA4 CONTENTS INDOOR UNIT COOL DRY AUTO FAN HEAT TEMP. 1. REFERENCE MANUAL................................... 2 2. SAFETY PRECAUTION................................... 3 3. PART NAMES AND FUNCTIONS................... 4 4. SPECIFICATIONS............................................ 7 5. NOISE CRITERION CURVES.......................... 8 6. OUTLINES AND DIMENSIONS....................... 9 7. WIRING DIAGRAM.........................................10 8. REFRIGERANT SYSTEM DIAGRAM............ 11 9. TROUBLESHOOTING....................................12 10. SPECIAL FUNCTION .....................................26 11. DISASSEMBLY PROCEDURE.......................29 PARTS CATALOG (OCB483) ON/OFF WIRED REMOTE CONTROLLER (Option) IR WIRELESS REMOTE CONTROLLER (Option) 33223 1 REFERENCE MANUAL 1-1. OUTDOOR UNIT SERVICE MANUAL Service Ref. Service Manual No. PUZ-A18/24/36NHA4 PUZ-A18/24/36NHA4-BS PUY-A12/18/24/36NHA4 PUY-A12/18/24/36NHA4-BS OCH481 OCB481 Remote controller (Optional parts) Radio frequency interface Wired remote controller IR wireless remote controller COOL DRY AUTO FAN HEAT RF thermostat TEMP. ON/OFF 2 2 SAFETY PRECAUTION 2-1. ALWAYS OBSERVE FOR SAFETY Before obtaining access to terminal, all supply circuits must be disconnected. 2-2. CAUTIONS RELATED TO NEW REFRIGERANT Cautions for units utilising refrigerant R410A Use new refrigerant pipes. Do not use refrigerant other than R410A. Make sure that the inside and outside of refrigerant piping is clean and it has no contaminants such as sulfur, oxides, dirt, shaving particles, etc, which are hazards to refrigerant cycle. In addition, use pipes with specified thickness. Contamination inside refrigerant piping can cause deterioration of refrigerant oil etc. Store the piping to be used indoors during installation, and keep both ends of the piping sealed until just before brazing. (Leave elbow joints, etc. in their packaging.) If other refrigerant (R22 etc.) is used, chlorine in refrigerant can cause deterioration of refrigerant oil etc. Use a vacuum pump with a reverse flow check valve. Vacuum pump oil may flow back into refrigerant cycle and that can cause deterioration of refrigerant oil etc. Use the following tools specifically designed for use with R410A refrigerant. The following tools are necessary to use R410A refrigerant. If dirt, dust or moisture enters into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor. Gauge manifold Charge hose Gas leak detector Torque wrench Tools for R410A Flare tool Size adjustment gauge Vacuum pump adaptor Electronic refrigerant charging scale The refrigerant oil applied to flare and flange connections must be ester oil, ether oil or alkylbenzene oil in a small amount. Handle tools with care. If large amount of mineral oil enters, that can cause deterioration of refrigerant oil etc. If dirt, dust or moisture enters into refrigerant cycle, that can cause deterioration of refrigerant oil or malfunction of compressor. Charge refrigerant from liquid phase of gas cylinder. Do not use a charging cylinder. If the refrigerant is charged from gas phase, composition change may occur in refrigerant and the efficiency will be lowered. If a charging cylinder is used, the composition of refrigerant will change and the efficiency will be lowered. Ventilate the room if refrigerant leaks during operation. If refrigerant comes into contact with a flame, poisonous gases will be released. [1] Cautions for service (1) Perform service after recovering the refrigerant left in unit completely. (2) Do not release refrigerant in the air. (3) After completing service, charge the cycle with specified amount of refrigerant. (4) When performing service, install a filter drier simultaneously. Be sure to use a filter drier for new refrigerant. [2] Additional refrigerant charge When charging directly from cylinder · Check that cylinder for R410A on the market is syphon type. · Charging should be performed with the cylinder of syphon stood vertically. (Refrigerant is charged from liquid phase.) 3 Unit Gravimeter [3] Service tools Use the below service tools as exclusive tools for R410A refrigerant. No. 1 Tool name Gauge manifold Specifications · Only for R410A · Use the existing fitting specifications. (UNF1/2) · Use high-tension side pressure of 5.3MPa·G or over. 2 Charge hose 3 Electronic scale 4 Gas leak detector · Use the detector for R134a, R407C or R410A. 5 Adaptor for reverse flow check · Attach on vacuum pump. 6 Refrigerant charge base 7 Refrigerant cylinder 8 Refrigerant recovery equipment · Only for R410A · Use pressure performance of 5.09MPa·G or over. 3 — — · Only for R410A · Top of cylinder (Pink) · Cylinder with syphon — PART NAMES AND FUNCTIONS Indoor unit Filter Louver Air intake Vane Air outlet 4 ● Wired remote controller (Option) Display Section For purposes of this explanation, all parts of the display are shown. During actual operation, only the relevant items will be lit. “Sensor” indication Day-of-Week Displays when the remote controller sensor is used. Shows the current day of the week. Time/Timer Display “Locked” indicator Shows the current time, unless the simple or Auto Off timer is set. If the simple or Auto Off timer is set, the time to be switched off is shown. Indicates that remote controller buttons have been locked. Identifies the current operation “Clean The Filter” indicator Shows the operating mode, etc. *Multilanguage display is available. To be displayed on when it is time to clean the filter. TIME SUN MON TUE WED THU FRI SAT TIMER Hr ON AFTER Indicates that operation from the remote controller has been prohibited by a master controller. FUNCTION FILTER °F°C °F°C “Centrally Controlled” indicator Timer indicators AFTER OFF ERROR CODE The indicator comes on if the corresponding timer is set. WEEKLY SIMPLE AUTO OFF ONLY1Hr. Fan Speed indicator Shows the selected fan speed. “Timer is Off” indicator Indicates that the timer is off. Up/Down Air Direction indicator The indicator shows the direction of the outcoming airflow. “One Hour Only” indicator Temperature Setting Shows the target temperature. Room Temperature display Shows the room temperature. The room temperature display range is 46–102˚F. The display blinks if the temperature is less than 46˚F or 102˚F or more. Ventilation indicator Appears when the unit is running in Ventilation mode. Louver display Displays if the airflow is set to low or downward during COOL or DRY mode. (Operation varies according to model.) The indicator goes off in 1 hour, when the airflow direction also changes. Indicates the action of the swing louver. Does not appear if the louver is not running. (Power On indicator) Indicates that the power is on. Operation Section ON/OFF button Temperature setting buttons Down Fan Speed button Up Timer Menu button (Monitor/Set button) Filter button (<Enter> button) Mode button (Return button) TEMP. ON/OFF Set Time buttons Check button (Clear button) Back Ahead Timer On/Off button (Set Day button) Test Run button MENU BACK PAR-21MAA MONITOR/SET ON/OFF FILTER DAY CLOCK CHECK TEST OPERATION Airflow Up/Down button CLEAR Louver button ( Operation button) To return operation number Opening the cover Ventilation button ( Operation button) Built-in temperature sensor To go to next operation number Note: WAIT” message • “PLEASE This message is displayed for approximately 3 minutes when power is supplied to the indoor unit or when the unit is recovering from a power failure. AVAILABLE” message • “NOT This message is displayed if an invalid button is pressed (to operate a function that the indoor unit does not have). If a single remote controller is used to operate multiple indoor units simultaneously that are different types, this message will not be displayed as far as any of the indoor units is equipped with the function. 5 ● IR wireless remote controller (Option) CHECK TEST RUN display Indicate that the unit is being checked or test-run. MODEL SELECT display display Blinks when model is selected. Lights up while the signal is transmitted to the indoor unit when the button is pressed. Temperature setting display Indicates the desired temperature setting which is set. CLOCK display OPERATION MODE display Displays the current time. OPERATION MODE display Indicates which operation mode is in effect. COOL DRY AUTO FAN HEAT display The vertical direction of airflow is indicated. TIMER display CHECK TEST MODEL RUN SELECT FAN °F °C STOP AMPM SWING “ START AMPM NOT AVAILABLE ON/OFF Displays when in timer operation or when setting timer. “ TEMP ”“ ” display Displays the order of timer operation. ”“ ” display Displays whether timer is on or off. display button Displays selected fan speed. Sets any desired room temperature. ON/OFF button The unit is turned ON and OFF alternately each time the button is pressed. FAN SPEED SELECT button MODE FAN AUTO STOP VANE AUTO START CHECK LOUVER h Changes the fan speed. TEST RUN min MODE SELECT button Switches the operation mode between COOLING/DRY/FAN/HEATING and AUTO mode. SET RESET TIMER CONTROL buttons AUTO STOP (OFF timer): when this switch is set, the air conditioner will be automatically stopped at the preset time. AUTO START (ON timer): when this switch is set, the air conditioner will be automatically started at the preset time. CLOCK "h" and "min" buttons In case the outdoor unit is cooling only type, the heating and auto mode are not available. Buttons used to set the “hour and minute” of the current time and timer settings. LOUVER button CHECK-TEST RUN button Changes left / right airflow direction. (Not available for this model.) Performs an inspection check or test operation. Do not use it for normal operation. CLOCK button VANE CONTROL button RESET button Changes the air flow direction. SET button 6 INDOOR UNIT INDOOR UNIT 4 SPECIFICATIONS Service Ref. Power supply(phase, cycle, voltage) Max. Fuse Size Min.Circuit Ampacity External finish Heat exchanger Fan Fan(drive) % No. Fan motor output Fan motor Airflow(Low-Middle-High) External static pressure Operation control & Thermostat Noise level(Low-Middle-High) Field drain pipe O.D. Dimensions W D H Weight Service Ref. Power supply(phase, cycle, voltage) Max. Fuse Size Min.Circuit Ampacity External finish Heat exchanger Fan Fan(drive) % No. Fan motor output Fan motor Airflow(Low-Middle-High) External static pressure Operation control & Thermostat Noise level(Low-Middle-High) Field drain pipe O.D. W Dimensions D H Weight PKA-A12HA4 1 phase, 60Hz, 208/230V 15 1 White Munsell 1.0Y 9.2/0.2 Plate fin coil Line flow fan (direct) % 1 0.030 0.33 Dry: 9-10.5-12 (320-370-425) Wet: 8-9.5-11 (290-335-380) 0(direct blow) Remote controller & built-in 36-40-43 16(5/8) 898 (35-3/8) 249 (9-13/16) 295 (11-5/8) 13 (29) A A kW F.L.A m3/min(CFM) Pa(mmAq) dB mm(in.) mm(in.) mm(in.) mm(in.) kg(lbs) PKA-A18HA4 1 phase, 60Hz, 208/230V 15 1 White Munsell 1.0Y 9.2/0.2 Plate fin coil Line flow fan (direct) % 1 0.030 0.33 Dry: 9-10.5-12 (320-370-425) Wet: 8-9.5-11 (290-335-380) 0(direct blow) Remote controller & built-in 36-40-43 16(5/8) 898 (35-3/8) 249 (9-13/16) 295 (11-5/8) 13 (29) A A kW F.L.A */min(CFM) Pa(mmAq) dB mm(in.) mm(in.) mm(in.) mm(in.) kg(lbs) 7 5 NOISE CRITERION CURVES PKA-A12HA4 PKA-A18HA4 NOTCH SPL(dB) High 43 36 Low LINE 90 OCTAVE BAND SOUND PRESSURE LEVEL, dB (0dB=0.0002 μbar) 80 70 NC-70 60 NC-60 50 NC-50 40 NC-40 30 NC-30 20 10 APPROXIMATE THRESHOLD OF HEARING FOR CONTINUOUS NOISE 63 125 NC-20 250 500 1000 2000 4000 8000 BAND CENTER FREQUENCIES, Hz UNIT WALL 3.3ft 3.3ft MICROPHONE 8 OUTLINES AND DIMENSIONS PKA-A12HA4 PKA-A18HA4 Unit: inch (mm) 15-3/16(387) 7-1/2(192) 7-3/4(197) Top side Mount board 23-9/16(599) Front side Right side 11-5/8(295) D Left side A 27-1/16(688) 2-1/8 (55) Knock out hole for left piping 9-13/16(249) 6-1/16(155) 35-3/8(898) 3/16(5) Knock out hole for right piping Front side(Grille open) Sleeve (purchased locally) :2-1/2~:3-1/8 (:65~:80) Through hole :2-1/2~:3-1/8 (:65~:80) Terminal block for indoor/outdoor connecting line Terminal block for power supply (option) Terminal block for MA-remote controller 17-15/16(457)Gas pipe 21-3/16(539)Liquid pipe 24(610)Drain hose 6-5/8(169) 6-3/16(158) DEFROST/STAND BY lamp Operation lamp 24-1/16(612) 5/16(8) Emergency operation switch (cooling/heating) 7-3/16(184) Under side Vane(auto) Refrigerant Liquid pipe Piping Gas pipe 1/4F (:6.35) Drain hose :5/8 (:16) O.D Knock out hole for lower piping Knock out hole for lower piping Louver(manual) C 1/2F (:12.7) Receiver B Center measurement hole :3/32(:2.5) 5/32(3.8) 12-7/8(237.5) 14(356.3) 14-5/8(372.3) 4-7/8(125) Mount board 7-13/16(200) 8-13/16(225) 9-5/16(238) 10-3/8(265) 11-7/16(291.5) 2-1/4(58) 0 5/8(16) 1-1/16(28.5) 1-9/16(41) 3-1/16(78.5) 3-9/16(91) 4-1/16(103.5) 4-9/16(116) 6-1/2(166) 7(178.5) 8(203.5) 9-1/8(232.5) 9-15/16(253.5) 2-3/4(70) 0 2-3/4(70) 9/16(15) 0 9/16(15) 4-7/8(125) 8-13/16(225) 7-13/16(200) 77-:3/16(:5.1) Tapping screw hole 11-7/16(291.5) 10-3/8(265) 14-5/8(372.3) 14(356.3) 12-7/8(327.5) 4-:5/16(:9) Bolt hole Indoor unit outline 13/16(21.8) 0 3/4(20) 1-1/4(32.7) 2-1/16(53.5) 2-9/16(66) 5(128.5) 6(153.5) 11-1/16(281) 7-9/16(193.5) Knock out hole for left rear piping 2-3/4×12-3/16(70×310) 4-1/2(115) 5-1/2(140) 6-9/16(167) 7-1/16(180.3) 10-15/16(278.3) 9-5/16(238) 8-3/8(213) 6-13/16(174) 15-1/2(394) 17-5/8(449) 0 17-5/8(449) 9-1/16(231.5) Wall hole for left rear piping 10-3/4(273.2) Wall hole for right rear piping Required space(Indoor unit) D 1-3/4(46) Min.1/4(7) 2-5/16(59) 1-11/16(43) A 1-11/16(43) 1-11/16(43) B 2-5/16(60) 9 Min.1-31/32(50) 250mm,9-13/16inch or greater with optional drain pump installation. 2-3/16(56) C 1-11/16(43) 2-3/16(56) 1-3/4(46) 2-3/16(56) 7/16(12.5) Air inlet 3/16(6) 2-11/16(69) (mm) Air inlet Air outlet Min.1-31/32(50) Min.8-5/8 (220) Min.5-7/8(150) Min.9-13/16(250) Knock out hole for piping 3/16(6) 6 7 WIRING DIAGRAM PKA-A12HA4 PKA-A18HA4 [LEGEND] Symbol I.B CN2L CN30 CN32 CN41 CN51 CN90 CN105 CN152 FUSE LED1 LED2 LED3 SW1 SW2 SWE RFI Name Indoor controller board Connector (LOSSNAY) Connector (LLC) Connector ( Remote switch) Connector (HA terminal-A) Connector (Centrally control) Connector (Remote operation adapter) Connector (Radio frequency interface) Connector (Back-up heating) FUSE(T3.15AL250V) Power supply (I.B) Power supply (R.B) Transmission (Indoor-outdoor) Switch (Model selection) +See Table 1 Switch (Capacity code) +See Table 2 Connector (Emergency operation) Radio frequency interface for RF thermostat Symbol M MS S.W SWE2 TB2 TB4 TB5 TH1 Name Vane motor Fan motor Switch board Emergency operation Terminal block (Indoor unit Power (option)) Terminal block (Indoor/outdoor connecting line) Terminal block (Remote controller transmission line) Room temp. Thermistor (32°F/15ΚΩ, 77°F/5.4ΚΩ Detect) TH2 Pipe temp. Thermistor/liquid (32°F/15ΚΩ, 77°F/5.4ΚΩ Detect) TH5 Cond./eva. temp. Thermistor (32°F/15ΚΩ, 77°F/5.4ΚΩ Detect) W.B Pcb for IR wireless remote controller LED1 LED (Operation indication : Green) LED2 LED (Preparation for heating : Orange) REC1 Receiving unit OPTION PART Wired remote controller board R.B Terminal block (Remote controller transmission line) TB6 MS 3~ <Table 1> SW1 (MODEL SELECTION) I.B 1 CNMF 6 (WHT) FUSE DB1 SWE LED2 1 Refer to tables 1and 2 1 2 CN2L (RED) 1 1 1 5 CN41 (WHT) 10 CN152 (WHT) CN151 (WHT) 9 CN90 (WHT) CN20 (RED) 1 2 1 CN44 (WHT) 4 BLK 3 X1 1 CNP(BLU) CN3C 3 (BLU) 1 LED3 1 CN32 3 (WHT) 1 CN51 (WHT) LDSWE (A) (BLU) 2 4 1 4 <+1> TO OUTDOOR UNIT 5 ORN BRN S.W W.B CNRU (WHT) 6 CN105 (RED) 1 5 CN22 (BLU) 1 2 SETTING 1 2 3 4 5 ON OFF <Table 2> SW2(CAPACITY CODE) LDSWE (B) SWE2 1 CN30 3 (BLK) CN4F (WHT) TB4 YLW S1 ORN S2 S3 YLW ORN CN01 (BLK) LED1 ON OFF 1 3 5 PKAA12HA4 PKAA18HA4 1 2 3 4 5 ON OFF ON OFF LED2 TB5 1 2 2 SETTING 1 2 3 4 5 The black square (■) indicates a switch position. RU LD101 (B) REC1 LED1 MODELS R.B 1 2 TB6 5 M RFI t° TH1 t° t° TH2 TH5 Notes: 1. SymboIs used in wiring diagram above are, : Connector, : Terminal (block). 2. Indoor and outdoor connecting wires have poIarities, make sure to match terminal numbers (S1, S2, S3) for correct wirings. 3. Since the outdoor side electric wiring may change, be sure to check the outdoor unit electric wiring diagram for servicing. 4. This diagram shows the wiring of indoor and outdoor connecting wires. (specification of 230V), adopting superimposed system of power and signal. +1 : Use copper supply wires. 10 8 REFRIGERANT SYSTEM DIAGRAM PKA-A12HA4 PKA-A18HA4 Strainer (#50) Heat exchanger Refrigerant GAS pipe connection (Flare) Thermistor TH2 Pipe temperature(Liquid) Thermistor TH5 (Cond./ Eva.temperature) Refrigerant flow in cooling Refrigerant flow in heating Refrigerant LIQUID pipe connection (Flare) Thermistor TH1 (Room temperature) Distributor with strainer (#50/#50) 11 Strainer (#50) 9 TROUBLESHOOTING 9-1. TROUBLESHOOTING <Error code display by self-diagnosis and actions to be taken for service (summary)> Present and past error codes are logged and displayed on the wired remote controller or controller board of outdoor unit. Actions to be taken for service and the trouble reoccurrence at field are summarized in the table below. Check the contents below before investigating details. Unit conditions at service Error code Actions to be taken for service (summary) Displayed Judge what is wrong and take a corrective action according to “9-3. Self-diagnosis action table”. The trouble is reoccurring. Not displayed Logged The trouble is not reoccurring. Not logged Conduct troubleshooting and ascertain the cause of the trouble according to “9-4. Troubleshooting by inferior phenomena”. Consider the temporary defects such as the work of protection devices in the refrigerant circuit including compressor, poor connection of wiring, noise and etc. Re-check the symptom, and check the installation environment, refrigerant amount, weather when the trouble occurred, matters related to wiring and etc. Reset error code logs and restart the unit after finishing service. There is no abnormality in electrical component, controller board,remote controller and etc. Re-check the abnormal symptom. Conduct trouble shooting and ascertain the cause of the trouble according to “9-4. Troubleshooting by inferior phenomena”. Continue to operate unit for the time being if the cause is not ascertained. There is no abnormality concerning of parts such as electrical component, controller board, remote controller and etc. 12 9-2. MALFUNCTION-DIAGNOSIS METHOD BY REMOTE CONTROLLER <In case of trouble during operation> When a malfunction occurs to air conditioner, both indoor unit and outdoor unit will stop and operation lamp blinks to inform unusual stop. <Malfunction-diagnosis method at maintenance service> ■IR wireless remote controller [Procedure] Refrigerant address display CHECK CHECK display Temperature button TEMP ON/OFF 1. Press the CHECK button twice. • "CHECK" lights, and refrigerant address "00" blinks. • Check that the remote controller's display has stopped before continuing. 2. Press the temperature buttons. • Select the refrigerant address of the indoor unit for the self-diagnosis. Note: Set refrigerant address using the outdoor unit’s DIP switch (SW1). (For more information, see the outdoor unit installation manual.) ON/OFF button MODE FAN AUTO STOP VANE AUTO START h CHECK LOUVER CHECK button 3. Point the remote controller at the • If an air conditioner error occurs, the sensor on the indoor unit and indoor unit's sensor emits an intermitpress the HOUR button. tent buzzer sound, the operation lamp blinks, and the error code is output. (It takes 3 seconds at most for error code to appear.) HOUR button min TEST RUN RESET SET CLOCK 4. Point the remote controller at the • The check mode is cancelled. sensor on the indoor unit and press the ON/OFF button. ■Wired remote controller Turn on the power. Press the [CHECK] button twice. Set address with [TEMP] button if system control is used. Press the [ON/OFF] button to stop the self-check. CHECK button Address TEMP. button IC : Indoor unit OC: Outdoor unit – – – – : No trouble generated in the past. Check code F F F F : No corresponding unit. Unit No. ERROR CODE ERROR CODE TEMP. ON/OFF MENU BACK PAR-21MAA MONITOR/SET ON/OFF DAY CHECK TEST OPERATION CLOCK FILTER ERROR CODE Timer ON/OFF button CLEAR <To delete check code> Display the error code on the self-check result display screen. The address for self-check will blink when the ON/OFF button is pressed twice within 3 seconds. 13 • Refer to the following tables for details on the check codes. [Output pattern A] Beeper sounds OPERATION INDICATOR lamp blink pattern Beep Beep Beep Beep Off Beep 1st 2 nd 3 rd nth On On On On Beep Beep 1st Off On 2 nd · · · Repeated On 0.5 sec. Approx. 2.5 sec. 0.5 sec. 0.5 sec. Self-check Approx. 2.5 sec. 0.5 sec. 0.5 sec. 0.5 sec. starts (Start signal Number of blinks/beeps in pattern indicates the check Number of blinks/beeps in pattern indicates received) code in the following table (i.e., n=5 for “P5”) the check code in the following table [Output pattern B] Beeper sounds OPERATION INDICATOR lamp blink pattern Beep Beep Beep Beep 1st Off On Approx. 3 sec. Self-check Approx. 2.5 sec. starts (Start signal received) 2nd Beep Beep nth 1st 3 rd On On On 0.5 sec. 0.5 sec. 0.5 sec. On Off 0.5 sec. Approx. 2.5 sec. Number of blinks/beeps in pattern indicates the check code in the following table (i.e., n=5 for “U2”) On Approx. 3 sec. Beep 2 nd · · · Repeated On On 0.5 sec. 0.5 sec. Number of blinks/beeps in pattern indicates the check code in the following table [Output pattern A] Errors detected by indoor unit IR wireless remote controller Wired remote controller Beeper sounds/OPERATION INDICATOR lamp blinks Check code (Number of times) 1 P1 P2 2 P9 3 E6,E7 4 P4 P5 5 PA 6 P6 7 EE 8 P8 9 E4, E5 – 10 – 11 12 Fb E0, E3 – – E1, E2 Symptom Remark Intake sensor error Pipe (TH2) sensor error Pipe (TH5) sensor error Indoor/outdoor unit communication error Float switch connector (CN4F) open Drain pump error Forced compressor stop(due to water leakage abnormality) Freezing/Overheating protection operation Communication error between indoor and outdoor units Pipe temperature error Remote controller signal receiving error – – Indoor unit control system error (memory error, etc.) Remote controller transmission error Remote controller control board error [Output pattern B] Errors detected by unit other than indoor unit (outdoor unit, etc.) IR wireless remote controller Wired remote controller Beeper sounds/OPERATION INDICATOR lamp blinks Check code (Number of times) 1 E9 2 3 4 UP U3,U4 UF 5 U2 6 U1,Ud 7 8 9 10 U5 U8 U6 U7 11 U9,UH Symptom Indoor/outdoor unit communication error (Transmitting error) (Outdoor unit) Compressor overcurrent interruption Open/short of outdoor unit thermistors Compressor overcurrent interruption (When compressor locked) Abnormal high discharging temperature/49C operated/ insufficient refrigerant Abnormal high pressure (63H operated)/Overheating protection operation Abnormal temperature of heatsink Outdoor unit fan protection stop Compressor overcurrent interruption/Abnormal of power module Abnormality of superheat due to low discharge temperature Abnormality such as overvoltage or voltage shortage and abnormal synchronous signal to main circuit/Current sensor error – – Other errors (Refer to the technical manual for the outdoor unit.) Remark For details, check the LED display of the outdoor controller board. As for outdoor unit, refer to outdoor unit's service manual. – 12 – 13 Others 14 *1 If the beeper does not sound again after the initial 2 beeps to confirm the self-check start signal was received and the OPERATION INDICATOR lamp does not come on, there are no error records. *2 If the beeper sounds 3 times continuously “beep, beep, beep (0.4 + 0.4 + 0.4 sec.)” after the initial 2 beeps to confirm the self-check start signal was received, the specified refrigerant address is incorrect. 14 • On IR wireless remote controller The continuous buzzer sounds from receiving section of indoor unit. Blink of operation lamp • On wired remote controller Check code displayed in the LCD. (Refer to the previous page, check code.) • If the unit cannot be operated properly after the test run, refer to the following table to find out the cause. Symptom Cause Wired remote controller LED 1, 2 (PCB in outdoor unit) For about 2 After LED 1, 2 are lighted, LED 2 is •For about 2 minutes following power-on, opPLEASE WAIT minutes after turned off, then only LED 1 is eration of the remote controller is not possible power-on lighted. (Correct operation) due to system start-up. (Correct operation) •Connector for the outdoor unit’s protection Only LED 1 is lighted. device is not connected. Error code PLEASE WAIT LED 1, 2 blink. •Reverse or open phase wiring for the outdoor Subsequent to unit’s power terminal block (L1, L2, GR) about 2 minutes after power-on Only LED 1 is lighted. Display messages do not •Incorrect wiring between indoor and outdoor appear even when operation LED 1 blinks twice, units (incorrect polarity of S1, S2, S3) switch is turned ON (operation LED 2 blinks once. •Remote controller wire short lamp does not light up). On the IR wireless remote controller with condition above, following phenomena take place. • No signals from the remote controller can be received. • OPE lamp is blinking. • The buzzer makes a short ping sound. Note: Operation is not possible for about 30 seconds after cancellation of function selection. (Correct operation) For description of each LED (LED1, 2, 3) provided on the indoor controller, refer to the following table. LED1 (power for microprocessor) LED2 (power for wired remote controller) Indicates whether control power is supplied. Make sure that this LED is always lit. Indicates whether power is supplied to the wired remote controller. This LED lights only in the case of the indoor unit which is connected to the outdoor unit refrigerant addresses “0”. LED3 (communication between indoor and outdoor units) Indicates state of communication between the indoor and outdoor units. Make sure that this LED is always blinking. 15 9-3. SELF-DIAGNOSIS ACTION TABLE Error Code P1 Abnormal point and detection method Room temperature thermistor (TH1) The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) Constantly detected during cooling, drying, and heating operation. Short: 90 Open: -40 Note: Refer to the manual of outdoor unit for the details of display such as F, U, and other E. Countermeasure Cause Defective thermistor – Check resistance value of thermistor. • • • • • • • • • • 15.0k characteristics 0 • • • • • • • • • • • • 9.6k 10 Contact failure of connector • • • • • • • • • • • • 6.3k (CN20) on the indoor controller 20 • • • • • • • • • • • • 4.3k board (Insert failure) 30 • • • • • • • • • • •3.0k 40 Breaking of wire or contact failure of thermistor wiring If you put force on (draw or bend) the lead wire while measuring resistance value of thermistor, Defective indoor controller board breaking of wire or contact failure can be detected. Check contact failure of connector (CN20) on the indoor controller board. Refer to 9-7. Turn the power on again and check restart after inserting connector again. Check room temperature display on remote controller. Replace indoor controller board if there is abnormal difference with actual room temperature. Turn the power off, and on again to operate after check. P2 Pipe temperature thermistor/Liquid (TH2) The unit is in 3-minute resume prevention mode if short/open of thermistor is detected. Abnormal if the unit does not reset normally after 3 minutes. (The unit returns to normal operation, if it has been reset normally.) Constantly detected during cooling, drying, and heating (except defrosting) operation. Short: 90 Open: -40 Defective thermistor – Check resistance value of thermistor. characteristics For characteristics, refer to (P1) above. Contact failure of connector Check contact failure of connector (CN44) on (CN44) on the indoor controller the indoor controller board. Refer to 9-7. board (Insert failure) Turn the power on and check restart after Breaking of wire or contact inserting connector again. failure of thermistor wiring Check pipe <liquid> temperature with remote Defective refrigerant circuit is controller in test run mode. If pipe <liquid> causing thermistor temperatemperature is extremely low (in cooling ture of 90 mode) or high (in heating mode), refrigerant -40 circuit may have defect. Defective indoor controller Check pipe <liquid> temperature with remote board controller in test run mode. If there is extremely difference with actual pipe <liquid> temperature, replace indoor controller board. Turn the power off, and on again to operate after check. P4 (5701) P5 Contact failure of drain float switch (CN4F) Extract when the connector of drain float switch is disconnected. ( and of connector CN4F is not short-circuited.) Constantly detected during operation. Contact failure of connector (Insert failure) Drain overflow protection operation Suspensive abnormality, if drain float switch is detected to be underwater for 1 minute and 30 seconds continuously with drain pump on. Turn off compressor and indoor fan. Drain pump is abnormal if the condition above is detected during suspensive abnormality. Constantly detected during drain pump operation. Malfunction of drain pump Defective drain Clogged drain pump Clogged drain pipe Defective drain float switch Catch of drain float switch or malfunction of moving parts cause drain float switch to be detected under water (Switch On) Defective indoor-controller board Defective indoor controller board Check contact failure of float switch connector. Turn the power on again and check after inserting connector again. Operate with connector (CN4F) short-circuited. Replace indoor controller board if abnormality reappears. Check if drain pump works. Check drain function. Remove drain float switch connector CN4F and check if it is short (Switch On) with the moving part of float switch UP, or OPEN with the moving part of float switch down. Replace float switch if it is short with the moving part of float switch down. Replace indoor controller board if it is shortcircuited between - of the drain float switch connector CN4F and abnormality reappears. It is not abnormal if there is no problem about the above-mentioned ~ Turn the power off, and on again to operate after check. 16 Error Code P6 Abnormal point and detection method Countermeasure Cause Freezing/overheating protection is (Cooling or drying mode) (Cooling or drying mode) operating Check clogs of the filter. Clogged filter (reduced airflow) Freezing protection (Cooling mode) Remove blockage. Short cycle of air path The unit is in 6-minute resume prevention Low load (low temperature) mode if pipe <liquid or condenser/evapooperation out of the tolerance rator> temperature stays under range Refer to 9-6. Defective indoor fan motor the compressor started. Abnormal if it • Fan motor is defective. • Indoor controller board is defecagain within 16 minutes after 6-minute tive. resume prevention mode. Check outdoor fan motor. Defective outdoor fan control Overcharge of refrigerant Check operating condition of refrigerant circuit. Defective refrigerant circuit (clogs) Overheating protection (Heating mode) The units is in 6-minute resume prevention mode if pipe <liquid or condenser/evaporator> temperature is detected as over 70°C[158°F] after the compressor started. Abnormal if the temperature of over 70°C[158°F] is detected again within 10 minutes after 6 minute resume prevention mode. Pipe temperature <Cooling mode> Detected as abnormal when the pipe temperature is not in the cooling range 3 minutes after compressor start and 6 minutes after the liquid or condenser/evaporator pipe is out of cooling range. Note 1) It takes at least 9 minutes to detect. Note 2) Abnormality P8 is not detected in drying mode. Cooling range : (TH-TH1) TH: Lower temperature between liquid pipe temperature (TH2) and condenser/ evaporator temperature (TH5) TH1: Intake temperature P8 <Heating mode> When 10 seconds have passed after the compressor starts operation and the hot adjustment mode has finished, the unit is detected as abnormal when condenser/ evaporator pipe temperature is not in heating range within 20 minutes. Note 3) It takes at least 27 minutes to detect abnormality. Note 4) It excludes the period of defrosting (Detection restarts when defrosting mode is over) Heating range : (TH5-TH1) (Heating mode) (Heating mode) Clogged filter (reduced airflow) Check clogs of the filter. Remove blockage. Short cycle of air path Overload (high temperature) operation out of the tolerance range Defective indoor fan motor Refer to 9-6. • Fan motor is defective. • Indoor controller board is defective. Check outdoor fan motor. Defective outdoor fan control Overcharge of refrigerant ~ Check operating condition of refrigerant circuit. Defective refrigerant circuit (clogs) Bypass circuit of outdoor unit is defective. Slight temperature difference between indoor room temperature and pipe <liquid or condenser/evaporator> temperature thermistor • Shortage of refrigerant • Disconnected holder of pipe <liquid or condenser/ evaporator> thermistor • Defective refrigerant circuit Converse connection of extension pipe (on plural units connection) Converse wiring of indoor/ outdoor unit connecting wire (on plural units connection) Defective detection of indoor room temperature and pipe <condenser/evaporator> temperature thermistor Stop valve is not opened completely. 17 ~ ( Check pipe <liquid or condenser/evaporator> temperature with room temperature display on remote controller and outdoor controller circuit board. Pipe <liquid or condenser/evaporator> temperature display is indicated by setting SW2 of outdoor controller circuit board as follows. Conduct temperature check with outdoor controller circuit board after connecting ‘A-Control Service Tool(PAC-SK52ST)’. ) Check converse connection of extension pipe or converse wiring of indoor/outdoor unit connecting wire. Error Code Abnormal point and detection method Pipe temperature thermistor/ Condenser-Evaporator (TH5) The unit is in 3-minute resume protection mode if short/open of thermistor is detected. Abnormal if the unit does not get back to normal within 3 minutes. (The unit returns to normal operation, if it has been reset normally.) Constantly detected during cooling, drying, and heating operation (except defrosting) P9 Cause Defective thermistor characteristics Contact failure of connector (CN44) on the indoor controller board (Insert failure) Breaking of wire or contact failure of thermistor wiring Temperature of thermistor is Countermeasure – defective refrigerant circuit. Defective indoor controller board ( PA (2500) E0 or E4 Check resistance value of thermistor. For characteristics, refer to (P1) above. Check contact failure of connector (CN44) on the indoor controller board. Refer to 9-7. Turn the power on and check restart after inserting connector again. Operate in test run mode and check pipe <condenser/evaporator> temperature with outdoor controller circuit board. If pipe <condenser/evaporator> temperature is exclusively low (in cooling mode) or high (in heating mode), refrigerant circuit may have defect. Operate in test run mode and check pipe <condenser/evaporator> temperature with outdoor control circuit board. If there is extreme difference with actual pipe <condenser/evaporator> temperature, replace indoor controller board. There is no abnormality if none of above comes within the unit. Turn the power off and on again to operate. In case of checking pipe temperature with outdoor controller circuit board, be sure to connect A-control service tool (PAC-SK52ST). ) Forced compressor stop (due to water leakage abnormality) The unit has a water leakage abnormality when the following conditions, a) and b), are satisfied while the abovementioned detection is performed. a) The intake temperature subtracted with liquid pipe temperature detects to be less than -10 [14 30 minutes. (When the drain sensor is detected to be NOT soaked in the water, the detection record of a) and b) will be cleared.) b) Drain float switch detects to be in the water for more than 15 minutes. *Once the water leakage abnormality is detected, abnormality state will not be released until the main power is reset. Drain pump trouble Drain defective · Drain pump clogging · Drain pipe clogging Open circuit of float switch Contact failure of float switch connector Dew condensation on float switch ·Drain water descends along lead wire. ·Drain water waving due to filter clogging. Extension piping connection difference at twin, triple, quadruple system. Miswiring of indoor/outdoor connecting at twin, triple, quadruple system. Room temperature thermistor/ liquid pipe temperature thermistor detection is defective. Remote controller transmission error(E0)/signal receiving error(E4) Abnormal if main or sub remote controller cannot receive any transmission normally from indoor unit of refrigerant address “0” for 3 minutes. (Error code : E0) Abnormal if sub remote controller could not receive for any signal for 2 minutes. (Error code: E0) Contact failure at transmission Check disconnection or looseness of indoor wire of remote controller unit or transmission wire of remote controller. All remote controllers are set Set one of the remote controllers “main” as “sub” remote controller. In if there is no problem with the action above. this case, E0 is displayed on Check wiring of remote controller. remote controller, and E4 is displayed at LED (LED1, LED2) (Do not use cable 3 or more.) on the outdoor controller circuit • The number of connecting indoor units: board. max. 16 units Miswiring of remote controller • The number of connecting remote controlDefective transmitting receiving ler: max. 2 units circuit of remote controller When the above-mentioned problem of ~ Defective transmitting receiving are not applied, circuit of indoor controller board Diagnose remote controllers. of refrigerant addresses “0”. a) When “RC OK” is displayed, remote conNoise has entered into the trollers have no problem. Turn the power transmission wire of remote off, and on again to check. If abnormality controller. generates again, replace indoor controller board. b) When “RC NG” is displayed, replace remote controller. c) When “RC E3” or “ERC 00-06” is displayed, noise may be causing abnormality. If the unit is not normal after replacing indoor controller board in group control, indoor controller board of address “0” may be abnormal. Abnormal if indoor controller board cannot receive any data normally from remote controller board or from other indoor controller board for 3 minutes. (Error code: E4) Indoor controller board cannot receive any signal from remote controller for 2 minutes. (Error code: E4) 18 Check the drain pump. Check whether water can be drained. Check the resistance of the float switch. Check the connector contact failure. Check the float switch leadwire mounted. Check the filter clogging. Check the piping connection. Check the indoor/outdoor connecting wires. Check the room temperature display of remote controller. Check the indoor liquid pipe temperature display of outdoor controller board. Error Code E3 or E5 E6 E7 Fb E1 or E2 Abnormal point and detection method Remote controller transmission error(E3)/signal receiving error(E5) Abnormal if remote controller could not find blank of transmission path for 6 seconds and could not transmit. (Error code: E3) Remote controller receives transmitted data at the same time, compares the data, and when detecting it, judges different data to be abnormal 30 continuous times. (Error code: E3) Abnormal if indoor controller board could not find blank of transmission path. (Error code: E5) Indoor controller board receives transmitted data at the same time, compares the data,and when detecting it, judges different data to be abnormal 30 continuous times. (Error code: E5) Countermeasure Cause 2 remote controllers are set as “main.” (In case of 2 remote controllers) Remote controller is connected with 2 indoor units or more. Repetition of refrigerant address Defective transmitting receiving circuit of remote controller Defective transmitting receiving circuit of indoor controller board Noise has entered into transmission wire of remote controller. Set a remote controller to main, and the other to sub. Remote controller is connected with only one indoor unit. The address changes to a separate setting. ~ Diagnose remote controller. a) When “RC OK” is displayed, remote controllers have no problem. Turn the power off, and on again to check. When becoming abnormal again, replace indoor controller board. b) When “RC NG” is displayed, replace remote controller. c) When “RC E3” or “ERC 00-66” is displayed, noise may be causing abnormality. Indoor/outdoor unit communication error (Signal receiving error) Abnormal if indoor controller board cannot receive any signal normally for 6 minutes after turning the power on. Abnormal if indoor controller board cannot receive any signal normally for 3 minutes. Consider the unit as abnormal under the following condition: When 2 or more indoor units are connected to an outdoor unit, indoor controller board cannot receive a signal for 3 minutes from outdoor controller circuit board, a signal which allows outdoor controller circuit board to transmit signals. Contact failure, short circuit or, miswiring (converse wiring) of indoor/outdoor unit connecting wire Defective transmitting receiving circuit of outdoor controller circuit board. Defective transmitting receiving circuit of indoor controller board Noise has entered into indoor/ outdoor unit connecting wire. Check LED display on the outdoor control circuit board. (Connect A-control service tool, PAC-SK52ST.) Refer to EA-EC item if LED displays EA-EC. Check disconnection or looseness of indoor/ outdoor unit connecting wire of indoor unit or outdoor unit. Check all the units in case of twin indoor unit system. - Turn the power off, and on again to check. If abnormality generates again, replace indoor controller board or outdoor controller circuit board. Other indoor controller board may have defect in case of twin indoor unit system. Indoor/outdoor unit communication error (Transmitting error) Abnormal if indoor controller board receives “1” 30 times continuously when indoor controller board transmits “0” signal. Defective transmitting receiving circuit of indoor controller board. Noise has entered into power supply. Noise has entered into outdoor control wire. - Indoor controller board Abnormal if data cannot be read normally from the nonvolatile memory of the indoor controller board. Defective indoor controller board Replace indoor controller board. Remote controller control board Abnormal if data cannot be read normally from the nonvolatile memory of the remote controller control board. (Error code: E1) Defective remote controller Replace remote controller. Abnormal if the clock function of remote controller cannot be operated normally. (Error code: E2) 19 Turn the power off, and on again to check. If abnormality generates again, replace indoor controller board. 9-4. TROUBLESHOOTING BY INFERIOR PHENOMENA Note: Refer to the manual of outdoor unit for the detail of remote controller. Phenomena (1)Upward/downward vane performance failure Cause Countermeasure The vane is not downward during defrosting and heat preparation and when the thermostat is OFF in HEAT mode. (Working of COOL protection function) Vane motor does not rotate. • Defective vane motor • Breaking of wire or connection failure of connector Upward/downward vane does not work. • The vane is set to fixed position. (2)Receiver for IR wireless remote controller Weak batteries of IR wireless remote controller Contact failure of connector (CNB) on IR wireless remote controller board (Insert failure) Contact failure of connector (CN90) on indoor controller board (Insert failure) Contact failure of connector between IR wireless remote controller board and indoor controller board 20 Normal operation (The vane is set to horizontal regardless of remote control.) Check (left). • Check the vane motor. (Refer to “How to check the parts”.) • Check for breaking of wire or connection failure of connector. Normal operation (Each connector on vane motor side is disconnected or setting the fixed vanes by wired remote controller.) Replace batteries of IR wireless remote controller. ~ Check contact failure of each connector. If no problems are found of connector, replace indoor controller board. When the same trouble occurs even if indoor controller board is replaced, replace IR wireless remote controller board. 9-5. EMERGENCY OPERATION 9-5-1. When IR wireless remote controller fails or its battery is exhausted When the remote controller cannot be used When the batteries of the remote controller run out or the remote controller malfunctions, the emergency operation can be done using the emergency buttons. DEFROST/STAND BY lamp (ORANGE) Operation lamp (GREEN) Emergency operation switch (cooling/heating) Receiver E.O. SW • Each press of the emergency operation switch will toggle the operation mode. • Check “COOL/HEAT” with the operation monitor display. (The display will appear orange for 5 seconds after pressing the emergency operation switch.) [Heat pump type] Cooling Heating Stop [Cooling Only type] Cooling Stop Operation Monitor Display GREEN ORANGE STOP The orange lamp follows the switch operation as indicated at the left for 5 sedonds, and then it will return to the normal display. COOL HEAT OFF ON * Details of emergency mode are as shown below. Operation Mod Set Temperature Fan Speed Airflow Direction Up and Down COOL 24°C, 75°F High Horizontal HEAT 24°C, 75°F High Downward 9-5-2. When wired remote controller or indoor unit microprocessor fails 1. When the wired remote control or the indoor unit microprocessor has failed, but all other components work properly, if you set the switch (SWE) on the indoor controller board ON, the indoor unit will begin Emergency Operation. When Emergency Operation is activated, the indoor unit operates as follows: (1) Indoor fan is running at high speed. + Note on the IR wireless remote control: when the remote control does not function, it is possible to activate emergency operation by using the indoor unit emergency operation switch. However, if the indoor unit microprocessor has failed, it is nesessary to proceed with points 2 and 3 below as in the case of the wired remote control. 2. When you activate Emergency Operation of the cooling or heating, you have to set the switch (SWE) on the indoor controller board and activate Emergency Operation of the outdoor unit. For details on how to activate Emergency Operation of the outdoor unit, refer to the outdoor unit wiring diagram. 3. Before you activate Emergency Operation, check the following points: (1) Emergency operation cannot be activated when: • the outdoor unit malfunctions. • the indoor fan malfunctions. • when it has detected the malfunction of drain pump during self-diagnosing. (2) Emergency Operation becomes continuous only by switching the power source on/off. ON/OFF on the remote control or temperature control etc. does not function. (3) Avoid operating for a long time when the outdoor unit begins defrosting while Emergency Operation of the heating is activated, because it will start to blow cold air. (4) Emergency cooling should be limited to 10 hours maximum (The indoor unit heat exchanger may freeze). (5) After Emergency Operation has been deactivated, set the switches etc. to their original positions. (6) Movement of the vanes does not work in Emergency operation, thereforeyou have to slowly set them manually to the appropriate position. 21 9-6. HOW TO CHECK THE PARTS PKA-A12HA4 PKA-A18HA4 Parts name Check points Room temperature thermistor (TH1) Liquid pipe thermistor (TH2) Condenser/evaporator temperature thermistor (TH5) Disconnect the connector then measure the resistance with a tester. (At the ambient temperature 50"F~86"F) Vane motor (MV) Measure the resistance between the terminals with a tester. (Coil temperature 77"F) Red Yellow Brown Connect pin No. Normal 4.3k~9.6k Abnormal Open or short Normal Abnormal - - - - Brown-Red Brown-Orange Brown-Yellow Brown-Green Open or short M Orange Green 350 ± 7% Fan motor (MF) (Refer to the next page for a detail.) Refer to 9-6-2. 9-6-1. Thermistor <Thermistor Characteristic graph> Thermistor for lower temperature <Thermistor for lower temperature> 50 Room temperature thermistor (TH1) Pipe temperature thermistor/liquid (TH2) Condenser/evaporator temperature thermistor (TH5) 1 t( )Rt=15exp { 3480( 273+t 1 273+ T-32 1.8 Resistance (k ) Thermistor R0=15k ± 3% Fixed number of B=3480 ± 2% 40 1 )} 273 1 273 0 10 20 25 30 40 30 20 10 0 22 -20 -10 0 10 20 30 40 50 °C -4 -14 32 50 68 86 104122 °F Temperature 9-6-2. DC Fan motor (fan motor/indoor controller circuit board) Check method of DC fan motor (fan motor/indoor controller circuit board) Notes · High voltage is applied to the connecter (CNMF) for the fan motor. Pay attention to the service. · Do not pull out the connector (CNMF) for the motor with the power supply on. (It causes trouble of the indoor controller circuit board and fan motor.) Self check Symptom : The indoor fan cannot rotate. Wiring contact check Contact of fan motor connector (CNMF) Is there contact failure? Wiring recovery Yes No Power supply check (Remove the connector (CNMF)) Measure the voltage in the indoor controller circuit board. TEST POINT : VDC (between 1 (+) and 3 (-) of the fan connector): VDC DC294~325V TEST POINT : VCC (between 4 (+) and 3 (-) of the fan connector): VCC DC15V Is the voltage normal? No Indoor controller board fuse check Yes No Is the fuse normal? Replace the fuse. Yes Replace the indoor controller board. OK NG Check the operation OK END Check the operation NG Replace the fan motor. Sensor signal check Measure the voltage between CNMF and DC 0V and DC 15V in the indoor controller circuit board. No Does the voltage repeat DC 0V and DC 15V? Replace the fan motor. Yes Yes Check the operation of fan. Replace the indoor controller board. NG Replace the indoor controller board. OK Check the operation OK END NG Replace the fan motor. 23 END END 9-7. TEST POINT DIAGRAM Indoor controller board PKA-A12HA4 PKA-A18HA4 CNMF Connect to the fan motor (MF) 1-3 : DC294~325V 4-3 : DC15V 5-3 : DC0~6.5V 6-3 : DC0 or DC15V CN105 RFI (Radio frequency interface) CN01 Connect to the Terminal block (TB4) 1-3 : 208/230VAC SWE Emergency operation connector FUSE (3.15A 250V) SW1 Model selection { LED1:Power supply (I.B) LED2:Power supply (R.B) LED3:Transmission (Indoor/outdodr) CN3C Transmission (Indoor/outdodr) (DC 0~24V) SW2 Capacity setting CN22 Connect to the terminal block (TB5) (Remote controller connecting wire) CN151 Connect to the vane motor (MV) CN30 Jumper wire J41,J42 Connector (LLC) Pair No. setting for IR wireless remote controller CN32 Remote switch CN90 Connect to the remote operation adapter CN152 Connector (Back-up heating) CN20 Room temp. thermistor (TH1) CN2L CN41 Connector (LOSSNAY) Connector (HA terminal-A) CN44 Pipe temperature thermistor 1-2 : Liquid (TH2) 3-4 : Condenser/Evaporator (TH5) SWE2 Emergency operation switch IR wireless remote controller board 24 CN51 Centrally control 1-2 : Control signal 13VDC pulse input (1: +) 3-4 : Operation indicator 13VDC (3: +) 3-5 : Malfunction indicator 13VDC (3: +) 9-8. FUNCTIONS OF DIP SWITCH AND JUMPER WIRE Each function is controlled by the dip switch and the jumper wire on control P.C. board. The black square (■) indicates a switch position. Jumper wire Functions SW1 Model settings Setting by the dip switch and jumper wire MODELS PKA-A·HA4 MODELS SW2 Capacity settings A12 A18 J41 J42 Pair number setting with IR wireless remote controller JP3 Indoor controller board type setting SETTING 1 2 3 4 5 ON OFF SETTING 1 2 3 4 5 1 2 3 4 5 ON OFF ON OFF Wireless remote Control PCB setting controller setting J41 J42 0 1 2 3~9 Jumper wire ( Remarks : Short Indoor controller board type For product Spare parts : Open) JP3 25 <Initial setting> IR wireless remote controller: 0 Control PCB: (for both J41 and J42) 4 pair number settings are supported. The pair number settings of the wireless remote controller and indoor control PCB (J41/J42) are given in the table on the left. (' ' in the table indicates the jumper wire is disconnected.) : With JP3 : Without JP3 10 SPECIAL FUNCTION 10-1. Rotation Function (and back-up function, 2nd stage cut-in function) This function is only available when using wired remote controller. 10-1-1. Operation (1) Rotation function (and Back-up function) Outline of functions · Main and sub units operate alternately according to the interval of rotation setting. w Main and sub unit should be set by refrigerant address. (Outdoor Dip switch setting) Refrigerant address "00" Main unit Refrigerant address "01" Sub unit · When error occurs to one unit, another unit will start operation. (Back-up function) System constraint · This function is available only by the grouping control system (INDOOR UNIT: OUTDOOR UNIT=1:1) of 2 refrigerant groups. (Refer to Fig. 1) · Main indoor unit should be connected for wired remote controller and the transmission line (TB5) for main and sub unit should also be connected. (Refer to Fig. 1) (This function cannot be set by IR wireless remote controller.) · Set refrigerant address of each unit. (Dip switch on the outdoor unit ··· Refrigerant address 00/01) Fig. 1 Operation pattern [Back-up function only]··· Request code number "312" Error occurs on main unit. Main Sub Start operation Main unit IC-1 Sub unit IC-2 Refrigerant address "00" Run Abnormal condition Stop Run 3(2) 2 Start operation Sub unit IC-2 3(2) Main Sub Sub Error occurs on main unit. Main Main Sub Abnormal condition Run Stop Run Stop Run Stop 1~28 days Sub unit IC-2 IC-1 [Rotation function] & [Back-up function]··· Request code number "313~318" Main unit IC-1 OC-2 OC-1 Main unit Refrigerant address "01" 2 RC OC : Outdoor unit IC : Indoor unit RC : Wired remote controller Run 1~28 days (Ex:When the request code number is "313", each unit operates alternately in daily cycle.) Note: · When the uint is restarted to operate after turning off the power or OFF operation, the unit which was operating will start operation. · To operate the main unit, refer to the 10-1-2. and set the request code No. which is not the same as the current one, and set again the former request code No. (2) 2nd stage cut-in function Outline of functions · When the 1st unit can NOT supply with sufficient capacity for exceptionally high-demand conditions and the actual room temperature reaches set point *, the 2nd unit starts operation in conjunction with the 1st unit. · Once the actual room temperature goes down to 4 degrees C (7.5 degrees F) below set point*, the 2nd unit stops operation automatically. (* set point = set temperature by R/C (remote controller) + 4, 6, 8:(7.5, 10.8, 14.4°F) (selectable)) · Number of operating units is determined according to the room temperature and set point. · When room temperature becomes higher than set point, standby unit starts. (2 units operation) · When room temperature falls below set point -4:(-7.5°F), standby unit stops. (1 unit operation) 26 System constraint · This function is available only in cooling mode. Ex.) Set temp. by R/C = 20:(68°F) Set point = 26:(79°F) When request code number is “323”. [2nd stage cut-in function]··· Request code number "322~324" Start operation 26: (79°F) 22: (71.5°F) 2nd unit Cut-in 4 degree C (7.5 degreeF) 2nd unit Cut-out Main unit IC-1 Room temp. Set point Sub unit start operation Run Sub unit IC-2 Stop Run 20: (68°F) 10-1-2. How to set rotation function (Back-up function, 2nd stage cut-in function) You can set these functions by wired remote controller. (Maintenance monitor) NOTE Both main and sub unit should be set in same setting. Every time replacing indoor controller board for servicing, the function should be set again. (1) Request Code List Rotation setting Setting No. (Request code) No.1 (310) No.2 (311) No.3 (312) No.4 (313) No.5 (314) No.6 (315) No.7 (316) No.8 (317) No.9 (318) Initial setting Setting contents Monitoring the request code of current setting. Rotation and Back-up OFF (Normal group control operation) Back-up function only Rotation ON (Alternating interval = 1day) and back up function Rotation ON (Alternating interval = 3day) and back up function Rotation ON (Alternating interval = 5day) and back up function Rotation ON (Alternating interval = 7day) and back up function Rotation ON (Alternating interval = 14day) and back up function Rotation ON (Alternating interval = 28day) and back up function 2nd stage cut-in setting Setting No. (Request code) No.1 (320) No.2 (321) No.3 (322) No.4 (323) No.5 (324) Room temp. < Set point -4(-7.5°F) Sub unit stop Initial setting Setting contents Monitoring the request code of current setting. Cut-in function OFF Cut-in Function ON(Set point = Set temp.+ 4°C(7.5°F)) Cut-in Function ON(Set point = Set temp.+ 6°C(10.8°F)) Cut-in Function ON(Set point = Set temp.+ 8°C(14.4°F)) 27 Stop (2) Setting method of each function by wired remote controller B: Refrigerant address C: Data display area D: Request code display area 1. Stop operation( ). 2. Press the TEST button () for 3 seconds so that [Maintenance mode] appears on the screen (). After a while, [00] appears in the refrigerant address number display area.(at ) 3. Press the CHECK button () for 3 seconds to switch to [Maintenance monitor]. Note) It is not possible to switch to [Maintenance monitor] during data request in maintenance mode (i.e., while “----” is blinking) since no buttons are operative. [----] appears on the screen () when [Maintenance monitor] is activated. (The display () now allows you to set a request code No.) 4. Press the [TEMP ( [ScreenB] and 5. Press the [CLOCK ( )] buttons () to select the desired refrigerant address. and )] buttons () to set the desired request code No.(“311~318”, “321~324”) 6. Press the FILTER button () to perform function setting. If above setting operations are done correctly, "Request code number" will appear in data display area.() [Example: When the "311" of "Request code number" is set, [311] appears on the screen.()] [Refererence] You can check current "request code number" setting by setting the "request code number"(“310” or “320”) and pressing the FILTER button.() [Example: When the current setting is "Setting No.2(Request code 311)", [311] appears on the screen.()] 7. To return to normal mode, press the ON/OFF button ( ). 10-2. BACK-UP HEATING FUNCTION (CN152) Temperature difference (Z=Set temp. - Room temp.) 10-2-1. Operation Outline of functions The back-up heater signal is sent out according to the temperature difference between indoor room temperature and set temperature. This function is available only in heating operation. Back-up heater signal output 1 Z 0˚C(˚F) OFF 2 0 < Z < 2.5˚C(4.5˚F) Keeping condition 3 2.5˚C(4.5˚F) Z ON ON 10-2-2. How to connect When connecting to the connector CN152 of the indoor unit, use PAC-SE59RA-E(optional parts). Z 28 0 2.5˚C(4.5˚F) OFF 11 DISASSEMBLY PROCEDURE PKA-A12HA4 PKA-A18HA4 Be careful when removing heavy parts. OPERATION PROCEDURE PHOTOS & ILLUSTRATIONS 1. REMOVING THE LOWER SIDE OF THE INDOOR UNIT FROM THE INSTALLATION PLATE Figure 1 (1) Remove the front panel. (2) Insert the screw driver to the corner hole at both left and right side as shown in the figure 1. (3) Push it up, then pull down the lower side of indoor unit and remove the hook. Push Corner hole Be careful not to damage the airflow adjustment plate with the screw driver. Push 2. REMOVING THE FRONT PANEL Down Photo 1 (1) Press and unlock the knobs on both sides of the front panel and lift the front panel until it is level. Pull the hinges forward to remove the front panel. (See Photo 2) (2) Move the horizontal vanes in a downward direction. (3) Remove the screw caps of the panel. Remove the screws. (See Photo 1) (4) Hold the lower part of both ends of the panel and pull it slightly toward you, and then remove the panel by pushing it upward. Vanes Front panel Screw caps Photo 2 29 OPERATION PROCEDURE PHOTOS 3. REMOVING THE INDOOR CONTROLLER BOARD AND IR WIRELESS CONTROLLER BOARD Photo 3 Screw (top cover) (1) Remove the front panel. (Refer to step 2) (2) Remove the room temp. thermistor TH1. (see Photo 3) (3) Remove the electrical box covers (screw 4 × 12). (See Photo 3) (4) Disconnect the connectors on the indoor controller board. (5) Remove the switch board cover. (6) Pull out the indoor controller board toward you, then disconnect the rest of connectors. Remove the indoor controller board and switch board. (7) Remove the holder of IR wireless controller board. (8) Disconnect the connector of IR wireless controller board and remove the IR wireless controller board from the holder. Screw (side cover) Electrical box cover (top) Electrical box cover (side) Room temp. thermistor (TH1) Thermistor holder Screw (side cover) Nozzle assembly Photo 4 Terminal block (TB4) Switch holder Holder of IR wireless controller board Indoor controller board (I.B) Fixture (right) Photo 5 4. REMOVING THE ELECTRICAL BOX (1) Remove the front panel. (Refer to step 2) (2) Remove the electrical box covers. (See Photo 3) (3) Remove the nozzle assembly. (Refer to step 5) (4) Disconnect the connecting wire from terminal block (TB4) and terminal block for MA-remote controller (TB5). (5) Disconnect the connectors on the indoor controller board. (6) Disconnect the connector for the ground wire. (See Photo 5) (7) Pull the disconnected lead wire out from the electrical box. (8) Remove the screw of electrical box. (See Photo 6) (9) Push up the upper fixture (See Photo 5) catch to remove the box, then pull the right fixture (See Photo 4) and remove it from the box fixture. Connector for ground wire Photo 6 Fixture (upper) Terminal block (TB4) Terminal block (TB5) Screw (Electrical box) 30 OPERATION PROCEDURE PHOTOS 5. REMOVING THE NOZZLE ASSEMBLY (with VANE and VANE MOTOR) AND DRAIN HOSE Photo 7 (1) Remove the front panel (Refer to step 2). (2) Remove the electrical box cover. (3) Disconnect the vane motor connector (CN151) on the indoor controller board. (4) Remove the corner box. (5) Pull the nozzle assembly and detach. (6) Push the fixture and remove the drain hose. Electrical box cover (side) Electrical box cover (top) Screw (side cover) Screw (top cover) Switch board cover Nozzle assembly 6. REMOVING THE INDOOR FAN MOTOR AND THE LINE FLOW FAN (1) Remove the front panel (Refer to step 2) and the corner box at right lower side. (2) Remove the electrical box (Refer to step 4) and the nozzle assembly (Refer to step 5). (3) Remove the screws fixing the motor bed. (See Photo 8) (4) Loosen the screw fixing the line flow fan. (See Photo 9) (5) Remove the motor bed together with fan motor and motor band. (6) Release the hooks of the motor band. Remove the motor band. Pull out the indoor fan motor. (7) Remove the screws fixing the left side of the heat exchanger. (See Photo 10) (8) Lift the heat exchanger, and pull out the line flow fan to the lower-left. Photo 8 Holder of IR wireless controller board Motor band Water cover Heat exchanger Screws of the motor bed Photo 9 Photo 10 Screws of the left side of the heat exchanger 7. REMOVING THE VANE MOTOR Screw of the line flow fan Photo 11 (1) Remove the nozzle assembly. (Refer to step 5) (2) Remove the screws of the vane motor unit, and pull out the vane motor unit. (3) Remove the screws of the vane motor unit cover. (4) Remove the vane motor from the vane motor unit. (5) Disconnect the connector from the vane motor. Screws of the vane motor unit Screws of the vane motor unit cover 31 Screw (side cover) OPERATION PROCEDURE PHOTOS Photo 12 8. REMOVING THE LIQUID PIPE THERMISTOR AND COND/EVA TEMP. THERMISTOR (1) (2) (3) (4) (5) Remove the front panel. (Refer to step 2) Remove the electrical box cover. Remove the motor band. Cut the wiring fixed band. Remove the liquid pipe thermistor and cond/eva temp. thermistor. (6) Disconnect the connector (CN44) on the indoor controller board. Condenser/evaporator temp. thermistor (TH5) Heat exchanger Liquid pipe thermistor (TH2) 9. REMOVING THE HEAT EXCHANGER Photo 13 (1) Remove the front panel (Refer to step 2) and the corner panel at right lower side. (2) Remove the electrical box (Refer to step 4) and the nozzle assembly (Refer to step 5). (3) Remove the motor band. (4) Remove the pipe thermistors (Refer to step 8). (5) Disconnect the connector (CN60) on the indoor controller board and the connector for ground wire. (See Photo 5) (6) Remove the screws fixing the left side of the heat exchanger. (See Photo 9) (7) Remove the heat exchanger. Heat exchanger Water cover Electrical box cover (side) Electrical box cover (top) Screw (side cover) Screw (top cover) Switch board cover Nozzle assembly 10. REMOVING THE ROOM TEMPERATURE THERMISTOR (1) (2) (3) (4) Remove the front panel (Refer to step 2). Remove the electrical box cover. Remove the room temperature thermistor. Disconnect the connector (CN20) on the indoor controller board. Holder of IR wireless controller board Screw (side cover) Photo 14 Screw (top cover) Screw (side cover) Electrical box cover (top) Electrical box cover (side) Room temp. thermistor (TH1) Thermistor holder Screw (side cover) Nozzle assembly 32 Switch holder Holder of IR wireless controller board 33 34 35 TM HEAD OFFICE : TOKYO BLDG., 2-7-3, MARUNOUCHI, CHIYODA-KU, TOKYO 100-8310, JAPAN CCopyright 2010 MITSUBISHI ELECTRIC ENGINEERING CO., LTD. Distributed in Nov. 2010 No.OCH483 Made in Japan New publication, effective Nov. 2010 Specifications subject to change without notice
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